History of Locomotive Boiler Construction in Australia Part 20 discnsses the Boiler or Washout Plugs and Fusible Plugs by J.D. Baxter

fina[Droutings for pubticotbn prcpuzd 5y Iat fbztcr

Boiler (or'Washout) Plugs As an aside, In the Victorian Railways "Rolling Stock Book of Instruction", although the Instruction No. 144 says "Tbe washout plugs whictr must be drawing has been removed on the occasion of each washout and through which "checked", a close washing out must be carried out are indicated belew:-" From this look will show that instruction thme people involved in washing out boilers therefore Class E, NA and Y called them washout plugs. have only two The Boiler Inspecting staff called them inspedion plug holes. plugs. On the actual The drawing E in G (Engines in General) 53398 BOILER PLUGS locomotives, this in shows that the material used for these plugs is GM-B2. The Rolling facl is far from I k Branch list of metals manufactured at Newoort Foundrv correct. stat6s the 82 Standard GM be a.s follows:- The location of Tin and Antimony 8 - 8.5Vo the plugs is such Antimony less than 1% I-ead | - 1.5Vo that all the interior Zinc2-3Vo Copper 87 -89V0 of the boiler can be General purposes for GM-82:- thoroughly washed I'IIJD PLUG TAP Boiler mountings (Except Injectors), C-ocks, Valves, Coupling and out and inspected. Connecting Rod Brasses, Axlebox Brasses (Oil lubricated), Bushes, Tlte l3/q" diameter Oil Boxes, Nuts and all other small castings. plup are located at the Firebox front comers and bottom to The drawing of the Boiler Plug shows that the size was faciiitate the removal of scale and sediment and to allow for the stamped on the point or water end of the plug. Imported boilers ingress of Tee headed bolts and removal of spent rivets when from the U.K. had the size stamped on the point as per drawing. repairing copper fi reboxes. This was not the practice canied out by the V.R. workshops. The The I3/4" plug holes in the Back Plate were to facilitate the size was stamped on the opposite end so that should a plug be entry of the crown stay gauge as it was necessary to state the leaking under steam it was easy to ascertain the size and thus have diameter of the crown stays on the Boiler Inspection Certificate. the correct tap and new plug available. Further information on this will be in the article dealins with Boiler The spanner referred to in Figure 1 on the next page was a Inspection and Testing. Newport forged tool, the jaws being about one inch deep with the In the manufacture of a new boiler the plug holes were first opening to fit thc head, the shank was 74" diameter about 24" long reamed with a taper to form the 1 in 12 taper before with the end drawn down to about t2" over 4" to fit into a box commencing to cut the thread. spanner used for tapping holes or for removing plugs. The Mud Plug Tap had a L3A.6" head, 13/6" de€p with the tapping thread 4" long. The letter A was marked 11,8" up from the point with the distance between A to C being 14" and the line locating B in another flute being half way between A-C. It can be seen that the variation of each plug size was equal to Squane xax' 1'39" V+" penetration of the tap. Both the reamer and the tap had six f.in.1.37" flutes and in addition to the size, the letters CS were also '13/1,6" 7:r sDanner stamped on the top of the square. This refened to the material f'1 which in those times was carbon steel. A liberal amount of fish based tapping oil was used while tapping and extreme care was taken to have the tap enter the reamed hole symmetrical to the face of the hole. If this was not done it would give the impression that the plug S:rewed L1 TPI L"ihit. was in cross threaded and if it showed a leak under steam it taper I in 12 would necessitate the cooling down of the boiler. Plugs that were applied cross threaded were not to be tampered with under steam whereas a conectly applied plug could be nipped up under steam. l\ With full threads for the full depth of the holes, the size Stamp No. I N tap & mark lette" was obtained by heavily chalking the thread of the tap, P ug dia. with 3,u 8,, ietters & numbers screwing it in by hand till tight and removing. The depth that the tap entered couid be readily seen and the size would be BOILER PLUG chalked adjacent to the hole. When boilers were in full production the stores had dozens of each size in stock. Each c.x. 8.2. plug was temporarily allocated to its correct hole for final fiuing.

Autralian MODEL Engineering May/June 1992 on the edge of a coke fire and allowed to slowly melt. The correct temperature for f')onth tn cla:n pouring was obtained by what was known as Cr own stag heads the pap€r test". consisted of I "white This t folding a piece of white paper (as used for typing) into a sedion about 1" wide to give it rigidity so it could be passed through the molten lead. The correct temperature for pouring had been reached when the paper tumed brown after passing through the molten lead. The pouring operation had to take place in one continuous pour, and with experience it was soon learned when to cease so as to form a nice blob on the countersunk of the Appr ox head. The lead solidified almost Square to fit instantaneously and the plug was picked Fusible plug up 5/8 thick with a pair of tongs and placed between tbe jaws of an engineers 6" vice. The jaws engaged on the cone formed at the point and the blob formed on the head and the vice tightened so that the knurled faces of the jaws were imprinted on the lead. This procedure was used in lieu of I -T^Ftl. I All Dimensions riveting (as stated on the drawing) and when in Inches canied in this manner there was never any sign of leaking through the lead. It was found that plugs as tumed, when applied to holes as Aiso not stated on the drawing, it was usual practice to wrap in tapped, were not steam tight. So each plug was ground in to its the groove between the end of the thread and the head two layen of respective hole. The grinding compound used was the same a.s the graphited asbestos string and to apply the plug with a light smear of fitters used to grind the seats of gunmetal valves. The procedure graphite and tallow on the thread. was to apply the compound to the effective threads, in by The correct size plug for each sizp hole should be able to be hand and keep tightening and lomening about 20 times. A short screwed up to the face of the crown sheet by tund and finally spanner was then used for the final tightening and loosening. The nipped up with the special wrench Fig 1. the plug with a plug and hole was then cleaned up and finally fitted From the drawing it can be seen that the material (G.M. 82) is mixture of graphite and tallow, pulled up with a plug spanner until the same as that used for boiler plugs. tight then backed off a quarter tum. The backing off was to allow for the extra expansion of the gunmetal in relation to the steel boiler plate. The tallow bound the Sheet lead melted and poured in. graphite together for adhering to the threads Aporox merting point o' lead = 6?A deg. F to assist in the removal at a later date. The Lead to be riveted af ter pluq is f illed tallow disappeared at the first steaming. Further information on plugs will be dealt '7 /A" Plug No. to be stamped he^e with in the AB Examination. 3/4" vith l/4" figures rrusible Plugs I have not been able to ascertain when fusible plugs were fint introduced but from Screwed 11 TPI the drawing 'BOILERS lN GENERAL 5643A .1" dated 5-10-1944, this type of /l fusible plug was used in copper and steel 6 ir t.' firebox boilers till 1956 when a modified .t type was introduced for steel fireboxes. ol\ The 11 TPI was the standard Whitworth -l form for sA" Whifworth bols inespective of // ltreoox cro||n ti the diameter greater than 5/8", the tapping -T 'I/64" Tapped 7/8" l"lhit. 3/4"J size being wtder the finished diameter. t To fill the plug, the point or water side end was placed on a base which was a steel disc about 3" diameter and about 1" thick, in the centre of which a countersunk hole had been formed with the point of a 1" . Both the plug and base were heated to about 50 degrees Celsius and the point placed in the countersunk hole. The sheet lead to be r:sed was wually FUSIBLE PLUG cut up into pieces about 2" square and c.f1. 8.2. placed in the ladle which in tum was placed

MaylJune 1992 Austral ian MODEL Engineering i< the plug should be minimum lrt" maximum 3Au. far as can Lead to be to this line to dies suppliec! b9 As be ascertained the rcason for the change S.L.H. lor plugs used at Ararat, Geelong, in design of fusible plugs for steel boilers was that 74,, l''largborough, Ballarat & Traralgon or as the heat transfer from the thick head to the steel crown was not verv efficient and this caused the heads to burn away. Why the thrcaded hole was changed to converging tapered holes I have not been able to Taper 1 in 12 discover. Screwed 11 TPI To apply the lead successfuUy to the trapers it was first qgT_ssary to tin the inside using Bakers soldering flux and 50/50 solder and while still hot wipe the tapered holes clean by passing a piece of clean cloth attached to a piece of wire through the hole and witMrawing it. The lead was poured in the same way as for copper firebox fusible plugs. Fusible Plug Modifi cations With the introduction of steel fireboxes and the feed water in the tender tank was treated by the addition of soda ash and tannin. This treatment came in the form of dissolving briquettes. This treatment was very effedive for the steel but had a detrimental effect on non-ferrous metals consequently it tended to eat down between the lead and body of the plug causing the plug to "leak through the lead". This was treated as a suspeded partially fused plug until proved otherwise. This was most prevalent on engines operating out of Maryborough where the boilermaking staff came up with the suggestion tbat a lead cap be placed on the water side of the plug. This was introduced in 1960 to areas mentioned on the drawing and before very long it was used throughout the state. A sketch of the dies pro/ided is shown in Fig 2. The filling operation was the revers€ to the previous procedure, The head or fireside was placed over the countesunk hole in the base, the die being on the point or FUSIBLE PLUG water side upper most and the lead poured in from the opening at the top of the die it was flush G.f1. 8.2 Dimensions until with the top. in Inches With the introduction of caps it was necessary to tin the area around the point of the plug and down the sides below the At the beginning of 1956 a new type of plug was introduced edge of the cap. for all steel firebox boilers as per drawing "BOILERS IN Tapered plugs were applied with a smear of graphite and GENERAL" 5643A.6. The copy was obtained from a preservation tallov screwed in by hand and finally nipped up with the correct society hence the note of 29-7-88, re - dimensions which may be spanner. At first firing of the boiler the lead melted on the fire side misunderstood by them. Nowhere on the drawing is it mentioned up approximately to the level of the cror /n plate. that the distance between the crown of the firebox and the head of The "Schedule For Examination of l.ocomotive Parts, "AB" Examination - Every 3000 miles" states that:- [-ocomotives which do not run 3000 miles within 6 weeks are to have the "AIl" examination canied out every 6 weeks. (Permissible to extend by 4 days, tbe maximum time period not to exeed 46 days). AIso listed under work on the Boiler:- Firebox fusible plugs to be examined and refilled with new lead. Towards the end of the steam era the times above were ^f increased to 8 weeks and a maximum of 60 davs. rl Al'{E

Dowels f or l_ lining up die.

tu,.--/- Diameten allowing for 1/16" of lead on side r- I & depth for I/4" on top

ll | -l Tight f it on poinr or ------::::-"e of plus Section on A-A

FIC 2 DIE for CAP

46 Austral ian MODEL Engineering MaylJuneL992 History of Locomotive Boiler Construction in Australia Part 21 discusses the subject of Longitudinal Stays by J.D. Baxter

fina-ttraukgs for pu1[icatbn 59 lan ffoater \|/rought iron was used from 1880 to 1910, ingot iron to 1!X5 The overall length of the longitudinal stay was determined and Y Y and mild steel from then on. The stays had a forged hexagon the lengh of the head and tail deducted to give the required body head and a jumped up section in front of the head. The tail was of length. This was Ieft a little longer to allow for any loss during fire equal diameter to the body of the stay and had a jumped up point . The wrought iron or ingot iron stays were fire welded by section. These two parts were about 10" to 12" long. The body of the Boilersmith at the coke fires in the usual manner and the weld the stay was a round bar of the diameter required for the stay. The rounded up with the aid of top and bottom swages. Should at any head and tail sections were turned and threaded as shown in time a longitudinal stay be either too long or too short it was always Figures I & 2. possible to draw it out or jump it up as required. From 1945 until the end of production of locomotive boilers in the late 1950's all three sections were mild steel, drop forged and butt welded together by the resistance welding process. The flash area was cleaned up with the use of course files and any adjustments in length were made in a similar manner as for the wrought iron stays. As the boilers increased in lenglh, so did the stays and it became necessary to fit longitudinal stay carriers at about the centre of the boiler. These caniers were fabricated from 6" by 12" mild steel flat and riveted to the banel of the boiler. The threads of the stays are standard Whitworth 1l TPI and from a close look at Figures 1 & 2 it can be seen that the point will just clear the tapped hole in the back plate. Some of the later boilers Wosher from about 1910 had a doubling plate riveted inside the back plate covering the longitudinal stay area in order to give a tapping thickness of 1V4". A copper washer was slipped over the point and \ the stay was gently fed through the back plate hole, guided onto the tl, t 1/4" Sponner longitudinal stay canier if fitted, and taken forward until it was \t" about a foot clear of the smokebox tube plate. Then using the main steam pipe opening or the flue tube holes a nut was screwed onto FIG 1 the point far enough to clear the smokebox tube plate. A copper washer was then applied to the point and pushed back up against the nut and the stav was then passed through its appropriate hole in

To Fit 1 1/4" Spcnner

rv

\ Copper Woshers Screwed to 1i T.P.r 1 1/+" Dio Fusibte Ptug \

FI6 2

J+ Australian MODEL Engineering Sept/Oct 1992 plate, washer and nut face and by reaching in through the main steam pipe hole or a flue tube hole, the nut was screwed up by hand until the washer was up against the tube plate. An open jaw spanner about 18" Iong was fed through the main steam pipe hole or flue tube hole and the nut tightened as far as physically possible by hand. Then with the 's assistant holding the spanner on the nut and the handle visible through either the flue or fire tube holes. the boilermaker used a wooden lever and forced the spanner handle around using the tube holes as a fulcnrm. A mirror was used to see when the washer and nut were hard up against the tube plate. The spanner used to tighten the inside nuts had a hole at the end of the handle through which a light rope was attached so that should it slip from the assistant's hand and drop to the bottom of the banel it could be readily recovered. Certain nuts on the outside of the smokebox tube plate that the smokebox tube plate. At this stage the thread on the head would could foul the header were reduced in thickness by r/q". he ready to commence being screwed into the back plate with care With the introduction of longer boilers, namely with three taken that the nut at the point was clear of the smokebox tube .ng strakes in the barrel (the S, and classes) the 1920's, prate. The head was screwed up with a ring spanner about 2 foot X N in longitudinal stays were eliminated and diagonal stays substituted long and when tight, a pipe about 4 foot long was applied to finally and this was continued in the H and R classes. In the original S nip it up (there being no tension wrenches available in the Boiler class boiler the "T" iron to which the diasonal stavs were attached Shop). Before applying the longitudinal stays to the boiler, the was horizontal and "2 hole T" irons slightiy radial either side of the threads were well covered with red lead and a little was also added main steam pipe opening. In the H class the irons, 3 either side between the plate, copper washer and head. Annealed copper "T" of the steam pipe, were riveted radially. These irons were a washers were used to assist in making a steam tight joint between "T" drop forged steel section with each leg being l1/4" thick and the the plate and the head or nut and should there be a steam leak later, base machined flat to form a good fit to the tube plate. the copper washer was caulked between the plate and head/nut. These stays consisted of a fork that straddled the vertical face Red lead, copper washer and nut was then applied to the point of the iron and the other was usually a "3 hole palm". These protruding at the smokebox tube plate. The nut was tightened with "T" stays were made up of 3 sections; the fork, body and palm, and the 2 foot hexagon spanner and a check made for tension in the stay were welded in the same way as longitudinal stays. The palm was by using a bar of 12" round steel with a hook on one end and a forged on a radius to suite the banel plate. With the rivet line handle on the other. The boilermaker applying the longitudinal marked on the barrel side of the palm, thi: stay was held in position stays had many years of experience and knew the exact tension to by a pin through the hole in the fork and vertical face of the be in the stay by lifting the hook. "T" iron. The palm wedged against the rivet holes (which were drilled We retum now to the washer and nut on the inside of the boiler when the barrel was in the flat) and centre dabbed. The stav was at the smokebox tube plate. Red lead was applied to the thread, then removed, the rivet holes were rung, popped and drilled at the stationery radial driils. Using this procedure it was not nec€ssary to either lengthen or shorten the stay. In the R class firebox, "T" irons and forks are attached to the back plate, and the pears fitted between the gussett plates. Figures 3 & .t show the secuflng arrangement.These stays were assemblecj in three pieces and it was necessary to either lengthen or shorten them to obtain a perfect fit for the pins. Atl pins were retained with a flat split pin. In the H class boiler photograph adjacent, seven diagonal stays can be seen radially around the bottom, the white around the nuts is red lead and it can be noted that the nuts just cover the thread. A further lmk below the 3 bottom stays on the barrel, the 2 rivet heads can be seen which attach the "2 hole palms" to the inside of the banel. AII{E

Sept/Oct 1992 Australian MODEL Engineering 35 History of Locomotive Boiler Construction in Australia Part 22 - Staying Procedures for the Inner Firebox Crown by J.D. Baxter

firu[ Drazttings fo r eub [ication 5y I an fbwu Background to Staying was up for scrapping it was decided to have apparent that there was movement in the The original Victorian Railways (V.R.) a close inspection. All femrles were firebox crown sheet adjacent to the firebox drawing of "Light Locomotive for Branch carefully removed and it was found that the tube plate as the first two rows of crown Lines" dated 1892, from which the first bolts were in perfect condition due to the support stays had provision for expansion. locomotive boiler was built at the Newport steam tight irt between the copper crown Figs. 4 & 5 show the type applied to "8" Railway Workshops refers to "6 Roof Bars and the face of the stay. No doubt a good and "Y" class boilers from about 1900 and Thus Wrought Iron" and held in place by dose ofred lead would have been applied at remained as such for their life. "36 set thus" (Figs. 1, 2 & 3). There the time of installation since the age of that The angles and plate were a is no doubt that this type of stay was particular boiler was about 30 years. sub-assembly and riveted to the outer necessary as the dome was situated above With the increase in the size of the wrapper before the firebox was applied. firebox crown and this form of support boilers and the relocation of the dome to the The web plate was known as the spectacle tol the crown remained the same for the trailing barrel, the inner firebox crown was plate, a name no doubt acquired from the sixty years that this type of boiler was built. stayed to the outer wrapper, bearing in two holes which were to facilitate the surge In later years they became known as crown mind that all boilers were wagon type and of water while the locomotive was girder stays and bolts. With the the inner fireboxes were copper. It was travelline. non-availability of wrought iron early this century they were then forged from miid steel. 50 Years On. At about 1960 concem was raised by the Foreman Boilermaker who was also Chief Boiler Inspector as regards the condition of the crown girder bolts inside the fem:les and as one of this type of boiler

e- Fig. 1 6 rloo- dar-s hus nrougn c ]r-on

0uter !.apper

lr2" Spectace plate

Fiq. 3

Ferrule 36 Thus -Steel firebox rrapper ) ) I & Y CLASS CROIiN BOLT ARRGT. rrg c 35 Set Screws Ihus

Mar/Apr 1993 Australian MODEL Engineering 35 Fig. 8 is fiom the both outer and inner the crown stays a--OuterhrapPe. firebox of the "K" class became vertical. About this time the Barrei Place a Belpaire boiler of 1922. screwing machines gave way to tunet head With the introduction of which had a fixed lead screw at li all steel boilers the TPI. The die head which cut the thread was (narr:ria Pl: ta principle of allowing for known as a "Landis die J LI' X J L/C box". I Angie iron movement of the first The crown stays were drop forged with i Cro*n Stags two rows of stays was a hexagon head, the section adjacent to the n- the same except tbr the head and the point being about V+" larger rn shape of the head of the diameter than the body of the stay. The stay Crown Boits stay on the fire side. material was initially wrought iron then Fig. 14 shows the nuts ingot iron and finally about 1950 mild steel on the machined face of was used. The inside surface of the heads -'rll the hanging brackets are were machined to form a good tace against Copper Tube Place applied opposite to the the copper crown but it was later found that practice Section usual trade and if the stay was forged with a larger hexagon in relation to the ,A.2 head it was possible to machine the inside & Y CLASS CRO'.]| ] BOL-: ARRCI. t class the pin is reversed surt'ace of the head leaving a 1/16" Fig.5 and the elongated hole triangular bead which fbrmed an absolute tbr the solit cotter taces steam tight joint (Fig. 9). With the introduction of Belpaire type the tiont of the boiler. On the "D" Fig. 10 shows the full details of the boilers in the 1900's the crown angles certificate used by the Boiler Inspector crown stay tap, the point having a Morse became straight and a hanging bracket these were ret-ened to as "Crown Bolts". taper to take the pilot as shown in Fig. 11. r 1ed between the angles by a pin, in The pilot was to guide the tap into the outer tuiil'retained by a split cotter. The stays Crown Stays casing plate. From these remarks it can be were held in position by a lock nut on the The crown stays in the wagon top gathered that the crown stay holes were water side. Up to this time all stays were boilers around 1900 were known as radial tapped from inside the firebox. The trvo formed lines threaded in a screwing machine (No. 43 in crown stays as they radial square sections at the head of the tap were the inner crown and the outer AME Feb. 1989) with the pitch being between to attach an extension to allow the tap to be was controlled by the die box as these machines wrapper. The inner crown slightly fed through the crown space and finallv be symmetrical had no lead screw. Figs. 6 & 7 show the curved to allow the heads to removed. Tapping was carried out with plate form a steam first row of crown stays on the "NA" class to the surface of the and pneumatic machines and the tap given l joint. were r-rveted boilers (commonly known as "PutTing tight Initially these stays good dip in fish based oil. The tradesman's edges tucked in with a Billy") which were itemized in the drawing at both ends and the assistant was on the outside to remove the whipping tool as seen in Figs. 6 & 7. The as expansion stays. pilot and take the tap as it came through the Belpaire boilers, having flat crown plates,

e -@ -o -o q -9 -e -o Crown Staus on i\iA Ciass Crown Stags (Puf f ing tsiilu) i'lA Class 1st Row Cn 9 Fiq 6 Fig. 7

,1 ), flo.2

1" - Il TPI

A lz'16" Triangv,ar

-JY_adird Fac6 .i Fi9 l0 ffi !9r{- 9€!ie! A4 KcZ rAF Fig 9 1 i,,9,, CROhil STAy H.S.S. Eeaded l.iut 4 FLUTES LL THRD. PER iNCIl. GROUNO THRD. rlld St..i - Forgod

36 Australian MODEL Engineering Mar/Apr 1993 the tap had opened up the hole, it was withdrawn with pilot attached. The turner then turned the crown stay with the thread adjacent to the head to be a perf'ect pull up fit and red lead was also applied. At the point that is at the top of the crown, a copper washer was first placed on the stay and a beaded nut was applied, again with a dollop of red lead. The hexagon spanner used to pull up the crown stays had a handle about 3 feet long. With the introduction of steel boilers Fig 8 the head of the crown stays changed. Fig. 14 shows the change from large hexagon heads to small domes with square attached Crown Stags on for screwing in. The first thread adjacent to the head was undercut and in this groove RoL^e ina R^ilar :_ _=r1. was applied a grommet of hemp and red lead, the same procedure was used at the -----.1 point as for copper fireboxes, ie. a clearance hole, copper washer and beaded nut. AI4E Coming Events Eore to l.lo. 2 Pitot Bor Fig. 11 Xorse Taper 13th - 14th Nlarch, 1993 38 class, 50th Anniversary A special invitation to owners of 38 u--______to class locomotives in all gauges to attend. All other types also welcome. Sydney Society of Model Engineers, R53. Luddenham Rd. St MARYS tapped hole. This operation was carried out Pilot. No. 2 while the boiler was lying on its side, 20th - 21st March 1993 l'1orse Taper access being through the foundation ring Bendigo Steam & Oil engine area. Preservation Group Inc. !ffi*ffi- No matter how carefully the tapping Fourth National Rally, includes operation was carried out and with the use working historical display of steam, oil. of the lead screw on the die box it was bullock teams, tractor pull. impossible to get the crown stays to be a Further Details for camping perfect fit, it was decided that the outside facilities & display site registration from: hole be opened up t/64" larger by a separate Dawn & Barry Milsom (054) 395378 Point dia. approx Bore to No. 2 operation. Figs. 12 & 13 show the tap and for L'g" smaller ilorse l-aper piiot that was used. They were attached by '- Lead in 9th - l2th April 1993 the Morse tapers and the pilot was guided - 37th A.A.L.S Annual Convention through the tapped outer crown hole into Castledare Miniature Railways of the inner firebox crown stay hole and the W.A Incorporated located at Fem Road, threads at the point of the tap picked up the Piloi Sleeve Fig. 13 BENTLEY W.A. existing threads in the outer crown. This Registration of intention to attend is operation was carried out by hand, and once necessary. please direct your enquiries to: The Convention Secretary l4 Ranmore Way, Morley W.A. 6062

lSth April 1993 HDMES Boating Regatta Fagan Park, Arcrdia Road, CALSTON. For lurther details: Alan Fern, C/- F{DMES, P.O. Box 172. Galston NSW 2159 -o 9th May 1993 o -o -o The 1993 Festival ofSteam Toowoomba Live Steamers Inc. at I (, - the Willow Springs Adventure Park, rJ"-(, \, Spring St, Toowoomba QLD For more infbrmation ph. (076) Cnown R Ciass Steei Boiier 308847 or write: TLS Inc., P.O. Box Stag lreaos Fig'14 9r6, TOOWOOMBA QLD 4350

Mar/Apr 1993 Australian MODEL Engineering a1 History of Locomotive Boiler Construction in Australia Part 23 looks at Water Space Staying by J.D. Baxter

fina[Draruings for puStbation 6y Ian fbwer

ith the original inner fireboxes being constructed ofcopper it fbllows that the water space stays be copper. On the V.R. drawing "Light Locomotives for Branch Lines" dated 2l- Il-1893 it states "'7/s copper stays II threads per inch", and a close look at a section of this drawing (Fig. l) will show that the stays are continuous diameter over their fult length. It is without doubt that these stays were screwed in the screwing machine which in 1927 was relocated in the nerv Boiler Shop (machine 43 on page 46 AME February 1989). With the introduction of turret lathes in the early 1900s the centre section thread on either side of the inner and outer plate was reduced to 74" less in diameter r the outside diameter of the stay. The amount of 7a" was arrived at by virtue of the fact that all stay threads are 1 I TPI Whitworth standard for 5/s" and the correct allowance fbr tapping ' i size was 7o+", thus 7a" just allowed the stay to pass through the Figl tapped hole and pick up the tapped hole in the inner plate. The length ol taps used for tapping water space stays were about four 7 f8" Copper Stoys 1 1 Ihreods per Inch times the distance between the sides of the t'irebox plates and consisted of fbur parts. The flrst section acted as a reamer to line up the holes, the second section was a tapered tapping part, the TARY third a parallel threaded length to maintain the pitch while the 1 /)" A

50 Australian MODEL Engineering SepVOct i993 plate was maintained by a cap Ou ter which Costing had a hole equal in Sleeve diameter to thc tap drilled in centre of the applying square. 7/1Atl This cap was applied to the sleeve Tell Tole too Copper Gosket and the tap fed through until the -\ Hole pilot picked up the hole in the plate. \ Slot for Applying inner The tapping operation was carried out by a pneumatic machine. The length of the stays Nominol were measured with a gauge as Dio. shown in Fig. 5. /)R / 1 "\ A anangement consisting { of a plare with a sleeve and a rule set up similar to the gauge was used. The stay was applied to the Plote sleeve and the required length was marked with a chisel line. Screwed Cop OriginallY t/q" was allowed to f\n tnnnar 1/4" f or Riveting protrude through for riveting with Gosket 1 0 TPI the rotary gun and from about - 3/16" if Seoled by 1950 this was reduced to3As" Arc Welding for seal welding arc. Plote by the The stays were applied with a Counterbored lonn+h af afarr Sleeve Arc Welded special tool that fitted into the In Locotion sleeve and had a hardened blade that fitted into the slot in the head. The slot was machined after the Knurled Hondle stays were forged but before being tumed to length and threaded. The tell tale hole was drilled 3lo" diameter to a depth of 15ls" and served to accommodate the pip on r tillrill|li the rotary gun snap thus closing the head evenly all around. The handle of the applying tool was about 18" long and rhe srays were /^ pulled up tight then backed off half with -/'>ome Dicmeter of / Veas-'emeris in 1/E' a turn the exception of the 17s" diameter stays around syphons which were backed off Boil of trlc n ihle S tn 'r one and a quarter tums. The copper gaskets were applied with a FLfXIBLE STAY LENGTH GAUG- special tool and finally the caps applied wirh a mixture of engine oil and graphite to assist future removal. It was usual procedure tbr one of the to apply use in the down position, such as the throat and back plates, it was all the flexible stays in order to obtain the same degree slung on a steel cable from a spring loaded support. It was not possible of flexibility. In service the Boiler Inspector sounded the flexible stays when the hvdraulic pressure 100 to hold the rotary gun manually in the horizontal position due to its was PSI, an "even" sound was heard except the stay was weight (about aOlb/18kg) as the operator was required to squeeze the if broken or fractured. The turret lathes were well in operation when trigger with one hand and at the same time operate the rotary the ingot iron and mild steel water space stays were introduced. mechanism air cock. They followed the same procedure as the copper. continuously 1940 was the year the "H" class steel firebox was manutactured threaded with the cenrre portion of the thread removed. A special horizontal double headed ^nd saw the introduction of flexible and rigid steel water space stays. machine was used to the two tell rvas .:xible stays were also known as Flannery stays since they were drill tale holes. The stay gripped on the non threaded area with vee jaws, briginally manufactured by the American tlrm of The Flannery Stay and on rotating the lever two 3le" came in. The staying operation Co. For the tlrst ten years the material used tbr rigid stays was ingot was carried out alongside the lathes. The boilermaker told the rvas iron and when it became unavailable after 1950 a suitable quality mild tumer how the lit as each stay was applied and the tumer then adjusted the steel was used. Flexible stays were drop forged to shape, having a ball die box accordingly. The measuring was a standard l/2" at one end and the point varying in diameter as required. It was the ball -qauge wide steel one tbot rule riveted to a steel strip with a lip at rhe end plate. acting in a machined sleeve that generated the flexibility in atl to engage the inner An amount equal to twice that required directions. tbr riveting had been cut off the rule befbre tlxing to the steel strip. The measurement read at Flexible stays were located in two rows around the stay area of the the edge of the outer plate was the required length I back plate and flre hole plate, Iower outer and inner throat plate, both of the stay. From about 950. rigid steel water space stays were fiont and back ends and the top two rows of the outer and inner side sealed on the fire side by arc welding while on the outer plate side they were closed gun. sheets, while the combustion chamber was completely flexibly stayed. with the rotary The outside plates were counter bored with a special To be continued ... countersinking tool to the contour AI4E of the sleeves. The sleeves were Nib to tumed from mild steel black bar so Engoge Inside 1 1 Foot Rule Riveted as to obtain a good weld, free of Pl ote /2" on Top Side porosity. The pitch of the thread of the sleeve and cap was l0 TPI. the only occasion in e locomotir e boiler when it vrricd tiom the Fig 6 standard 11 TPI (Fig. 4). Hond I e The correct inline angle between the slecvc antl thc inncr RIGID STAY LENGTH GAUGE

1993 Australian MODEL Engineering SepVOct 5l The History of Locomotive Boiler Construction in Australia Part 24 - Tubing Copper Firebox Boilers by J. D. Baxter

firnfDrautings for pu|[icatbn 6y Ian fbwer I section of the drawing taken from the first llengine built in the Victorian Railway's Newport Workshops in 1892/1893 @ig. 1) shows the tubes to be brass 13l+" diameter. The tube holes refened to at the smokebox end also have l3/q" diameter holes, and fiom this we note that a parallel tube was used. It soon became apparent that it was not always possible to get a l3/+" tube in a 73/q" hole, so the firebox end was swaged down about tAo" for about 112". When it was necessary to Fig.2 ROLLER TUBE (for withdraw a tube it was found that the build-up of EXPANDER hand use) sediment on the water side of the tube madc it i --rssible to withdraw the tube through the smokebox tube plate hole. then horizontally across at centre of nest of tubes. Second the Cross of '"-" led to the hoies at the smokebox end being driiled 7s" larger than St Andrew: diagonally from the outside towards the centre. Finally, fill the tube diameter and the tubes being flared prior to being placed in the gaps in with the Cross of St Patrick, alternating diagonally. position. At the turn of the century, copper tubes became available in The femrles were placed in the expanded tubes by hand so that the required diameters and length and were used in conjunction with they protruded beyond the end of the tube Vc" then finally they were brass although never mixed in the same boiler. driven flush with the rube (with a light flogging hammer) ready for The- operation of tubing a boiler was carried out by a boilermaker beading. So that over-expanding of the tubes could not be carried out, and an apprentice. The length oftube was equal to the distance between the drawing stated: "In no case must the length of podger bar of the outside faces of the smckebox and firebox tube plates plus 3lo" for expander exceed 1'6" ". The expanders were made in either left hand beading at the firebox end plus h" at the smokebox end. The tubes or right hand, the reason being that the podger bar was always used in a were fed in through the smokebox tube plate by the boilermaker to downward action, the difference between left and right was the stight about two feet from the firebox tube plate when an apprentice with a wooden rod through the appropriate hole entered it in the end of the nrbe and guided it to its correct location. The expanders were the three-roller type, fitted with a guard. The was tapered i in 20, the head approximately twice the diameter of the shank with two holes drilled through at 90 degrees to 5 take a podger bar of V1" diameter spring steel (Fig. 2). All copper or I r- I Shonk Fit brass fire tubes were beaded with steel ferrules. These were made from I to 1t/2" by 3/to" flat bar with a tensile strength of about 40 tons. They were Pneumctic made in a special machine, rolled to the I in 20 taper and fire welded at iommer the buttjoint. They came in various sizes only a few thousandths ofan r different so as to fit the slight variation of the diameter of the expanded tubes. Due to the ductility of the copper tube plate, the correct sequence of expanding and ferruling the tubes was specified in the drawings. In the workshop, the practical method used was referred to as the Union Jack method. First the Cross of St Ceorge: vertical down on centre line

Qhar^ trr{na ln Close Down Edge a',+ Beod ":'"^^A Y"' "^f+ 7 ony >urprus /,/

This Groove Acted on Steel Ferrule

Beoding Tool for Copper or Bross Tubes fitted with Ferrules ? Irra I\J J

AA Australian MODEL Engineering Jan/Feb 1994 I

I I I s/16" I -l I i I r.) I I I I 2" Rod ,i ___1 I \

L-<-->-

FIG + Fig.5 FIVE ROLLER TUBE EXPANDER

incline in the line of the rollers. Copious lubricating oil was applied to were used and applied with ferrules and beading similiar to fire tubes, the rollers of the expanders to facilitate the operation. but by 1928 it was realized this was nor the besr method. Orginally the operation of beading tubes was carried out by hand The body of the flue rubes were No 6 BWC or 0.203" rhick and held tools. The tum of the century saw the introduction of pneumatic varied in diameter 51Ad" for A2, D3, K: 5sAa" for C, N. X, & Sl and driven beading tools in a medium sized gun. The beading tool acted on 11" at the smokebox end was flared an additional 3/ro" while the neck the femrle and the protruding tube at the same time, continuing to drive ofthe firebox end reduced for 13" by lrAa". The method adopted in : femrle into the tube and fbrming the bead with the protruding 3/6" 1928 was to have the end of the neck or firebox end thickened to 5/ro" -' the tube. In Fig.3 it can be seen that the edge of the beading tool is for a distance of 3". This end was then threaded l l TPI standard sharp, thus tucking the edge of the bead down firmly ro the nrbe plate. Whitworth for about 2" The flue tube holes in the firebox nlbe plate It also cut off any surplus which may have been caused by the tube were tapped a corresponding size, allowing the flue tubes to be screwed being a little over the correct protrusion. in to the firebox plate; again a protrusion of 3AA" was allowed for As the trigger of the pneumatic gun was squeezed with one hand, beading (Fig.a). the other hand holding the beading tool commenced to rorare it around They were then expanded with a five roller expander as in Fig.5. the tube. care being taken not to allow the tool to jump ofT the Before beading was commenced with a special shaped tool. the protruding tube and f1y up the femrle, jamming itseif. Depending on protrusion was laid over about 45 degrees with the ball peen of a light the experience of the operator, it usually took four times around with flogging hammer. It was necessary for boilermakers engaged in the the beading tool to complete the beading. With the fire tubes held in operation of tubing locomotive boilers to be ambidextrous. With the position the smokebox end was then expanded. This operation was flues fixed in position at the firebox it was a straightforward operation relatively easy, being away from the confined space of the ilrebox, and to expand the smokebox end. The sequence for expanding the flues was nearly always carried out in the right hand manner due to no was from left to right on the top row, second rorv right to left and third smokebox being applied at this stage. row left to right, with the fire tubes in bet,,veen left to right and right to The year 1914 saw the introduction ofsuperheating in the A2 class left in the next row. The nest of fire rubes was treated very similiar to 4-6-0s, hence the introduction of "flue tubes", the conect name for the Union Jack method. with the length of the podger bar for flue tubes tubes containing superheating elements; the type used was the not exceeding 2'3". "Schmidt System". At first, both solid drawn brass or copper tubes fu

George Corliss and his Engines The eccentrics are interesting. They overcome by providing the chequer plate Continuedfrom page I2 are free on the crankshaft and a side walkway, stairs and handrail, gau_ee panel stepped diameter provided with Engine Type and is a number and operating staff. of small holes to enable them to be tumed The engine has now been pur to bed in Components to the correct position with a small bar. the workshop under a perspex (acrylic) The enrrine is ot- rhe double eccentric They are then tightened against a shoulder cover to keep the dust off. The cover keeps the valves type, one fbr inlet and one for on the shait by a locknut, therefore giving a it nice and clean ready for a run at the next the exhaust valves operating the valves very easy method of adjusting the throw. exhibition. through individual wrist plates. Some The dash pot which return the valves Corliss engines have only one eccentric but to the shut position when they are tripped Bibliography:- the two eccentrics enable the range the of were designed to be vacuum operated. I A History of Mechanical Engineering points to be extended considerably, cut-otT found this to be impracticable in view of Aubrey E. Burstall - giving improved valve control. the small areas available to provide Steam Engines I.C.S. Library differential pressure; I adopted the Who's Who in America- (p. 122) alternative spring design shown on the Encyclopedia Americana (p. 798) drawings and this is satisfactory. Live Steam, May 1976 The governor driven flat is by a Steam and Other Engines Duncan endless belt from the crank shaft. After Steam Engine Theory and- Practice much searching I eventually found a Ritter - manufacturer to make this, but I will never Thanks ro Live Steam Magazine tbrget the price! The bare engine standing for permission to reproduce the photo on alone provided no sense of scale; this was page I1... ed. A^

Jan/Feb 1994 Australian MODEL Engineering 45 History of Locomotive Boiler Construction in Australia by J. D. Baxter

Drauingsfor pu|ficatbn 6y Ian fbwer Part 25 (final) - Tubing Steel Firebox Boilers uperheatcd boilers had been in operation Q Adjust boiler and flue tubes ro project the tJin the Victorian Railways for about 40 correct amount for beading and lightly "all years bcfbre steel boilers" became the fasten boiler tubes at smokebox end. norm. The fire tubes were mostly 2" diameter Boiler tubes to project at smokebox 72" except the N class which werc 27+" diamcter maximum, 7s" minimum and at firebox and the H class were 23/s" diameter. They 310". Flue tubes project at smokebox was were supplied by the tube mills at the correct 72" maximum, 7s" minimum whiie at length fbr each class of boiler and with the firebox it was 3/8". They were fastened trrebox end swaged for about 1t,/2" to t/s" with small wedges made from stubs oi under size and the smokebox end flared tbr Detoil @ "A" electrodes. : 't 4" to 7s" over size. All fire tubes were Expand boiler tubes at firebox with hand lv€auge thick and solid drawn. operated roller expander. These steel tube expanders were tapered 1 in 30. Towards Flue tubes were solid drawn 8 gauge and Steel Boiler Tube the end of the steam era it was permitted supplied by the tube mills reduced at the rli a firebox end for a distance of approximately f l\r I to carry out this operation at the firebox 12" by l" in relation to the body of the tube. end with a suitable pneumatic machine. The smokebox end was flared an extra Vt" Expand flue tubes at firebox end with over a distance of about 4". The diameter for Apply copper ferrules in holes in firebox hand operated roller expander. the lighter engines, D3, K and J was 5" while tube plate t/iz" under llush with fire side. Expand boiler tubes at smokebox end tbr the larger engines A2, S, N and X it was Copper terrules were equal to the with air operated roller expander. This 5V+" arl') the H class was 5lllo". The firebox diameter of the holes in the t'irebox tube machine was usually held by two people. t/2" end was machined as in Fisure I to facilitate plate. wide by ho" thick (Figure 2). Expand flue tubes at smokebox end with the beading. Set copper f-errules in flue tube holes with air operated roller expander. This was hand operated expander. carried out with fined rhe Correct sequence for steel an attachment to Set copper t'em:les in boiler tubes with air t-lange of the smokebox tube plate to boiler tubes operated prosser expander (Figure 2) which a large V4 piston driven pneumatic o Round edges of tlue and boiler tube holes which consisted of eight segments. The machine was fitted with a telescopic shati joints. to 1Ao" radius and thoroughly clean. The mandrel was driven in by a medium sized and universal edges of the boiler tubes were rounded on pneumatic hammer that also used to Prosser expand all flue and boiler tubes at "vas both sides immediately the tube plate had eventually bead the tubes. firebox end. A prosser was a sesmented been drilled with a special tool used in the Clean ends of boiler tubes with emerv expander having eight segments for boiler stationary radial drills while the flue tubes cloth and place in position. tubes and twelve for tlue tubes (Fi,eure 3). vere done at commencement of tubins The segments were evenlv expanded by Clean end of flue tubes and place in using a half round tlle. driving the appropriate mandrel in with a ' position. medium sized pneumatic hammer and this caused the tube to be expanded just inside the tube piate and in conjunction with the berding locked the tube to the rubc plrte. Lightly bellmouth firebox end of r.-roiler 5Ti E ET tubes. The bellmouth tool was used in a a r^DD.? and this action standard sized riveting -{un f'lared the 3/ro" protrusion tbr beading out about 45 degrees. Bead all flue and boiler tubes. To a"-rrrt"a:'Gil tacilitate the beading of the flue tubes the etrGes I I scarf'ed down protrusion was laid over lv-t I wirh the ball pein of a light tlog_uing w hammer. The shape of the beading tool tbr i: steel tubes is shown in Figure 4. The beading tools were used in a medium sized pneumatic hammer usually refened to in the trade as a "-qun". SETS F.RRI-.LE IX 1 .J?- FROM FRG:.T OF SHEET Test the boiler with hot watcr to 257n SF:CTIO};,; TILT ENL.{RCINC FERR:,'LE AT B ALJO *{iSgS SHOULDTR. PERT(IITItiG above working prcssure. This value is TO E:{TAR FR€SLY & CANNOT DISLOOCE FEFRT:LE from the SAA Codc relating to Locomotive Boilers as bcing not under 25Vo i]nd not ovcr 50Vo. llot water wils

38 Australian i\{ODEL Engincering MayiJune 1994 uscd to takc thc chill olf thc platcs, but prior to tcsting, the boilcr rvas subjcctcd to u hot washouf to rcmovc as much as possiblc all thc oil uscd lbr tapping and swarf liom drilling lnd tapping. Under tcst all lcaks werc caulked or rivets whipped in and occasionally a tube would split necessitating its rcplacemcnt. FIG 3 Stcam test boiler at working pressurc fbr at lcast thrce hours. The testing location was at the north end of the shop (areas 7l md'72, illustrated in AME February 1989 r Fill boiler with hot water to above level of removed from the end of one half and page 46) wherc portable structures served t'luc tubes and arc weld the beads of flue each short length rvas used to seal weld ls smokcboxes )cading into underground and boilcr tubes. If this operation was f'rom the top to the bottom of the boiler ducting connecting to the smokestack of cirrried out on the next working day the tubes, thc flue tubes usually took two passes thc stationary boilcr causins the drau_chr water in thc boilcr from the previous day down on either side. The shorr to kccp thc I'irc burning. At this sta_tc no was hot enough. The seal welding of the electrodes also cnlbied accurxte brick arch was in pilcc lnd onlv tubes was carricd out by two operators. manipuiation ol the arc. tcrnporary gratcs wcre in position. Thc onc entcred the flrebox and sealed a o Steam test boilcr at working pressurc fbr tucl uscd was wood. eithcr sliLhers liom couplc of tubes and came out and the next at least three hours to provc wcldine. thc sarvrnill or 5 lbot lcnlrths ol llrcwoori. man entercd and sealed a fcr.v more. This Thc "Rolling Book oi Insrrucrions" it usuallv took about ibur hours to rctch was done sincc the heat in the fircbox instruction 100 (a) (iv) statcs "Al'ter rhe stcxm rvorking pressurc with thc saiet.,, valvcs rcachcd about 140"F or 60' C. From test.s have becn complcred thc boiicr shall bc rclriv alrvavs blorving oi'f at noon and expcrience the welders found thc best scal paintcd with sntudgc ovcr the extcrior just wcld could be obtained using __.,vcrc kcpt at that point ibr three hours bv short surfaces excepr the liont of the smokcbox clcctrodes. as no injcctors were in opcration on the The standarci packet of tube platc." test rack. eiectrodes was sawn in half, the flux The rerson thc boiler lvas tested immediately after tubin_c was that thc boilcr tltters had t'itted all the mountinss ctc. r.r'hilc the tubing was bein. carricd our. The boiler. having bcen allocated to a frante u,as then loldcd on a boilcr transf'er tnick rnd hlule d t,u thc Erectinr Shop. Shcnk Conclusion This conciudcs the anicics ir.r thc scrii':: Pneurnctic Lo,comotive l}riler Construction in nommer Australia.

l|t, tltuttJ: [)rttr,4 .fot' ihi.t t6ptitrt'itcttr;t t, 2-l tturt ortiLl( \ lticit itu.; itcut tt ltit,tisLtt t t() l)t'('put'.'urtti ltttlt!islt. Ll{)ll-g t.t t/{):r ltreituritr,: atrtl srtbtnitriilt urricics or, !ltt litt' ltrctett[irtr {LpDli({n(('s t:;ltLrk (Lrrc.\t()rs), testitt.q oj itoiiars uttd uisrt on iitt tttoinlcnonce o/' boilcrs, nantclt renutyirtg trntl reltiacenretrt oJ stavs tutd tttbes utttl tltt applicrttion of porcirc.t to tllrooi untl i.tatk plares es w'ell as otiter itt,rrts thar nnt bt ol intaresi. \Ye consider tlrcse urticles ycn' wofiht of publicuriott l- becuuse rr srr,c.r model engitteers utt irtsigltt into tlte so lttr Lttttlocutrtented raulirie.; oj liJc of u'ith u Rorrnrlcr{ lAna locotrtotive boiler untl 2, yye also knov tltrLt Form Suitoble ttt(ttt.\' hoiltr n l'ilit'(t't irt ltt'cr(t'\'(rtit)tl societies Australia wide ore referring to Beod for Seol Welding Doug's notes to assis/ in tlrc eJJbcting oJ'tlte restoriltion of boiler.s fo, tlrcir locomotives... bntc.

Beoding Tool for Steel Tubes

Itrta t\-7 ^fA

$n

Nllv/Junc 1994 Australian i\{ODE,L Enlinccring t9