Project Update - 30 January 2016

With the tube expanding out the way, the beading of the tube ends in the firebox was required next.

Beading of the tube is a metal forming process in which the ends of the tubes are rolled over onto the tubeplate to further seal or caulk the expanded joint.

It is performed by using a beading tool and a small pneumatic hammer (Caulking Gun). Slowly but surely the beading tool is knocked by the piston in the gun which in turn knocks the end of the tube curling it towards the tube plate.



Caulking Gun

Beading Tool

Beading of a tube.

Beaded Tube

The beading of the tubes took several days to complete, once again the team all contributed to the task with excellent results.

John in action

Greg checking to see how the bead is going closing up onto the tube plate

Kirk beading one of the top row, your arms soon let you know your working up there..!!

During the boiler tube replacement, members of the Bennett Brook Railway at Whiteman Park were invited to visit Bassendean to observe the process and give it a go on the training module as they also have boiler tube replacement on their future maintenance programme. Brayden Hesford and Michael Watson have since visited and I am sure taken away an understanding of what it involves.   

Brayden expanding and flaring a tube at the firebox end of the module.

Michael expanding a tube at the smokebox end of the module.

BEADING COMPLETE

We also had the opportunity today to remove the sandbox as working around it has been a pain in the (well you know where) since the start of the project. With the aid of the recently acquired forklift and its competent operator Dom, the job of re-cladding the barrel will be so much easier. The steam dome cover was also lifted into position in readiness for the next step, the hydro.

Sandbox, down you come.

Well not really down at all, it ended up on the top of the water space
at the rear of the tender out of harms way.

So what's the next step..? The hydrostatic test, so stay tuned..

Project Update - 5 January 2016

With the training on the module out of the way, work commenced on installing the tubes in 549's boiler. Fortunately (or unfortunately depending on your view) most of the team were on leave so this enabled mid week work as well as the normal Saturdays.

Over six work days the team expanded all 93 tubes, slow but steady, no point rushing the job and paying for it later.

We would do them in batches, firstly the tube plate holes required polishing to remove any surface rust followed by removing any contaminants on the external surface of the tubes, this took a fair bit of time in itself. In regards to the expanding, we commenced in the firebox end, this would take the longest time due to measuring the stick out, measuring the tube wall reduction, ensuring the tube doesn't flare immaturely and the shear awkwardness of being in the firebox. This was later followed by the smokebox end.

It was hard work due to the awkwardness of the confined spaces not to mention some bloody hot days thrown in.

All of the team contributed to getting the work done and without the commitment of each of them at different stages over the six days, the work would not have been completed in the professional format that it was. Thanks to John, Kirk, Greg, Andrew, Alex, Jayden & Josh.

Some snapshots of the work in progress.


Alex and Kirk in action

Kirk measuring tube stick out

Onto the top row, Jayden and Kirk

John at the controls, assisted by Jayden

Job complete, all tubes expanded - firebox end

Job complete, all tubes expanded - smokebox end

Next task - Tube beading in the firebox.