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5637 STEAM
LOCOMOTIVE GROUP

 

Boiler Washout plugs, Mudhole Doors and Live Steam Fittings

 
   

 Fitting/Removal Procedure

WARNING

Before commencing work on the boiler, ensure that there is no pressure within the boiler by referring to the boiler pressure gauge first, then opening the regulator or injector steam supply valves. Before removing any plugs or mudhole doors ensure the boiler water is COLD, this will prevent scalding from the draining water.

 

IF IN DOUBT DO NOT PROCEED ASK FOR ADVICE OR ASSISTANCE.

(1)       Only those persons authorised by the 5637 Steam Locomotive Group, the Railway and those whose names are held in a register may fit or remove the washout plugs and mudhole doors to the boiler. There are to be no exceptions.

(2)       An authorised person is one who is deemed competent to fit/remove boiler washout plugs and mudhole doors. A competent person is one who fulfils the following criteria:-

This is a person who by either theoretical or practical training has the necessary ability to safely fit/remove both boiler washout plugs and mudhole doors. They have the proper skills to identify any hazards present, determine the risks they represent to the workforce and the public and make the correct decisions based on their level of training and experience.

(3)       It is the Railway Management`s duty to ensure that a person is competent and therefore properly authorised. The Management has a duty to ensure that a competent person has the right level of competency to undertake the tasks of safely fitting/removing boiler washout plugs and mudhole doors before authorising them.

BOILER WASHOUT PLUGS  (qty 39)

(4)       Prior to fitting, all the washout out plugs must be scrupulously cleaned, especially the threads and heads. The threads of the washout plugs are to be coated with suitable sealant such as Foliac or Stag.

(5)       The washout plugs must be fitted in sequence as shown on the supplied boiler map, this ensures that the correct size plug is fitted into its proper threaded hole.

Due to the taper of the plugs, care must be taken to ensure that they have been correctly fitted and not cross threaded. The plugs are to be screwed in by hand until they can go no further, then a spanner used to achieve the final tightening.

(6)       When all the plugs have been securely fitted into the boiler, they must have a second independent check by a competent person. This is an independent means of ensuring that all is well and that all the washout plugs are properly secured in their rightful position.

(7)       Should a leak be noted from a washout plug, no attempt must be made to tighten the affected plug. The fire must be dropped, the boiler cooled down and the pressure dissipated to zero before any rectification can commence. To avoid any pressure, it is advisable to fully open the regulator or injector steam valves.


Boiler washout plug and mudhole door locations

MUDHOLE DOORS

(8)       There are eight (8) mudhole doors:-

            (a)       one at the firebox rear bottom backplate

            (b)       four on the upper curves of the firebox crown sides

            (c)        one in the firebox front plate

            (d)       one in the left hand corner front plate

            (e)       one in the right hand corner front plate 

Prior to fitting the mudhole doors, the doors must be scrupulously cleaned and the matching inner surfaces of the of the mudhole door apertures in the boiler plate must also be cleaned. All to be free old gasket and sealant material.

(9)       On fitting each door a new seal/gasket must be fitted, no old ones are to be reused. Sealant such as Foliac or Stag should be applied to each side of the seal.

The Fitter must ensure that the door is squarely and evenly located in its aperture before finally tightening the securing nut.

(10)     Should a leak be noted from a mudhole door no attempt must be made to tighten the door securing nut, the fire is to be dropped, the boiler cooled and all pressure dissipated to zero before any rectification commences. As a safety precaution it is advisable to fully open the regulator or the injector steam valves.          


Boiler washout plug and mudhole door locations

LIVE STEAM FITTINGS

(11)     Only to be removed and fitted by authorised and competent persons as described in paras one to three (1 - 3)

(12)     If a live steam fitting is to be removed from the boiler which contains a fire or steam pressure, then the fitting must only be removed if it is safely isolated from any source of pressure. Isolation will usually be via a nearby cock, valve or tap. If the fitting cannot be isolated, then the boiler must be made safe and all pressure dissipated to zero. Beware of scalding water, even if no pressure is shown to exist, it can be held inside the fitting.

(13)     To fit a live steam fitting, always ensure the isolation system is still protecting the system or fitting concerned. Use Foliac or Stag on any threaded component or pipework. Carry out a functional and leak check to ascertain if the fitting is now serviceable. If it is not, carry out any further rectification as necessary with due regard to para (12).
 

   
           

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