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New South Wales Government Railways Boiler Maintenance Regulations

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New South Wales Government Railways Boiler Maintenance Regulations NEW SOUTH WALES GOVERNMENT RAILWAYS BOILER MAINTENANCE REGULATIONS MAY, 1938 Department of Railways, New South Wales Boiler Maintenance Regulations Page ii This book is the property of the Commissioner for Railways, and is issued for the guidance of those concerned in the inspection, repair, construction and maintenance of locomotive, stationary and portable boilers, and unfired pressure vessels, in the service of the Department, with the exception of those controlled by the Chief Electrical Engineer. The Officer to whom this book is issued shall make himself acquainted with the regulations contained herein, and shall be held responsible for keeping the book clean and in good condition. He shall insert new, and return amended pages as may be directed from time to time by the Boiler Engineer. The book shall be located at the depot where the Officer is stationed, and shall remain there, unless recalled, irrespective of any staff changes. The regulations contained herein, and appended hereto, shall be complied with in all respects. All previous circulars dealing with subjects covered by these regulations are hereby cancelled insofar as those subjects are concerned. F. HODGSON H. YOUNG Boiler Engineer. Chief Mechanical Engineer. May, 1938. Department of Railways, New South Wales Boiler Maintenance Regulations Page iii CONTENTS SECTION 1 GENERAL REGULATIONS COVERING THE INSPECTION AND TESTING OF LOCOMOTIVE BOILERS Clause: Page 1.01 Internal examinations by Boiler Inspectors and preparation of boiler 1 1.02 Submission of boiler inspection reports 1a 1.03 Submission of estimates for repairs with inspection reports 1a 1.04 Filing of inspection reports 2 1.05 Boiler history record 2 1.06 Repairs to boilers on locomotives in workshops 2 1.07 Submission of reports for repairs to boilers on locomotives in workshops 2 1.08 Testing of new boiler plates 3 1.09 Marking of plate diagrams for new or re-built boilers 3 1.10 Inspection of work during construction of new boilers 3 1.11 Numbering of new boilers 3 1.12 Tests on completion of new boilers 4 1.13 Submission of report upon first inspection of new boilers 4 1.14 Service certificate 4 1.15 Co-operation to obtain efficient work 4 SECTION 2 INSPECTION, REPAIR AND TESTING OF LOCOMOTIVE BOILERS AT DEPOTS 2.01 Boilers due for examination or test 5 2.02 Examination and repairs 5 2.03 Filing of reports 5 2.04 Suspension of certificate during repairs 5 2.05 Stopping locomotives for boiler repairs 6 2.06 Submission of reports on boilers repaired at depots and not supervised by a Boiler Inspector 6 2.07 Boiler repair book 6 SECTION 3 HYDROSTATIC AND STEAM TESTS FOR LOCOMOTIVE BOILERS WITH COPPER FIREBOXES Clause: Page 3.01 Grouping for test purposes 7 3.02 Hydrostatic test 7 3.03 Hydrostatic test pressures 8 3.04 Hydrostatic test with mountings 8 3.05 Variations in pressure during Hydrostatic test 9 3.06 Steam test 9 3.07 Steam test pressures 9 3.08 Variations in pressure during steam test 10 3.09 Setting safety valves 10 Department of Railways, New South Wales Boiler Maintenance Regulations Page iv SECTION 4 INSTRUCTIONS FOR EXAMINATION, REPAIR, AND MAINTENANCE OF LOCOMOTIVE BOILERS AT DEPOTS Clause: Page 4.01 Monthly examination of boiler 11 4.02 Supervision of work by Sub-foreman or Leading Boilermaker 11a 4.03 Daily supervision by Officer-in-Charge 11a 4.04 Repairs at monthly examinations 12 4.05 Repairs for broken rivets in copper fireboxes 12 4.06 Attention to leakages 12 4.07 Foreign matter in boilers 12 4.08 Monthly examination of firebox and firebox shell plates 13 4.09 Special examination of vital positions 13 4.10 Lubrication of expansion brackets 13 4.11 Progress of pitting and corrosion 13 4.12 Boiler Inspector’s report of condition of boilers at depots 14 4.13 Lax supervision and faulty or neglected repairs 14 4.14 Co-operation to obtain efficient work 14 4.15 Daily examination of fireboxes 14 4.16 Daily examination of smokeboxes 14a 4.17 Special examination of fire prevention appliances 14a 4.17a Examination of boilers on locomotives away from home depot 14a 4.17b Prevention of cold air entering fireboxes 15 SECTION 4a EXAMINATION AND MAINTENANCE OF WATER GAUGE COLUMNS Clause: Page 4.18 Responsibility of Steam Shed Inspectors 15a 4.19 Water gauge column steam pipes 15a 4.20 Cleaning steam and water-way passages of water gauge columns 15b 4.21 Maintenance of water gauge column cocks 15b SECTION 5 INTERNAL EXAMINATION PERIODS AND SERVICE LIMITS FOR LOCOMOTIVE BOILERS Clause: Page 5.01 Internal examination periods for locomotive boilers 16 5.02 Examination and test periods of first term boilers having copper fireboxes and tubes 17 5.03 Examination and test periods of second and subsequent term boilers having copper firebox and tubes 17 5.04 Examination and test periods of first term boilers having all steel fireboxes and tubes 17 5.05 Examination and test periods of second and subsequent term boilers having all steel fireboxes and tubes 18 5.06 Examination and test periods of first term boilers having composite fireboxes, i.e., steel tubes and tubeplates 18 Department of Railways, New South Wales Boiler Maintenance Regulations Page v 5.07 Examination and test periods of second and subsequent term boilers having composite fireboxes, i.e., steel tubes and tubeplates 18 5.08 Preparation of old boilers for internal examination 18a 5.09 Reclamation of usable material for condemned boilers 18a SECTION 6 CROWN STAY EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page 6.01 Crown stay examinations by the Boiler Inspector 19 6.02 Issue of monthly list of boilers due for crown stay examination 19 6.03 Crown stay diagrams 19 6.04 Method of indicating withdrawn crown stays 20 6.05 Number of crown stays to be removed for examination 20 6.06 Reporting crown stay withdrawals and attention 20 6.07 Correct fitting of crown stays 21 6.08 Cutting off points of crown stays in Belpaire Boilers 21 6.09 Evidence of defective crown stays 21 6.10 Cleaning of crown stays 21 6.11 Condemning diameter of crown stays 21 6.12 xxxx x 6.13 Examination of rigid type crown stays in boilers with round top fireboxes 22 6.14 Plugging tell-tale holes in crown stays 22 6.15 Broken crown stays 22 SECTION 7 WALL STAY EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page 7.01 Examination of wall stays in fireboxes 23 7.02 Removal of clothing sheets to facilitate examination for broken stays 23 7.03 Importance of wall stay inspections 23 7.04 Broken wall stays 23 7.05 Cleaning of tell-tale holes in throat stays when brick arch is removed 23 7.06 Removal of side tanks and clothing sheets for wall stay examinations 24 7.07 Submission of wall stay diagrams 24 7.08 Plugging or hammering over tell-tale holes in wall stays 24 SECTION 8 COPPER TUBEPLATE EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page 8.01 Examination of copper tubeplates 25 8.02 Removal of tubes for purpose of inspection 25 8.03 Remove of additional tubes for purpose of inspection 25 8.04 Report on tubeplate thickness and condition 26 8.05 Inspection of interior of boiler whenever tubes are removed 26 Department of Railways, New South Wales Boiler Maintenance Regulations Page vi SECTION 9 TUBES FOR LOCOMOTIVE BOILERS; EXAMINATION, APPLICATION AND MAINTENANCE Clause: Page 9.01 Record of changed tubes 27 9.02 Examination of tubes 27 9.03 Maintenance of flues and tubes 27 9.04 Application of tube ferrules 29 9.05 Use of oxy-acetylene torches inside fireboxes 29 9.06 Driving up tubes 29 9.07 Testing after tube attention 29 9.08 Projection of boiler tubes in smokeboxes 30 9.09 Sag in tubes 30 9.10 Condition of expanded ends of sagged tubes 30 9.11 Cleaning of superheater and small tubes 30a SECTION 10 STUDS IN LOCOMOTIVE BOILERS Clause: Page 10.01 Breaking off studs 31 10.02 Restriction on removal of studs 31 SECTION 11 BRICK ARCH STUDS IN LOCOMOTIVE BOILERS Clause: Page 11.01 Reconditioning brick arch stud holes 32 11.02 Oversize brick arch studs 32 11.03 Brick arch studs out of alignment, plugged holes, and plate thickness and condition 32 11.04 Combined brick arch stud and wall stay 32a SECTION 12 FUSIBLE PLUGS FOR LOCOMOTIVE BOILERS Clause: Page 12.01 Types of plugs and fusible fillings 33 12.02 Examination and renewal 33 12.03 Return of used plugs and ordering of new stock 33 12.04 Reporting examination and renewal of fusible plugs 33 12.05 Renewal of plugs in locomotives leaving workshops 34 12.06 Graphite lubricant on threads of plugs 34 12.07 Oil or grease on tops of plugs 34 12.08 Examination of plugs for defects 34 Department of Railways, New South Wales Boiler Maintenance Regulations Page vii SECTION 13 DAMAGE TO LOCOMOTIVE BOILERS THROUGH SHORTAGE OF WATER OR OTHER CAUSES Clause: Page 13.01 Inspection of fireboxes on arrival of locomotive at depots 35 13.02 Sealing fireboxes when damage is suspected 35 13.03 Sealing firehole doors 35 13.04 Display of ‘Boiler Empty’ boards 36 13.05 Examination of boilers involved in accidents 36 SECTION 14 PAINTING INSIDE LOCOMOTIVE BOILERS WITH BITUMINOUS PAINT Clause: Page 14.01 Repaired boilers 37 14.02 New boilers 37 14.03 Application of paint 37 14.04 Inflammable vapour 38 14.05 Working in enclosed spaces 38 14.06 Supplies of paint 38 SECTION 15 INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ARCH TUBES IN LOCOMOTIVE BOILERS Clause: Page 15.01 Responsibility of Steamshed Inspector 39 15.02 Alteration to cleaning period due to bad water conditions 39 15.03 Officer to carry out examination 40 15.04 Periodical examinations 40 15.05 Exterior examination of arch tubes 40 15.06 Internal examination of arch tubes 40 15.07 Adherence of
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