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HGR-B9001-Is02 ______Tubing of Locomotive Boilers

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HGR-B9001-Is02 ______Tubing of Locomotive Boilers Ref No: HGR-B9001 Issue No: 02 Issue Date: November 2014 HERITAGE RAILWAY ASSOCIATION GUIDANCE NOTE TUBING of LOCOMOTIVE BOILERS Purpose This document describes good practice in relation to its subject to be followed by Heritage Railways, Tramways and similar bodies to whom this document applies. Endorsement This document has been developed with and is fully endorsed by Her Majesty’s Railway Inspectorate (HMRI), a directorate of the Office of Rail Regulation (ORR). Disclaimer The Heritage Railway Association has used its best endeavours to ensure that the content of this document is accurate, complete and suitable for its stated purpose. However it makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems of work or operation. Accordingly the Heritage Railway Association will not be liable for its content or any subsequent use to which this document may be put. Supply This document is published by the Heritage Railway Association (HRA). Copies are available electronically via its website www.heritagerailways.com Issue 02 page 1 of 18 © Heritage Railway Association 2014 The Heritage Railway Association, Limited by Guarantee, is Registered in England and Wales No. 2226245 Registered office: 2 Littlestone Road, New Romney, Kent, TN28 8PL HGR-B9001-Is02 ___________________________ Tubing of Locomotive Boilers Users of this Guidance Note should check the HRA website to ensure that they have the latest version. Table of Contents 1. Introduction ........................................................................................................................................... 3 2. Recommendations ................................................................................................................................ 3 3. Dimensional Notation............................................................................................................................ 3 4. Personal Protective Equipment ............................................................................................................ 3 5. Inspection ............................................................................................................................................. 3 6. Material Specifications. ......................................................................................................................... 4 7. Removal of Tubes ................................................................................................................................. 4 8. Cleaning of Tube Holes ........................................................................................................................ 5 9. Reaming of Tube Plate Holes ............................................................................................................... 6 10. Screwed Tube Plate Bushes and Plugs ............................................................................................... 6 11. Ferrules ................................................................................................................................................. 7 12. Tube Plate Liners .................................................................................................................................. 8 13. Tube Plates ........................................................................................................................................... 8 14. Preparing for Tube Installation ............................................................................................................. 8 15. Flue Tubes ............................................................................................................................................ 9 16. Tube Expanding .................................................................................................................................. 10 17. Beading ............................................................................................................................................... 14 18. Seal Welding of Tubes........................................................................................................................ 15 19. Welding procedure.............................................................................................................................. 16 20. Leaks .................................................................................................................................................. 17 21. Testing ................................................................................................................................................ 17 22. Record Keeping .................................................................................................................................. 17 Appendix A: Record Keeping ................................................................................................................... 18 Issue 02 page 2 of 18 © Heritage Railway Association 2014 The Heritage Railway Association, Limited by Guarantee, is Registered in England and Wales No. 2226245 Registered office: 2 Littlestone Road, New Romney, Kent, TN28 8PL HGR-B9001-Is02 ___________________________ Tubing of Locomotive Boilers 1. Introduction a) This Guidance Note is one of a series dealing with Locomotive Boilers that were produced by the “Steam Locomotive Boiler Codes of Practice” practitioners meetings. b) Railway locomotive boilers are designed to create, store and distribute steam at high pressure. The working life of such a boiler can be considerably shortened if due care is not taken at all stages of inspection, repair, running maintenance and day-to-day running. c) In the past there have been a series of accidents and explosions due to work being undertaken without having due regard to the inherent risks involved. It is with that in mind that HMRI and HRA set up the series of meetings of boiler practitioners to discuss the issues distil good practice and codify it into this series of Guidance Notes. d) This guidance is written for the assistance of people competent to perform these tasks. In places the terminology used may be specific to such practitioners. e) This guidance should also be useful to those in a supervisory or more general role. However no work should be undertaken unless the persons concerned are deemed competent to do so. 2. Recommendations a) This guidance note is issued as recommendations to duty holders. b) Where duty holders decide to take actions that are not in agreement with these recommendations following appropriate risk assessments or for other reasons, it is recommended that those decisions are reviewed by the senior management body of the organisation concerned and a formal minute is recorded of both the decision reached and the reasons for reaching it. 3. Dimensional Notation a) The dimensions in this document are variously described in a mixture of imperial and metric units. Where practical equivalent dimensions have been shown but in some cases the dimensions do not easily equate and so the units in force at the time the original designs were documented have been used. 4. Personal Protective Equipment a) Before undertaking any work a risk assessment must have been conducted. b) Protective equipment is to be supplied and used at work wherever there are risks to health and safety that cannot be adequately controlled in other ways. c) The equipment must be: i) Compliant with the latest Personal Protective Equipment Regulations. ii) Properly assessed before use to ensure it is suitable. iii) Maintained and stored properly. iv) Provided with instructions on how to use it safely. v) Used correctly by those undertaking the work. 5. Inspection a) In the event of finding the tubes are suspect seek guidance from the boiler Competent Person before proceeding with any replacement. Issue 02 page 3 of 18 © Heritage Railway Association 2014 The Heritage Railway Association, Limited by Guarantee, is Registered in England and Wales No. 2226245 Registered office: 2 Littlestone Road, New Romney, Kent, TN28 8PL HGR-B9001-Is02 ___________________________ Tubing of Locomotive Boilers 6. Material Specifications. a) No boiler tubes should be replaced without prior approval of the Competent Person. All tubes obtained as replacements should be to British Standard Specification, BS EN 10216-1: 2002 (Seamless steel tubes for pressure purposes), BS EN 10217-1:2002 (welded steel tubes for pressure purposes), the grade of steel within either EN specification must be specified as P195TR1 (No 1.0107) or P195TR2 (No 1.0108). Alternatively an equivalent standard; see table below - Tensile Strength BR Specification Equivalent Detail Material Tons / sq “ Number Grade Boiler Tubes BS 3602-320 and Steel 20-28 123 or 122 BS 3059 PT1 320 Flue Tubes HFS/CFS or ERW Boiler Tubes Copper 14.5 min 317a BS 2871 PT3 C107-PA3 b) All tubes must be perfectly sound, well finished, free from surface defects and rust, and the ends must be faced clean and square. c) The tubes must be normalised before fitting. d) The responsible person should retain the relevant material and test certificates for such tubes for as long as the tubes are in use. 7. Removal of Tubes a) There are two distinct methods of tube removal, with variations depending on the tools and skills available: i) One method involves loosening the tubes from both tube plates and removing each tube through its own hole in the front tube plate. ii) In the other procedure,
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