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NEW SOUTH WALESGOVERNMENT 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.

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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

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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

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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

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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

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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 clinker to tubes 40 15.08 Projection of flared ends of arch tubes not fitted with sleeves 41 15.09 Compressed air supply for arch tube cleaners 41 15.10 Storage of cleaners when not in use 41 15.11 Lubricating cleaners 41 15.12 Examination of cutters, etc., in cleaners 41 15.13 Cleaners requiring repairs 41 15.14 Operation of cleaners 41 15.15 Maintenance of arch tubes 42 15.16 Examination for brick wear 42 15.17 Prohibition of welding 42 15.18 Application of arch tubes 42 15.19 Cutting to length 43 15.20 Cutting and squaring ends of arch tubes 43 15.21 Annealing arch tubes 43 15.22 Prohibition of cooling in water 43 15.23 Setting arch tubes 43 15.24 Reporting renewals 44 15.25 Oversize holes for arch tubes without sleeves 44

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15.26 Replacing arch tube plugs 44 15.27 Leakage at arch tube plugs 44 15.28 Screwing up plugs under steam pressure 44 15.29 Reducing steam pressure before remedying defects 44

SECTION 16 RULES FOR WASHING OUT LOCOMOTIVE BOILERS Clause: Page

16.01 Washout record book 45 16.02 Making correct entries 45 16.03 Control of washout men 45 16.04 Responsibility for examining boilers after washing out 45 16.05 Stabling locomotive 46 16.06 Hot water washing out 46 16.07 Cold water washing out 47 16.08 Procedure for washing out a boiler 48 16.09 Washing out foreign locomotives 51 16.10 Filling cold boilers at depots equipped with hot water washout plants 51 16.11 Blowing down boilers 51a 16.12 Greasing joints of man holes, mud doors, inspection openings, screw plugs, cocks, etc. (all types of boilers and unfired pressure vessels) 51a

SECTION 17 STORAGE OF LOCOMOTIVES Clause: Page

17.01 Selection of locomotives for storage 52 17.02 Preparation for storage 52 17.03 Storage of saturated locomotives 55 17.04 Locomotives in storage 55 17.05 Preparation of locomotives for service after storage 55 17.06 Subsequent boiler washout period 56 17.07 Re-treatment of locomotives for continuous storage 56a

SECTION 18 STANDARDISATION OF BOILER RECORDS Clause: Page

18.01 Record books 57 18.02 Instructions for recording 57 18.03 Periodical inspection of records 57

SECTION 19 SPECIAL INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ALL-STEEL LOCOMOTIVE BOILERS Clause: Page

19.01 Scope 58 19.02 Type of construction 58 19.03 Hydrostatic test periods and pressure 58 19.04 Steam tests for new boilers 59 19.05 Steam tests for existing boilers 59

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19.06 Setting of safety valves 59 19.07 Internal examination periods 59 19.08 Internal examinations by Boiler Inspector 60 19.09 Preparation and internal examination 60 19.10 Examination of hollow flexible wall stays at internal examinations60 19.11 Examination and testing of flexible crown stays at internal examinations 62 19.12 Adjustment of nuts on flexible crown stays when tubes are fitted or re-expanded 62 19.13 Examination of exterior of boilers at internal examinations 63 19.14 Removal of lagging sheets 63 19.15 Testing boiler after internal examination 63 19.16 Annual examination 63 19.17 Biennial examination 65 19.18 Special examination and testing of flexible crown stays in ‘D57’, ‘D58’, ‘D59’, and

‘AD60’ class boilers 65 19.19 Monthly examinations 66 19.20 Responsibility for special and monthly crown stay examinations67 19.21 Renewing flexible crown stays at monthly examinations 68 19.22 Broken stays 68 19.23 Reporting stay withdrawals and attention 68 19.24 Maintenance of wall stays 68 19.25 Maintenance of firebox seams and rivets 69 19.26 Corrosion in fireboxes 69 19.27 Monthly examination of smokebox, ashpan and grates 69

SECTION 19 SPECIAL INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ALL-STEEL LOCOMOTIVE BOILERS (continued) Clause: Page

19.28 Records of monthly examinations 69 19.29 Removal of lagging to detect leaks 69 19.30 Daily examination of fireboxes 70 19.31 Daily examination of smokeboxes 70 19.32 Removal of side lagging sheets for examination of side plates 70 19.33 Washing out boilers 71 19.34 Attention to plugs after boiler washout 71 19.35 Examination and cleaning of water gauge columns 71 19.36 Filling boiler after washout 71 19.37 Changing water in boiler to prevent foaming 72 19.38 Daily blowing down 72 19.39 Attention to fires and prevention of cold air entering fireboxes (see also pages 15 and 28) 72a 19.40 Brick arches 73 19.41 Application and maintenance of flues, boiler tubes and arch tubes 74 19.42 Examination and cleaning of thermic syphons 77a 19.43 Diaphragm defects in thermic syphons 771 19.44 Examination of diaphragms of locomotives in workshops 77c 19.45 Neck fractures in thermic siphons 77c 19.46 Renewing syphon neck 77c

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19.47 Syphon barrel defects 77e 19.48 Syphon body defects 77e 19.49 Part syphon renewals 77e 19.50 Syphon renewals 77f 19.51 Relieving strain in syphon necks 77n 19.52 Cleaning thermic syphons 77n

SECTION 20 SAFETY VALVES Clause: Page

20.01 Safety valve Inspector’s duties 78 20.02 Ramsbottom type valves for locomotives 80 20.03 Repair, adjustment and record of Ramsbottom safety valves at Eveleigh and Cardiff Workshops 80 20.04 Officer responsible for adjustment of valves at Depots 81 20.05 Stamping ferrules or liner plate for Ramsbottom valves 81 20.06 Unauthorised interference with safety valves 81 20.07 Despatch of defective pop safety valves to Eveleigh Workshops for repairs 81 20.08 Correct adjustment of safety valves 82 20.09 Unauthorised increase of working pressure 82 20.10 Testing safety valves at Depots 82 20.11 Sealing pop safety valves 83 20.12 Depot name abbreviations 83 20.13 Issue of safety valve certificates 84 20.14 Issue of pop safety valves 84 20.15 Examination and testing of steam gauges at Depots 84 20.16 Damage to steam pressure gauges in transit 85 20.17 Standard test gauges 85

SECTION 21 REGULATIONS COVERING THE INSPECTION AND REPAIR OF STATIONARY AND PORTABLE BOILERS Clause: Page

21.01 Examination by Boiler Inspectors 87 21.02 Completion of repairs and tests 87 21.03 Filing of reports 88 21.04 Boilers due to examination 88 21.05 Examination for defects at periodical fusible plug inspection 89 21.06 Safety valves, periodical checking of the operation of 89

SECTION 22 MAINTENANCE REGULATIONS FOR STATIONARY AND PORTABLE BOILERS Clause: Page

22.01 Number tablet 90 22.02 Stamping number on boilers 90 22.03 Number tablets for new boilers 90 22.04 Issue of number tablets 90 22.05 Removal of number tablets from condemned boilers 90

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22.06 Fusible plug examination periods 90 22.07 Regulations governing attendants of stationary and portable boilers 91 22.08 Regulations governing Contract Pumpers working as Attendants in charge of steam plants 91a 22.09 Removal of lagging for examination of stationary and portable boilers 92 22.10 Lagging on stationary and portable boilers 93 22.11 Time allowance for washing out stationary boilers 93 22.12 Responsibility for safe-working 93 22.13 Maintenance of boilers by Boiler Attendants 93 22.14 Examination periods for stationary and portable boilers 94 22.15 Opportunity for interior inspection at Intermediate Examinations94

SECTION 23 HYDROSTATIC AND STEAM TESTS FOR STATIONARY AND PORTABLE BOILERS Clause: Page

23.01 Hydrostatic tests 95 23.02 Steam tests 95 23.03 Accumulation test for discharge capacity of safety valves 96 22.04 Setting safety valves 96

SECTION 24 EXAMINATION OF BOILERS AND UNFIRED PRESSURE VESSELS HAVING LONGITUDINAL LAP SEAMS Clause: Page

24.01 Cutting test grooves 97 24.02 Examination of test grooves under hydrostatic pressure 97 24.03 Recording positions of test grooves 97 24.04 Provision of labour and equipment for cutting test grooves 98 24.05 Sight holes in lagging and brickwork to permit inspection of test grooves 98 24.06 Regular examination of test grooves by attendant in charge of boilers or unfired pressure vessels 98 24.07 Examination of test grooves when sight holes are not provided 98 24.08 Examination of test grooves at washout periods and fusible plug examinations 99 24.09 Action to be taken when test grooves leak in service 99 24.10 Drilling core holes for further examination of plate 99

SECTION 25 REGULATIONS COVERING THE INSPECTION, REPAIR AND TESTING OF UNFIRED PRESSURE VESSELS Clause: Page

25.01 Scope 100 25.02 Examination by Boiler Inspectors 100 25.03 Completion of repairs and tests 101 25.04 Filing of reports 101 25.05 Vessels due for examination 101

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SECTION 25 REGULATIONS COVERING THE INSPECTION, REPAIR AND TESTING OF UNFIRED PRESSURE VESSELS (continued) Clause: Page

25.06 Drainage of air reservoirs 102 25.07 Protection from fire 102 25.08 Test grooves 102 25.09 Numbering and classification of unfired pressure vessels 102 25.10 Number tablets for new pressure vessels 103 25.11 Issue of number tablets 103 25.12 Unregistered vessels 103 25.13 Removal of number tablets from condemned pressure vessels103 25.14 New designs 103 25.15 Examination periods 104 25.16 Local periodical examinations 104 25.17 Safety of vessels 104 25.18 Maintenance of unfired pressure vessels 105 25.19 Location 105 25.20 Hydrostatic tests for vessels of riveted or solid drawn construction 105 25.21 Hydrostatic tests for vessels of welded or brazed construction 105 25.22 Hammer tests on welded vessels 106 25.23 Vessels defective under test 106 25.24 Safety valves – periodical checking of the operation of 106 25.25 Greasing joints of man holes, inspection openings, screwed plugs, cocks, etc. 106

DIAGRAMS IN APPENDIX

Fig. 1 Holes in tubeplates for steel flues and tubes. Fig. 2 Copper ferrules for steel flues and tubes in firebox tubeplates. Fig. 3 Tightening copper ferrules for steel flues and tubes in firebox tubeplates with sectional expander. Fig. 4 Swaged ends of steel boiler tubes – firebox end. Fig. 5 Swaged ends of steel flues – firebox end. Fig. 6 Setting steel flues and tubes in tubeplates with roller expander, prior to flaring, prossering and beading. Fig. 7 Flaring steel tubes. Fig. 8 Prossering steel flues and tubes in firebox tubeplates with sectional expanders. Fig. 9 Method of beading steel flues and tubes. Fig. 10 Method of welding steel flues and tubes in firebox tubeplates. Fig. 11 Plain and beaded steel tubes and flues – smokebox end. Fig. 12 Standard beading tools for steel flues and tubes. Fig. 13 Master gauges for standard beading tools for steel flues and tubes. Fig. 14 Tightening arch tubes in firebox plates with roller expanders. Fig. 15 Flaring tool for arch tubes. Fig. 16 Application of copper ferrules to oversize arch tube holes. Fig. 17 Clamp for holding arch tubes against slippage in setting. Fig. 18 Forming bossed hole for arch tube bushes in copper firebox plates. Fig. 19 Arch tube bush being expanded in copper firebox plates. Fig. 20 Beading arch tube bush in copper firebox plates.

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DIAGRAMS IN APPENDIX

Fig. 21 Method of beading arch tubes to copper firebox plates of D50, D53, D55 class standard boilers. Fig. 21a Method of applying arch tubes to copper firebox plates. Fig. 22 Method of applying arch tubes to steel firebox plates. Fig. 23 Arch tube cleaner. Fig. 24 Positions for test grooves and core holes in boilers and unfired pressure vessels having longitudinal lap seams. Fig. 25 Details of test groove and core hole. Fig. 26 Position of pilot hole for core drill. Fig. 27 Arrangement of drilling post and ratchet for drilling core holes. Fig. 28 Forming riveted heads on crown stays. Fig. 29 Re-dressing beaded wall stay heads. Fig. 30 fitting new front tubeplate to existing boiler barrel angle ring. Fig. 31 Effect of heavy caulking on riveted seams. Fig. 32 Cracks in plates at longitudinal lap joints. Fig. 33 Cracks in plates caused by tool marks. Fig. 34 Distortion of rivets due to plates being drifted. Fig. 35 Forming snap headed and rounded countersunk headed rivets. Fig. 36 Forming conical headed rivets.

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SECTION 1 General Regulations Covering the Inspection and Testing of Locomotive Boilers

1.01 INTERNAL EXAMINATIONS BY BOILER INSPECTORS AND PREPARATION OF BOILERS:

Boiler Inspectors shall examine all locomotive boilers due for internal examination or major repairs.

For the internal examination, the dome cover, regulator stand pipe, internal steam pipe, lagging sheets, all flues, tubes, arch tubes, mud hole doors, inspection doors, plugs and flexible stay caps shall be removed and the boiler efficiently cleaned in accordance with the requirements of the Boiler Inspector.

A careful examination shall then be made for the detection of wastage, cracks, pitting, corrosion and grooving; particular attention shall be paid to lapped seams, edges of plates, curvature of flanges, arch tube sleeves or openings in throat or backplates and other parts where defects most frequently develop. Braces and stays with pin jointed ends shall be examined to see they are taut, the pins are properly secured in place and each detail is in a satisfactory condition to support its proportion of the load.

All scale and dirt shall be removed from the caps and sleeves of flexible stays and the gasket and thread shall be thoroughly cleaned before the caps are re-applied. A graphite lubricant (see page 51a) shall be smeared on the threads of the caps each time they are assembled to ensure easy removal. Damaged gaskets shall be replaced by new ones.

1.02 SUBMISSION OF BOILER INSPECTION REPORTS:

The Boiler Inspector making an examination of a boiler shall be responsible for:

(a) Correctly recording, in duplicate, all particulars required on the proper form (X2819 or X2820) for report upon inspection of locomotive boilers.

(b) Directing in writing, on the repair form (X2822), in duplicate, all necessary repairs.

(c) Keeping in touch with the progress of the work to see that it is properly done.

(d) Certifying as to the satisfactory completion of repairs and tests of the boiler, and endorsing the originals, and their respective copies, of the report upon inspection and the repair form accordingly.

(e) Recommending that a certificate be issued to authorise the boiler being placed in service, or, if the boiler is considered unfit for service, recommending that it be condemned or reserved for duty at a reduced pressure.

1.03 SUBMISSION OF ESTIMATES FOR REPAIRS WITH INSPECTION REPORTS:

Where boilers require extensive or very costly repairs to put them in a satisfactory condition for service, the Boiler Inspector, after examining the boiler and preparing his report, shall seek the assistance of the Foreman Boilermaker and Costing Clerk to ascertain the total cost of carrying out the repairs. The estimate shall be forwarded to the Boiler Engineer with the inspection and repair forms.

1.04 FILING OF INSPECTION REPORTS:

Reports of examinations, crown and wall stay diagrams, repair forms, etc., of each boiler examined, shall be forwarded to the Boiler Engineer, and a copy of each report, ,diagram and repair form shall be forwarded to the workshop or depot concerned.


1.05 BOILER HISTORY RECORD:

Every locomotive boiler shall have a history record file, which shall be forwarded to each centre at which the boiler may be located for service, repair or storage. The history record shall consist of copies of all reports, diagrams, etc., referring to the boiler, and shall be additional to the file of original reports, etc., held by the Boiler Engineer.

The boiler history record shall be coupled with the locomotive history file, being detached only when necessary to facilitate examinations and the execution of repairs, or when the boiler is changed on the locomotive.

1.06 REPAIRS TO BOILERS ON LOCOMOTIVES IN WORKSHOPS:

Boilers on locomotives in workshops for light or medium repairs, shall be examined by the Foreman Boilermaker to determine if any repairs are required. If serious defects are disclosed, the Boiler Inspector shall be informed, and he shall direct the action to be taken.

1.07 SUBMISSION OF REPORTS FOR REPAIRS TO BOILERS ON LOCOMOTIVES IN WORKSHOPS:

The Foreman Boilermaker making the examination of a boiler undergoing repairs shall submit a typewritten report to the Boiler Engineer, giving full particulars of all repairs carried out and tests conducted. A copy of the report shall be attached to the boiler history record.

When the Boiler Inspector is called upon to make the examination, he shall submit the necessary report instead of the Foreman Boilermaker.

1.08 TESTING OF NEW BOILER PLATES:

When boiler plates are received from the Manufacturer, they shall be tested by the Testing Engineer, and he shall supply a copy of the test results to the Boiler Engineer.

1.09 MARKING OF PLATE DIAGRAMS FOR NEW OR RE-BUILT BOILERS:

A diagram of each boiler being constructed or re-built shall be supplied, in duplicate, to the Boiler Inspector in the workshops, and he shall mark the plate number and tensile test figures of each new plate on the diagram. The diagram shall be forwarded to the Boiler Engineer for filing, and a copy attached to the boiler history record at the workshop.

1.10 INSPECTION OF WORK DURING CONSTRUCTION OF NEW BOILERS:

During the construction of new boilers, the Boiler Inspector shall inspect the work at all stages; giving careful attention to the drilling of holes; annealing of dished, flanged or fireworked material; correct application of wall stays; and the absence of welds in steel stays excepting stays manufactured from steel to Departmental Specification No. G.1, and for which authority has been given for ends to be welded. He shall see that the construction, in every respect, conforms with approved practice, and is in conformity with the drawings issued in regard thereto.

1.11 NUMBERING OF NEW BOILERS:

Each locomotive boiler, when first constructed, shall be marked with a registered number on the bottom lip of the firehole ring, and on the left hand top corner of the firebox shell backplate just below the longitudinal stays.

In addition, a registration plug bearing the number of the boiler shall be fitted in the centre of the shell backplate above the firehole.

The registered number shall be issued by the Boiler Engineer.


Every boiler shall retain its original registered number throughout its life.

1.12 TESTS ON COMPLETION OF NEW BOILERS:

Each new boiler, on completion, shall be subjected to the hydrostatic and steam tests provided for elsewhere in these Regulations. The tests shall be conducted under the supervision, and to the satisfaction of the Boiler Inspector.

1.13 SUBMISSION OF REPORT UPON FIRST INSPECTION OF NEW BOILERS:

When the hydrostatic and steam tests on a new boiler have been satisfactorily completed, the Boiler Inspector shall submit a report upon first inspection (X2819), together with the diagrams described in Clause 1.09 to the Boiler Engineer.

1.14 SERVICE CERTIFICATE:

Before a new boiler, or an existing boiler repaired after internal examination, is placed in service, a certificate showing that it has satisfactorily passed all tests and is safe for service shall be issued. The certificate shall be issued from the Office of the Boiler Engineer, and will authorise the boiler for a specified term of service.

1.15 CO-OPERATION TO OBTAIN EFFICIENT WORK:

These Regulations shall not, in any way, lessen the responsibility of Foremen, Sub-foremen and Leading Boilermakers, when carrying out repairs, etc., in workshops and depots, for detecting and reporting defects that may not have previously been reported.

The workshops’ and depots’ staffs concerned shall co-operate with the Boiler Inspector to achieve the best possible results, both in the examination and in the efficiency of the work.

SECTION 2 Inspection, Repair and Testing of Locomotive Boilers at Depots

2.01 BOILERS DUE FOR EXAMINATION OR TEST:

Steamshed Inspectors shall be advised by Decision Form and Returns Nos. 3, 4 and 6, of boilers due for internal examination, intermediate test and crown stay examination.

2.02 EXAMINATION AND REPAIRS:

The Boiler Inspector shall carry out the examination of boilers due for inspection, and show on a repair form (X2822) what repairs are necessary. A copy of the repair form, addressed to the Steamshed Inspector of the district concerned, shall be served upon the Sub-foreman or Leading Boilermaker.

When the repairs and hydrostatic test have been satisfactorily completed, the Boiler Inspector shall endorse the repair form to this effect.

2.03 FILING OF REPORTS:

After repairs have been completed and tests conducted to the satisfaction of the Boiler Inspector, a copy of the report on subsequent inspection (X2820), together with a copy of the repair form, shall be endorsed and forwarded to the Steamshed Inspector for attaching to the boiler history record.

The original copies of the report and repair forms shall be forwarded to the Boiler Engineer.

2.04 SUSPENSION OF CERTIFICATE DURING REPAIRS:

When a boiler is stopped for repairs which will take several days to complete, the Boiler Inspector shall endorse the repair form (X2822) to suspend the currency of the


certificate during the time the boiler is out of service for repairs.

2.05 STOPPING LOCOMOTIVES FOR BOILER REPAIRS:

When a Boiler Inspector has occasion to stop a locomotive for workshop attention, due to some defect in the boiler, he shall direct, on a repair form (X2822) in duplicate, and by altering the printed wording thereon, that the locomotive be sent to the workshops for examination and repairs.

The original form shall be forwarded immediately to the Boiler Engineer, and the copy served on the Steamshed Inspector of the district to which the locomotive is allotted. The original form shall subsequently be forwarded by the Boiler Engineer to the Works Manager concerned to be noted. It shall then be sent to the Boiler Inspector in the workshops. On completion of the work, the original repair form, together with all reports in connection with the work, shall be returned to the Boiler Engineer.

2.06 SUBMISSION OF REPORTS ON BOILERS REPAIRED AT DEPOTS AND NOT SUPERVISED BY A BOILER INSPECTOR:

When repairs, other than running repairs, are effected at a depot and are not supervised by the Boiler Inspector, a report setting out the nature of the repairs, together with any necessary diagrams, shall be prepared by the Sub-foreman Boilermaker or Officer responsible. The report and diagrams shall be forwarded to the Boiler Engineer, and copies shall be attached to the boiler history record (see Clause 1.05) at the depot.

2.07 BOILER REPAIR BOOK:

A boiler repair book (X2885) shall be kept at each depot. It shall show the date and description of all repairs to boilers, and the name of the boilermaker who carries out the work. The boilermaker in charge shall supervise the work and see that correct entries are made.

SECTION 3 Hydrostatic and Steam Tests for Locomotive Boilers

3.01 GROUPING FOR TEST PURPOSES:

Every locomotive boiler, before being put into service, and at specified periods whilst in service, shall be tested by hydrostatic pressure in the manner described herein.

In addition, every new boiler, and every existing boiler after internal examination or heavy repairs to firebox, firebox shell or barrel, shall be tested by steam pressure test subsequent to the hydrostatic test.

Locomotive boilers requiring testing, and for the purposes of these tests only, shall be classified in one of the following groups:

Group A. New boilers prior to being placed in service.

Group B. Boilers, other than new boilers, which have received internal

examination or heavy repairs to firebox, firebox shell or barrel, etc.

Group C. Boilers, other than new boilers, due for intermediate hydrostatic test

at periods between internal examinations.

3.02 HYDROSTATIC TESTS:

For boilers in Groups A, B and C, the hydrostatic test shall be made with warm water at a temperature of approximately 150° F. In each boiler being tested, care shall be taken to see that all air has escaped, and that the boiler is completely filled with water. The


pressure shall then be steadily applied and when the correct test pressure has been reached, it shall be maintained for a period of 15 minutes. A thorough examination of the boiler shall be made during this period for signs of bulging, cracking, leakage or other defects.


Nov, 1944

Hydrostatic and Steam Tests for Locomotive Boilers.

3.03 HYDROSTATIC TEST PRESSURES:

The pressures for hydrostatic tests shall be calculated as follows: Group A. Test pressure = Working pressure plus 25 per cent. Group B. Test pressure = Working pressure plus 15 per cent. Group C. Test pressure = Working pressure plus 15 per cent.

The following table gives the necessary test pressures for the several working pressures quoted. For working pressures other than those quoted, the correct hydrostatic test pressure shall be calculated on the basis set out above:

Working Pressure

Hydrostatic Test Pressure

Group A (WorkingPressure) Plus 25 per cent.

Group B (Working Pressure) Plus 15 per cent.

Group C (Working Pressure) Plus 15 per cent.

120 150 138 138

130 163 150 150

140 175 161 161

150 188 172 172

160 200 184 184

170 212 195 195

180 225 207 207


190 238 218 218

200 250 230 230

245 306 282 282

3.04 HYDROSTATIC TEST WITH MOUNTINGS:

Boilers undergoing hydrostatic test, under the supervision of a Boiler Inspector at workshops or depots, but which are not to be subsequently steam tested, shall be tested complete with boiler mountings in position, to ensure that all joints, etc., are free from leaks or other defects.

3.05 VARIATIONS IN PRESSURE DURING HYDROSTATIC TEST:

During the period for maintenance of pressure in any hydrostatic test, the test pressure shall not be permitted to vary by more than 5 lb. per sq. in. above or 5 lb. per sq. in. below the test pressure prescribed herein.

3.06 STEAM TEST:

The steam test on boilers included in Groups A and B shall be made subsequent to the hydrostatic test, and by each boiler generating its own steam. The pressure shall be raised slowly and uniformly, allowing at least 2-1/2 hours to reach the prescribed test pressure.

Group A. The test pressure shall be maintained for 30 minutes, after which steam shall be blown off until the pressure is reduced to the approved working pressure. The working pressure shall be maintained for 60 minutes. During the periods in which the test pressure and the working pressure are maintained, the boiler shall be carefully examined for any signs of leakage or evidence of distress arising from the temperature changes following the variation in the pressure.

Group B. The test pressure shall be maintained for 60 minutes, during which the boiler shall be carefully examined for any signs of leakage or evidence of distress.

3.07 STEAM TEST PRESSURES:

The pressures for steam tests shall be calculated as follows:

Group A. Test pressure=working pressure plus 10 per cent.

Group B. Test pressure=working pressure.

The following table gives the necessary test pressures for the several working pressures quoted. For working pressures other than those quoted, the correct steam test pressure shall be calculated on the basis set out on page 9:

Steam Test Pressure

Working Pressure

Group A (Working Pressure plus 10 per cent).

Group B (Equal to Working Pressure)

120 132 120

130 143 130

140 154 140

150 165 150

160 176 160

170 187 170


180 198 180

190 209 190

200 220 200

245 270 245

NOTE. Steam tests need not be carried out on boilers Group C, unless conditions or circumstances render such tests necessary. Should a steam test be made, the test pressure shall be as for boilers Group B.

3.08 VARIATIONS IN PRESSURE DURING STEAM TEST:

During the period for maintenance of pressure in any steam test, the test pressure shall not be permitted to vary by more than 5 lb. per sq. in. above or 5 lb. per sq. in. below the test pressure prescribed herein.

3.09 SETTING SAFETY VALVES:

The safety valves on boilers in Groups A and B shall be adjusted and set in accordance with the requirements of Clause 20.08 after the satisfactory conclusion of the steam tests, and on boilers in Group C, during the first period that the boiler is steamed subsequent to the hydrostatic test.

SECTION 4 Instructions for Examination, Repair and Maintenance of Locomotive Boilers at Depots

4.01 MONTHLY EXAMINATION:

District Locomotive Engineers shall be responsible for seeing that the firebox and other parts of each locomotive boiler in their charge are examined personally by the Sub-foreman Boilermaker or Leading Boilermaker each month. It shall be clearly understood that where a Sub-foreman Boilermaker is employed he is the officer who shall personally make the monthly examinations. At depots where no Sub-foreman Boilermaker is employed, the Leading Boilermaker shall personally make the examinations. A permanent record of the monthly examinations shall be maintained at each Depot in the record book (X2883) provided for the purpose.

The monthly examination shall be carried out in accordance with the following:

(a) After the boiler has been washed out, all stays, the firebox crown plate, and every part of the interior that can be seen through the washout holes shall be examined for wasting and corrosion. The water spaces shall be examined for mud and scale, particularly above and below the firehole and amongst the stays.

(b) A careful examination shall be made to detect broken or wasted crown stays, flexible stays and rigid wall stays, bulged or wasted firebox plates between stays, cracks, corrosion, leaks, wasted or defective bolts, studs, inspection and mud doors, handholes, or any other defects. All boiler and arch tube plugs shall be examined for worn or defective threads, also the threaded openings into which they fit. Particular care shall be exercised to detect the presence of wasted, thin, sagged, blocked up or leaky tubes, defective beading or ferrules.

(c) The arch tubes shall be carefully examined for defects in accordance with the requirements of Section 15.

(d) Rigid wall stays shall be examined. The tell-tale holes shall be tested to see that they are open and free. Tell-tale holes shall not, under any circumstances, be


plugged up or hammered over.

(e) An examination shall be made of the smokebox, spark arrester, deflector plates, ashpan and grates and their operating gear.

The District Locomotive Engineer shall strictly supervise the monthly examinations and make occasional inspections of fireboxes, etc., to ensure that the duties are performed efficiently.

4.02 SUPERVISION OF WORK BY SUB-FOREMAN OR LEADING BOILERMAKER:

The Sub-foreman or Leading Boilermaker shall daily enter the firebox of each boiler under repairs, direct the Boilermaker carrying out the repairs as to the details of the work to be done, and inspect the work when completed to ensure that it has been satisfactorily executed.

4.03 DAILY SUPERVISION BY OFFICER-IN-CHARGE:

The District Locomotive Engineer or Officer-in-Charge shall confer with the senior hand and direct him daily as to the disposal of the work to the best advantage, and arrange, as far as practicable, for the boiler repairs and engine repairs to be carried out simultaneously.

4.04 REPAIRS AT MONTHLY EXAMINATIONS:

Defects located at monthly examinations shall be recorded in the repair book as provided for in Clause 2.07, and immediate attention given to the repairs. If immediate attention is not practicable, the repairs shall be carried out at the earliest opportunity.

The record of repairs booked shall be examined at frequent intervals by the Steamshed Inspector or Officer-in-Charge, and he shall take the necessary action to ensure repairs being given early attention.

4.05 REPAIRS FOR BROKEN RIVETS IN COPPER FIREBOXES:

Where copper rivets are found broken, they shall be carefully removed so as not to disturb the plates. Copper studs shall then be fitted and the seam chamfered and lightly fullered.

4.06 ATTENTION TO LEAKAGES:

Leakages in the firebox and outer shells, at angles around the front tubeplate, boiler plugs, studs and brick arch studs, shall be attended to as soon as possible after being detected.

Serious erosion has been found to take place when leakages have been neglected.

Employees are warned that plugs and studs shall not be screwed up in a boiler under steam pressure.

If a serious leakage occurs, the steam pressure shall be reduced immediately to zero before any attempt to remedy the defect is made.

4.07 FOREIGN MATTER IN BOILERS:

Locomotive boilers, after having been repaired at workshops or depots, shall be inspected closely by the Sub-foreman, Leading Boilermaker or other responsible Officer, to detect and have removed any portions or stays, rivets or other foreign matter lodged in the boiler.

Whenever a boiler is entered, the opportunity shall be taken to remove any obstruction found lodged between the tubes or in the water spaces, etc.


4.08 MONTHLY EXAMINATION OF FIREBOX AND FIREBOX SHELL PLATES:

At the monthly examinations of boilers, all washout plugs and doors shall be removed and the firebox and firebox shell plates carefully examined, using torch and reflector, to detect any indication of grooving, pitting or fractures in the flanges and other parts.

A record shall be kept of all examinations in the record book (X2883) provided for the purpose.

At each intermediate test of the boilers, the clothing plates, washout plugs and doors shall be removed, and for those classes of locomotives where it is possible for the boiler to be entered, the regulator also shall be removed. The plates shall then be carefully examined internally and externally for incipient pitting and surface cracks. Pitting and grooving of boiler plates shall be looked for in those parts where stress conditions are likely to be severe.

4.09 SPECIAL EXAMINATION OF VITAL POSITIONS:

In the examination of boilers, special attention shall be paid to those parts where it is known that bending actions occur.

4.10 LUBRICATION OF EXPANSION BRACKETS:

The expansion brackets on each side of a boiler shall be kept clean and frequently oiled to permit of free movement for the expansion and contraction of the boiler, and thereby lessen the bending action which is a contributory cause of the development of throatplate fractures.

4.11 PROGRESS OF PITTING AND CORROSION:

Where pitting is detected, its progress shall be carefully watched, and, should it persist as a line of pit marks for any distance which is considered dangerous, the matter shall be specially reported. A Boiler Inspector shall then make an examination of the affected area, and direct the action to be taken to restore the boiler to safe working condition.

All fractures observed in badly pitted plates shall be reported by the Examining Boilermaker. The date and condition of the plate at any previous examination shall be given. Negligence in reporting badly wasted plates will be seriously regarded.


Instructions for Examination, Repair and Maintenance of Locomotive Boilers at Depots.

4.12 BOILER INSPECTOR'S REPORT OF CONDITION OF BOILERS AT DEPOTS:

When a Boiler Inspector visits a depot, he shall inspect the fireboxes, smokeboxes, ashpans and other details of all boilers available during his visit. He shall render a return showing the condition of each item to the Boiler Engineer and supply a copy to the District Locomotive Engineer.

4.13 LAX SUPERVISION AND FAULTY OR NEGLECTED REPAIRS:

The Boiler Inspector shall submit a report, to the Boiler Engineer, on the conduct of boiler work generally at the Depot. He shall bring any case of lax supervision, or neglected attention to repairs, under the notice of the District Locomotive Engineer, who shall take prompt action to rectify the matter.

4.14 CO-OPERATION TO OBTAIN EFFICIENT WORK:

It shall be clearly understood that the Boiler Inspector does not relieve the District Locomotive Engineer of any responsibility in the efficient maintenance of boilers in his charge. The District Locomotive Engineer shall be guided by information or directions given by the Boiler Inspector. It is expected that District Locomotive Engineers and Boiler Inspectors will co-operate and bring about an improvement generally in the maintenance of boilers.

4.15 DAILY EXAMINATION OF FIREBOXES:

In addition to the regular monthly examinations, the fireboxes shall be inspected daily after the arrival of the locomotives at the Depot. This examination is to be carried out at the first opportunity when the boiler is out of steam, by the Sub-foreman, Leading Boilermaker or Examining Boilermaker (as the case may be) when on duty, for bulges, cracks, overheating, defective stay-heads, irregularly stopped-up or hammered-over tell-tale holes, leaking seams and any other defects that may have developed. The


firebars and ashpan shall also be examined. Leaking. stays, seams or cracks developing in plates around stays, are often evidence of the accumulation of mud or scale, and in giving attention to these defects, the cause shall be looked for and removed. Special attention shall be given to those parts of the firebox where the interior surfaces are difficult to reach with the jet from the washout nozzle. Any indication of overheating shall be investigated immediately.

4.16 DAILY EXAMINATION OF SMOKEBOXES:

(a) Spark arresters: The spark arrester netting and plates shall be examined by the Sub-foreman, Leading Boilermaker or Examining Boilermaker daily, to ascertain if any openings exist larger than the mesh of the netting. Any such defects shall be satisfactorily repaired before the locomotive re-enters service, and a careful record of these details shall be kept at the depot.

(b) Testing for air leaks: Every smokebox shall be examined for air leaks by the Sub-foreman or a competent man appointed in his stead. With the smokebox door properly fastened, and the blower turned on, a search shall be made with a lighted torch over all joints on the outside of the smokebox, around steam pipes, saddle casting, base of funnel, front ring and door, rivets, bolts, pipe connections, and any defects found shall be repaired immediately.

4.17 SPECIAL EXAMINATION OF FIRE PREVENTION APPLIANCES (During Summer Months)

From the 1st October, to the 31st March a special examination shall be made immediately prior to a locomotive leaving the Depot to determine whether the fire prevention appliances are in order and proper running position. This examination shall be made by the Boilermaker when on duty or by the Chargeman or his deputy and the information entered in the X2881 record book as an outgoing record under the appropriate headings.

4.17a EXAMINATION OF BOILERS ON LOCOMOTIVES AWAY FROM HOME DEPOT:

When a locomotive belonging to another district arrives at a depot for washing out or any other purpose, the Sub-foreman or Leading Boilermaker shall carry out a similar examination to that which would apply to a home depot locomotive.

A report on the examination, disclosing any defects, shall be made to the District Locomotive Engineer of the Depot where the examination is made, and a copy forwarded to the District Locomotive Engineer of the district to which the locomotive is allotted.Original page 15 – April, 1949

4.17b PREVENTION OF COLD AIR ENTERING FIREBOXES:

Officers shall exercise every precaution against the admission of cold air to hot fireboxes of locomotives when fires are drawn or banked.

Fuelmen and other employees authorised to move locomotives in steam, or whose duty it is to deal with fires or rake out ashpans, shall be instructed in the following:

(a) Precautions shall be taken to avoid the admission of cold air to hot fireboxes, and any other action which would be likely to chill the plates or tubes.

(b) The least possible use shall be made of the blower during the time the fire is being dealt with.

(c) Immediately the fire is drawn or banked in any locomotive firebox, and before the locomotive is moved from the ashpit, the blower shall be shut off and the firehole


door and damper doors shall be closed and remain closed during any movement of the locomotive until it is stabled.

Officers shall closely observe the handling of locomotives with hot fireboxes, and drawn or banked fires. Suitable action shall be taken with employees who fail to observe the above instructions.

Examination and Maintenance of Water Gauge Columns

4.18 RESPONSIBILITY OF STEAM SIZED INSPECTOR: The Steam Shed Inspector or Officer-in-Charge shall be held responsible for seeing that the following regulations for the examination and maintenance of water gauge columns, copper pipes, etc., are strictly adhered to.

4.19 WATER GAUGE COLUMN STEAM PIPES:

Water gauge columns of the type fitted with an independent steam pipe connection between the boiler and the top of the gauge column mounting shall be given periodical attention as follows:

Every twelve (12) months coinciding with the annual or biennial examination for all steel boilers, or nearest tone-up interval for other types of boilers:

(a) Remove and anneal the steam way connecting pipe and thoroughly examine it, also the union nuts, collars and flanges for defects. Any pipe found with flats, kinks, flaws, fractures, faulty connections, weak or thin area, shall be discarded and replaced by a pipe in satisfactory condition. It is essential that the bore of the pipe be unrestricted. Deposits lodged therein shall be removed. The repairing of steam pipes by brazing on patches or other means either in the body of the pipe or at the junction of the collars or flanges to strengthen flaws, thin areas, or fractures, shall not be permitted.

(b) Steam way pipes after having been annealed and examined shall be subjected to an hydrostatic test of 1-1/2 times the working pressure. Whilst under this test pressure, they shall be again examined and if found satisfactory, passed for service. This test shall be carried out on the pipe whilst disconnected from the water gauge column.

(c) Examine carefully the top steam pipe connection attached to the firebox casing, and also the waterway connection attached to the firebox back plate. Where either of these is found to be in a defective or wasted condition, they shall be renewed.

(d) Examine generally the water gauge columns. Should defects be found they are to be remedied immediately in order to maintain this important mounting in a safe and satisfactory working condition.

(e) The District Locomotive Engineer shall appoint a competent mechanic to carry out the duties stated in clauses ‘a’ to ‘d’ and institute a book record showing the date the water gauge column on locomotives are dealt with and tested. This record is to be initialled by the employee who conducts the tests.

It shall be the duty of the District Locomotive Engineer or Officer-in-Charge to witness the hydrostatic tests whilst they are being applied to the steam way connecting pipes or, in his absence the Sub-foreman or Leading Fitter.


4.20 CLEANING STEAM AND WATER WAY PASSAGES OF WATER GAUGE COLUMNS:

At each boiler washout the gunmetal plugs opposite to the ends of steam and water passages in the water gauge mountings shall be removed by the washout man and a 3/8 inch diameter brass rod passed through each passage to remove any obstruction, scale or sediment which may be deposited therein, and cause a false water level. All passages shall be kept clean and free and the gauge cocks tested for satisfactory operating condition.

4.21 MAINTENANCE OF WATER GAUGE COLUMN COCKS:

(a) Ordinary Plug Type Cocks. Coincident with the monthly boiler and firebox examination, the gauge cock plugs and test cock spindles shall be removed, thoroughly cleaned, ground in if found necessary, and greased with a graphite lubricant (see page 51a).

(b) Asbestos Packed Cocks. On washout days and also at the monthly boiler and firebox examination, all gauge cocks shall be checked for satisfactory operation and condition, and the distance the gland or blank nuts are screwed in. Should the cocks be stiff to operate, the cock plugs are to be removed and greased with a graphite lubricant (see page 51a) and the glands repacked with asbestos fibre. When gauge cocks are found to be in satisfactory working condition, not difficult to operate, and not leaking, there is no need to remove them.

In assembling or inspecting water gauge cocks and water gauge drain cocks of the asbestos fibre packed type on locomotives, the gland nuts on the cock spindles and the blank nuts on the opposite end must be screwed home to within the limits between a minimum of 1/8 inch to a maximum of 3/16 inch from the hexagon head on the gland nut (or blank nut) and the shell of the cocks. When thus screwed up, the cocks are to be in a free working condition.

It is the duty of a mechanic to remove and repack this type of gauge cock.

(c) Restricted Opening Through Cocks. On washout days and also at the monthly boiler and firebox examination, the condition of both plug type and asbestos packed cocks shall be checked for correct alignment of the opening through the cock with the passage ways. When it is not possible to pass a 3/8 inch diameter brass rod through the passage ways with the cock in the open position, due to wear of the plug, or after being ground in, action shall be taken to remedy the defect by removing the plug and filing out the opening in it sufficiently to provide an unrestricted bore, and to allow the brass rod to be easily passed through when again assembled.

At each monthly examination of gauge glass columns, the Fitter deputed to carry out this work shall, in addition to continuing to remove the two face plugs for the purpose of testing the water ways leading to the boiler, remove the plug immediately above the top of the gauge glass.

A wooden dowel stick, 1/4 inch diameter and from 16 in. to 18 in. in length, shall then be passed right through the gauge glass until it comes to rest in the bottom chamber from which the tray and ball shall have previously been removed, and it must be seen in this position by the Fitter before he is satisfied that the vertical passage ways areunobstructed.


SECTION 5

Internal Examination Periods and Service Limits for Locomotive Boilers

5.01 INTERNAL EXAMINATION PERIODS FOR LOCOMOTIVE BOILERS:

Locomotive Boiler Classes First Service Period to Internal Examination

Second and Subsequent Service Periods to Time Limit Examinations

All classes of Round Top or Belpaire type boilers having copper fireboxes and tubes 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36, 50 and Standard Classes.

6 years 3 years

All classes of Round Top or Belpaire type boilers having all steel fireboxes and tubes. 10, Standard, 35, 36, 38, 57, 58, 59, and 60 Classes.

4 years 3 years

All classes of Round Top or Belpaire type boilers having composite fireboxes, i.e. copper firebox wrapper plates with steel tubes and tubeplates. Standard and C36 Classes.

4½ years 3 years

Examination and Test Periods of Locomotive Boilers.

5.02 FIRST TERM BOILERS OF THE 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36 AND STANDARD CLASSES HAVING COPPER FIREBOXES AND TUBES:

At the age of three years, boilers shall be due for first intermediate hydrostatic test and examination of boiler and firebox generally; no stays or tubes shall be withdrawn unless directed.

At four and one half years the boiler shall be due for second intermediate hydrostatic test, the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn.

At six years the boiler shall be due for internal examination.

5.03 SECOND AND SUBSEQUENT TERM BOILERS OF THE 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36, 50 AND STANDARD CLASSES HAVING COPPER FIREBOXES AND TUBES:

At eighteen months after internal examination boilers shall be due for intermediate hydrostatic test; the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except that where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed, and if a new front tubeplate was fitted at the previous internal examination, no tubes need be withdrawn.

At three years the boiler shall be due for internal examination or further time extension in service, as thereupon determined.


5.04 FIRST TERM BOILERS OF THE 10, STANDARD, 35, 36, 38, 57, 58, 59 AND 60 CLASSES, HAVING ALL-STEEL FIREBOXES AND TUBES:

At the age of two years boilers shall be due for first intermediate hydrostatic test and examination of boiler and firebox generally. Four small tubes shall be withdrawn.

At three years boilers shall be due for second intermediate hydrostatic test; the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn.

At four years boilers shall be due for internal examination.

NOTE. For regulations covering the examination and testing of rigid type crown stays in round top fireboxes, see Clause 6.13.

5.05 SECOND AND SUBSEQUENT TERM BOILERS OF THE 10, STANDARD, 35, 36, 38, 57, 58, 59 AND 60 CLASSES, HAVING ALL-STEEL FIREBOXES AND TUBES:

One year after internal examination, boilers shall be due for intermediate hydrostatic test and examination of boiler and firebox generally. The specified number of crown stays (see Clause 6.05) shall be withdrawn except where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed. No tubes shall be withdrawn, unless for the purpose of removing mud deposits.

Two years after internal examination, boilers shall be again due for intermediate hydrostatic test and examination of boiler and firebox generally. The specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed.

At three years, the boiler shall be due for internal examination or further time extension in service, as thereupon determined.

5.06 FIRST TERM BOILERS OF THE COMPOSITE TYPE HAVING COPPER FIREBOX WRAPPER PLATES WITH STEEL TUBES AND TUBEPLATES.

At the age of eighteen months boilers shall be due for the first intermediate hydrostatic test and examination of boiler and firebox, generally. Four small tubes shall be withdrawn.

At the age of three years boilers shall be due for the second intermediate hydrostatic test, the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn.

At four and one half years of age the boilers shall be due for internal examination.

5.07 SECOND AND SUBSEQUENT TERM BOILERS OF THE COMPOSITE TYPE HAVING COPPER FIREBOX WRAPPER PLATES WITH STEEL TUBES AND TUBEPLATES:

At eighteen months after internal examination boilers shall be due for intermediate hydrostatic test. The specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except that where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed, and if a new front tubeplate was fitted at the previous internal examination no tubes shall be withdrawn.

At three years the boiler shall be due for internal examination or further time extension in service, as thereupon determined.


NOTE. For regulations covering the examination and testing of rigid type crown stays in round top fireboxes, see Clause 6.13.

5.08 PREPARATION OF OLD BOILERS FOR INTERNAL EXAMINATION:

Before boilers 18 years of age and over are prepared for internal examination in the workshops, a preliminary examination shall be made to determine if the repairs that are obviously necessary are such to warrant a recommendation being made for the condemning of the boiler.

The Shop Foreman shall confer with the Boiler Inspector in all such cases, so that in the event of the boiler being recommended for condemnation, the expense which would be incurred by scaling, cleaning, etc., will be avoided.

5.09 RECLAMATION OF USABLE MATERIAL FROM CONDEMNED BOILERS:

When boilers, are condemned on account of age or condition and are to be cut up, the tubeplates and any other details, if in good usable condition, shall be reclaimed for the purpose of obtaining further service.

Crown Stay Examinations for Locomotive Boilers

6.01 CROWN STAY EXAMINATIONS BY THE BOILER INSPECTOR:

Examinations of crown stays at intermediate hydrostatic test periods, as directed by Return No. 6 for Belpaire boilers, and in accordance with the requirements of Clause 6.13 for round top boilers, shall be carried out by the Boiler Inspector at workshops and depots. Steamshed Inspectors shall advise when boilers will be ready for examination, giving at least two days’ notice.

6.02 ISSUE OF MONTHLY LIST OF BOILERS DUE FOR CROWN STAY EXAMINATION:

The Boiler Engineer shall prepare a monthly list of boilers due for crown stay withdrawal and examination. The list shall be issued during the month preceding the month for examination.

6.03 CROWN STAY DIAGRAMS:

Prior to the withdrawal and examination of crown stays for each boiler concerned, the Boiler Engineer shall mark, in duplicate, a printed diagram showing the stays to be withdrawn.

The original copy shall be retained by the Boiler Engineer for reference, and the other copy sent to the Steamshed Inspector of the district to which the locomotive is allotted, and shall be filed on the history record at the depot when the examination is completed.

6.04 METHOD OF INDICATING WITHDRAWN CROWN STAYS:

The dates and positions of stays withdrawn shall be marked on the face of the printed diagrams in the manner illustrated by the following example:

6 and 11, 2/R } 115 and 12, 3/L } 17

The above indicates that the sixth and eleventh stays in the second row from the right and the fifth and twelfth stays in the third row from the left, were withdrawn in November, 1917.

The rows shall be the longitudinal lines of stays and the stays in each row shall be counted from the front end.


6.05 NUMBER OF CROWN STAYS TO BE REMOVED FOR EXAMINATION:

The minimum number of stays, where required, to be removed at each crown stay examination, is shown hereunder:

Locomotive Boiler Class Crown Stays to be Removed

12, 13, 14, 17, 19, 20, 24, 25, 30 4

32, 34, 35, 36*, 38, 50 Standard *Belpaire type firebox

6

6.06 REPORTING CROWN STAY WITHDRAWALS AND ATTENTION:

All withdrawals of crown stays, and the action taken subsequent thereto, shall be recorded on a crown stay diagram and forwarded to the Boiler Engineer. A copy shall be attached to the history file of the boiler at the depot concerned.

6.07 CORRECT FITTING OF CROWN STAYS:

Crown stays shall be of the correct length when fitted and the threads of the stays shall be tight in the plates. In Belpaire boilers, the point ends of the stays shall project through the nuts the correct distance shown on the drawings.

6.08 CUTTING OFF POINTS OF CROWN STAYS IN BELPAIRE BOILERS:

The use of an oxy-acetylene torch to cut long points of crown stays is forbidden. This practice damages the threads and necessitates the stays being cut through to be removed for examination, thus destroying stays that could possibly have been refitted.

6.09 EVIDENCE OF DEFECTIVE CROWN STAYS:

Stays which have become wasted at the necks, immediately above the crown sheet, can generally be detected by the irregular nature of the scale deposit or heavy incrustation. Special attention shall be given to stays found in this condition to determine the extent of the wastage.

6.10 CLEANING OF CROWN STAYS:

Where it is not possible to determine the wastage of crown stays, due to the incrustation of scale, the scale shall be broken away with plain ended brass rods; sharpened points will not stand up to the work. Steel rods shall not be used.

6.11 CONDEMNING DIAMETER OF CROWN STAYS:

The condemning diameter for all firebox crown stays shall be 9/16in. and stays shall be removed when or before they are reduced to that size.

6.13 EXAMINATION OF RIGID TYPE CROWN STAYS IN BOILERS WITH ROUND TOP FIREBOXES:

Round top fireboxes fitted with rigid type crown stays which screw into the outer firebox shell and are riveted over, are provided with a tell-tale hole at the riveted end of each stay to indicate the existence of fractures. In order to determine definitely the condition of these stays, the steel lagging sheets fitted over the firebox shell plates shall be removed at the monthly boiler and firebox examination, also at the intermediate hydrostatic test period, and the tell-tale holes examined for leakage. Stays showing signs of leakage at the tell-tale holes shall be renewed.

In cases where boilers have been fitted with complete new sets of crown stays, the period for this examination shall be extended as follows:


1st examination after three months’ service. 2nd examination after six months’ service. 3rd examination after nine months’ service.

Thereafter the examinations shall be carried out monthly, as previously stated above.

6.14 PLUGGING TELL-TALE HOLES IN CROWN STAYS:

The plugging or hammering over of tell-tale holes in rigid type crown stays in order to reduce or prevent leakage is forbidden. Any person found responsible for carrying out this practice will render himself liable to dismissal.

6.15 BROKEN CROWN STAYS:

No boiler shall be allowed in service under steam pressure with one or more broken crown stays.

SECTION 7 Wall Stay Examinations for Locomotive Boilers

7.01 EXAMINATION OF WALL STAYS IN FIREBOXES:

Sub-foreman and Leading Boilermakers shall closely inspect, personally, the tell-tale holes in wall stays in the firebox. Whenever the holes are ‘made up’, they shall be drilled out. Where there is any sign of bulging or leakage, due to broken wall stays, or incrustation as the result of leakage, the stay concerned shall be removed. Wall stays with defective heads on the fireside shall also be removed.

7.02 REMOVAL OF CLOTHING SHEETS TO FACILITATE EXAMINATION FOR BROKEN STAYS:

The firebox side clothing sheets shall be removed, and the backplate clothing loosened, during each monthly examination of the boiler, and a careful examination shall then be made to detect the existence of broken wall stays in the firebox shell plates.

7.03 IMPORTANCE OF WALL STAY INSPECTIONS:

The monthly inspection and testing of wall stays of boilers and the prompt renewal of those found broken shall be one of the most important duties of those responsible for the care and maintenance of boilers.

7.04 BROKEN WALL STAYS IN BOILERS:

No boiler shall be allowed to remain in service under steam pressure when more than one wall stay is broken. Where a boiler has one wall stay broken and the leakage from same is serious enough to interfere with normal operations, immediate attention shall be given. If no serious leakage occurs the boiler can continue in service until next out of steam when the stay shall be renewed.

7.05 CLEANING OF TELL-TALE HOLES IN THROAT STAYS WHEN BRICK ARCH IS REMOVED:

Each time a brick arch is removed, and before the new arch is put in the tell-tale holes in the throat stays shall be cleaned out to their full depth with a 3/16 in. diameter drill.

7.06 REMOVAL OF SIDE TANKS AND CLOTHING SHEETS FOR WALL STAY EXAMINATIONS:

When side tank locomotives are in the workshops for repairs, or are undergoing intermediate tests at depots, the side tanks, in addition to the firebox side clothing


sheets, shall be removed to permit a thorough examination of the wall stays.

7.07 SUBMISSION OF WALL STAY DIAGRAMS:

Each time an examination of wall stays is made, a wall stay diagram shall be forwarded to the Boiler Engineer. The diagram shall show the location of, and the defects in faulty stays. Broken stays shall be indicated by a circle, stays with broken heads by a square, and cracked or partly broken stays by a broken circle.

Before submission, the diagram shall be endorsed to show that all defective stays have been renewed.

7.08 PLUGGING OR HAMMERING OVER TELL-TALE HOLES IN WALL STAYS:

The plugging or hammering over of tell-tale holes in wall stays in order to reduce or prevent leakage is forbidden. Any person found responsible for carrying out this practice will render himself liable to dismissal.

SECTION 8 Copper Tubeplate Examinations for Locomotive Boilers

8.01 EXAMINATION OF COPPER TUBEPLATES:

Special examinations of tubeplates, as directed on Return No. 4, shall be carried out by the Boiler Inspector at workshops and depots. Steamshed Inspectors shall advise when the tubes will be withdrawn and the boilers ready for examination, giving at least two days’ notice.

When examining copper tubeplates, care shall be taken to detect the presence of cracks in the bridges between the tube holes. These cracks generally commence on the fireside, and develop gradually from a skin crack to a complete fracture through the plate. Any signs of cracks detected shall be recorded in the remarks column of the monthly examination book (X2883). The attention of the Boiler Inspector shall be drawn to the matter on his next visit to the depot, so that he may direct any necessary repairs. If a bridge is found completely fractured, screwed bushes shall be fitted in the tube holes on either side of the fracture, in accordance with Drawing No. 33937.

8.02 REMOVAL OF TUBES FOR PURPOSE OF INSPECTION:

Alternate tubes in the two bottom rows shall be removed from boilers at all intermediate hydrostatic tests, unless exempt by the provisions of Clauses 5.02 to 5.04, or by direction of the Boiler Engineer. While the tubes are out, the condition of the interior surfaces of both tubeplates and the barrel shall be determined, and the thickness of the tubeplates measured.

Any mud deposits found lodged between the tubes shall be removed.

8.03 REMOVAL OF ADDITIONAL TUBES FOR PURPOSE OF INSPECTION:

Where the Boiler Inspector, in his opinion, considers that more tubes than those provided for in these regulations should be removed, he shall direct their removal.

8.04 REPORT ON TUBEPLATE THICKNESS AND CONDITION:

Particulars of the thickness and condition of tubeplates, etc., shall be submitted on the subsequent inspection report form (X2820) to the Boiler Engineer, immediately following each examination.

8.05 INSPECTION OF INTERIOR OF BOILER WHENEVER TUBES ARE REMOVED:

Whenever a sufficient number of tubes are removed from a locomotive boiler, during repairs, to enable an examination to be made of the interior of the barrel and sheathing


plates, if fitted, such an examination shall be carried out by the Boiler Inspector, and a report submitted covering the condition of the barrel, etc., as found.

SECTION 9 Tubes for Locomotive Boilers: Examination, Application and Maintenance

9.01 RECORD OF CHANGED TUBES:

A record of all changed tubes, showing the dates fitted, shall be kept in the repair book (X2885) at each depot. A diagram showing the tubes changed shall be forwarded to the Boiler Engineer, and a copy attached to the boiler history record at the depot.

9.02 EXAMINATION OF TUBES:

The Leading Boilermaker shall make a thorough examination in the smokebox and firebox of the ends of all tubes to determine if leakage is in evidence.

9.03 MAINTENANCE OF FLUES AND TUBES:

(a) Beading which has lifted away from the tubeplate shall be set down again to transmit the heat and prevent burning and wastage. Neglect of this attention will necessitate early driving up or renewal of the flues or tubes.

(b) Tubes which have the beading badly wasted or broken away, and which are leaking or liable to leak, or have defective ferrules, shall have the ferrules removed. The tubes shall then be driven up, re-expanded, re-ferruled and re-beaded. If long enough, the tubes shall be driven up at the smokebox end until they are almost flush with the smokebox tubeplate. Short tubes shall be removed.

(c) Particular care shall be exercised when expanding tubes to avoid over-rolling and thinning the tube ends, but judicious rolling shall be resorted to where evidence of loose or leaky conditions exists.

(d) Re-expanding of loose or leaky flues and tubes shall be carried out carefully in order that those adjacent will not be disturbed. A light rolling of the adjacent flues or tubes is necessary to counteract any possible disturbance.


Tubes for Locomotive Boilers: Examination, Application and Maintenance.

9.04 APPLICATION OF TUBE FERRULES:

Tubes shall not be tightened in the firebox tubeplate by driving the ferrules up, but the ferrules shall be removed and the tubes expanded. The method of applying tube ferrules shown on Drawing No. 42473, shall be adhered to. A copy of this drawing shall be held at each depot for the guidance of the boilermaking staff.

9.05 USE OF OXY-ACETYLENE TORCHES INSIDE FIREBOXES:

When an oxy-acetylene torch is to be used inside a locomotive firebox to cut out tube ferrules, or for other repairs, it shall be lighted outside the firebox. When it is necessary to release gas from a torch, this shall also be done outside the firebox.

Tubes shall be blown through or swept prior to any work in the firebox being commenced with an oxy-acetylene torch. During the progress of the work, the smokebox door and firehole door shall be kept open to ensure the best ventilation possible.

9.06 DRIVING UP TUBES:

When driving up tubes in locomotive boilers, 14 to 18 tubes in saturated boilers, and 12 to 14 tubes in superheated boilers, shall be selected to act as stays during the progress of the work. The tubes selected shall be distributed in such a manner as to give the best support to the tubeplate; the ferrules shall remain in, and the tubes shall not be closed at the smokebox end. When all other tubes have been driven up, the tubes used as stays shall be similarly dealt with to complete the work.


9.07 TESTING AFTER TUBE ATTENTION:

After tubes have been renewed or driven up, the boiler shall be hydrostatically tested to ensure that tubes have been properly expanded and that brazed tubes have sound joints.

9.08 PROJECTION OF BOILER TUBES IN SMOKEBOXES:

The projection of small copper boiler tubes through the front tubeplate shall be as follows:

Locomotive Boiler Class Projection from Smokebox Tubeplate

12, 13, 14, 17, 18, 19, 20, 21, 24, 25, 26, 27

1 in.

All other classes 2 in.

NOTE. The above does not apply to boilers equipped with steel tubes.

9.09 SAG IN TUBES:

At the prescribed periodical examinations of fireboxes and tubeplates, the Officer making the examination shall determine the amount of sag evident in the boiler tubes by sighting through them from either end. For the purpose of obtaining a view through the tubes, advantage should be taken of the use of a light at the far end, and for tubes in positions low down at the brick arch, a mirror may also be employed. Tubes found to be totally blind to the vision, due to the sag, shall be removed and replaced by straight tubes.

9.10 CONDITION OF EXPANDED ENDS OF SAGGED TUBES:

Particular attention shall be given to the condition of the ends of sagged tubes, where expanded into the tubeplates. Where there is any indication of looseness, leakage, lifting of the beads, defective ferrules, etc., immediate attention shall be given to eliminate any possibility of failure occuring at that point.

9.11 CLEANING SUPERHEATER AND SMALL TUBES:

Flues and tubes shall be examined after each washout or at other times when the boiler is out of steam, and where found blocked or making up they shall be cleaned out. Clinkers forming on the ends of superheater elements shall be removed.

It is important that tubes and flues be kept clean in order to obtain efficient steaming results from the boilers. With this objective in view engines running main line passenger services should have, if at all possible, the small tubes blown out after every round trip, but for all classes of locomotives except AD60 class, this cleaning period should not exceed seven days.

For the AD60 class the flues and tubes shall be thoroughly cleaned each time the fire has been withdrawn for boiler washout or other cause.

SECTION 10 Studs in Locomotive Boilers

10.01 BREAKING OFF STUDS:

The practice of deliberately breaking studs off boilers is prohibited. Where studs are to be removed, a stud extractor shall be used. A serious view will be taken of any omission to carry out this instruction.


10.02 RESTRICTION ON REMOVAL OF STUDS:

Except when it is necessary to remove studs from boilers to enable the boiler to be taken out of the frame, or for purposes of repair, studs shall not be removed, unless one or more of the following conditions obtain:

(a) The studs are corroded.

(b) The thread on the stud is damaged.

(c) The studs leak under steam.

(d) The studs are bent.

(e) The studs are considered unsafe for further service.

SECTION 11 Brick Arch Studs in Locomotive Boilers

11.01 RECONDITIONING BRICK ARCH STUD HOLES FOR SHORT TYPE STUDS:

Brick arch stud holes shall be inspected at each internal examination of the boiler. Any holes found greater in diameter than 1-1/16 in. shall be welded and re-tapped to the original diameter of 7/8 in. and a standard size stud fitted.

Where a stud hole has been welded once, and would require welding a second time to restore the hole to the correct diameter, the condition of the metal adjacent to the hole shall be examined to determine its suitability for re-welding. Where the condition of the metal is doubtful, an expert opinion shall be obtained before proceeding further with the work.

11.02 OVERSIZE BRICK ARCH STUDS (SHORT TYPE):

At depots, oversize studs may be used for replacements up to but not exceeding 1-1/4 in. diameter. If it is desired to use a stud greater than 1-1/4 in. diameter, permission of the Boiler Engineer shall first be obtained.

11.03 SHORT TYPE BRICK ARCH STUDS OUT OF ALIGNMENT, PLUGGED HOLES, PLATE THICKNESS AND CONDITION:

Boilers received into the Workshops for internal examination fitted with short type brick arch studs out of alignment shall have the studs restored to their original position. The old holes shall be filled by copper welding or by the approved type of screwed copper plug which is also rivetted over on the water side of the copper plate as an additional safeguard. Any arch stud bushes, defective or incorrect plugs found in the firebox side plates shall be removed and the holes closed as previously stated.

When it becomes necessary at depots to renew brick arch studs in firebox side sheets, it shall be the responsibility of the Leading Boilermaker to observe the thickness of the plate and to personally supervise the work to ensure that the holes are tapped with good threads, and that sufficient threads exist in the copper plate to satisfactorily hold the stud.

If it is discovered that the copper plate around the brick arch stud hole is generally wasted to such an extent that, by fitting the maximum oversize stud the resulting plate thickness will not give sufficient threads to safely carry the stud, the matter shall be reported to the Boiler Engineer for direction, giving the necessary information, or, if a Boiler Inspector is in the district, particulars shall be reported to him for consideration.


11.04 COMBINATION BRICK ARCH STUD AND WALL STAY:

In order to overcome the frequent renewal of short type brick arch studs, the consequent enlargement of the tapped hole and the wastage of the plate necessitating re-conditioning by welding and re-tapping, a combined type of brick arch stud and wall stay has been adopted, and is now being applied to boilers. This combination stay fulfils the dual purpose of supporting the side firebox plates and holding up the brick arch. It is manufactured from heat resisting anti corrosion steel and has a tell-tale hole drilled into both the head and beaded ends. A thick monel metal washer is fitted under the head to provide a caulking medium in the event of leakage occurring past the threads.

Should it become necessary to renew any of these combined stays below the frame line due to leakage through the tell tale holes, etc., the new stays shall be fitted with steam tight threads on that portion passing through the outer steel casing.

SECTION 12 Fusible Plugs for Locomotive Boilers

12.01 FUSIBLE PLUGS

Fusible plugs shall be fitted into the firebox crown sheet of all locomotive boilers, to act as a safeguard against excessive damage occurring from a shortness of boiler water.

Two distinct types of fusible plugs are available for this purpose and the correct type to use for any class of boiler can readily be determined from the following description:

- For boilers having a working pressure of less than 200 lb. per square inch, use tin-filled fusible plugs having a square head.

- For boilers having a working pressure of 200 lb. per square inch, and over, use lead-filled fusible plugs having a square head with square aperture.

12.02 EXAMINATION AND RENEWAL:

Fusible plugs shall be examined every two (2) weeks and shall be replaced with freshly filled plugs at intervals not exceeding two (2) calendar months. At Depots where no boilermaker is available, this work shall be carried out by the Officer-in-Charge. Fusible plugs removed from boilers shall be forwarded to the Locomotive Works Manager (Country Order Section), Eveleigh.

In cases where the washout period of the boiler does not coincide with the fusible plug examination or renewal work, the matter should be submitted to the Boiler Engineer for consideration.

12.03 RETURN OF USED PLUGS AND ORDERING OF NEW STOCK:

When fusible plugs are removed they shall be stored in a locked box until forwarded to the Locomotive Works Manager. Consignments of used plugs shall be accompanied by an advice note containing particulars of the plugs returned, and an order on the proper form, for a similar number of replacement plugs. Boxes containing freshly filled plugs shall be kept locked and the plugs issued by a responsible person deputed to perform that duty. A proper record of receipt and issues shall be kept.

Fusible Plugs for Locomotive Boilers.

12.04 REPORTING EXAMINATION AND RENEWAL OF FUSIBLE PLUGS: The dates of examination and re

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