Boiler Testing

This topic has 21 replies, 12 voices, and was last updated 27 December 2016 at 23:15 by John Lintorn.

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30 December 2015 at 08:35 #32622
John Besley
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@johnbesley21290
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30 December 2015 at 08:35 #218386
John Besley
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@johnbesley21290
I need some help, I am in the process of building another small boiler for a traction engine and need to test this myself, if I use a hand pump and a 2" pressure gauge with a maximum callibration of 300psi how should the pipework run from the pump via the gauge to the boiler fitting should the gauge be teed off from the main pipe run
30 December 2015 at 08:53 #218388
David Jupp
Participant
@davidjupp51506
If at all possible gauge and pump should be separately connected to item under test.

If a single connection point is used, there is always the possibility that (due to a blockage) you are testing only the piping and gauge, not the boiler itself.
30 December 2015 at 10:11 #218404
John Besley
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@johnbesley21290
Posted by David Jupp on 30/12/2015 08:53:50:

If at all possible gauge and pump should be separately connected to item under test.

If a single connection point is used, there is always the possibility that (due to a blockage) you are testing only the piping and gauge, not the boiler itself.

Ok that makes sense, is there a picture or sketch somewhere I can view
30 July 2016 at 09:59 #248617
John Lintorn
Participant
@johnlintorn87585
So I am building a 5″ gauge Tich, I have completed the boiler and everything is connected up and running, but I did not realise I need a boiler certificate? Obviously I do not want to be taking everything apart again. As this will ruin threads on copper amd brass and destroy gaskets. Any ideas guys?
30 July 2016 at 10:15 #248621
JasonB
Moderator
@jasonb
Talk with the boiler inspector who will be doing the test. If he has not seen the boiler during the build it is more than likely he will want to see a bare boiler.

You really should not have many threads in copper, bushes should be bronze so they don't get damaged.
30 July 2016 at 11:47 #248645
colin hawes
Participant
@colinhawes85982
There should be no brass directly attached to the copper boiler and, yes, a bare boiler is required for the cold examination and the initial test at twice working pressure. It is likely the pressure gauge and obviously the safety valve(s) cannot be in place. Colin
30 July 2016 at 11:56 #248648
MW
Participant
@mw27036
Posted by colin hawes on 30/07/2016 11:47:50:

There should be no brass directly attached to the copper boiler and, yes, a bare boiler is required for the cold examination and the initial test at twice working pressure. It is likely the pressure gauge and obviously the safety valve(s) cannot be in place. Colin

I think anything brass above the waterline is fine. Of all the things on this forum, this seems to be the issue people and busybodies tend to get irate about, life is too short, so i'd rather keep out of it.

Michael W
30 July 2016 at 14:35 #248670
KWIL
Participant
@kwil
But of coure you could not resist the temptation
30 July 2016 at 15:16 #248676
Neil Wyatt
Moderator
@neilwyatt
Posted by John Lintorn on 30/07/2016 09:59:52:
So I am building a 5" gauge Tich, I have completed the boiler and everything is connected up and running, but I did not realise I need a boiler certificate? Obviously I do not want to be taking everything apart again. As this will ruin threads on copper amd brass and destroy gaskets. Any ideas guys?

I'm afraid that as a boiler inspector won't have seen the boiler during the build they will want to give it an all-over inspection which will probably mean taking it out of the frames.

I suggest you find your local ME club, join it, and talk to their inspector. On the plus side membership fees are usually are modest and you will get access to their track and usually plenty of advice.

Neil
30 July 2016 at 18:31 #248696
John Lintorn
Participant
@johnlintorn87585
Ahh well there surely aren’t any laws against running it without a certificate?
30 July 2016 at 18:51 #248698
duncan webster 1
Participant
@duncanwebster1
Posted by John Lintorn on 30/07/2016 18:31:53:
Ahh well there surely aren't any laws against running it without a certificate?

Do what you like in private, but if you hope to run it in public you'll need insurance, and you won't get insurance without a boiler ticket.
30 July 2016 at 19:54 #248710
S.D.L.
Participant
@s-d-l
Posted by duncan webster on 30/07/2016 18:51:03:

Posted by John Lintorn on 30/07/2016 18:31:53:
Ahh well there surely aren't any laws against running it without a certificate?

Do what you like in private, but if you hope to run it in public you'll need insurance, and you won't get insurance without a boiler ticket.

Quite hard to ensure private. If the meter reader or repair man was around due to a visit to do something paid they would be at work. If the grand children or a niece was around when something went wrong would they sue.

Best solution is to get it tested at a club for your own pice of mind. Your going to have to blank off all the connections other than the ones used for the times two test, but it's not onerous.

Steve
30 July 2016 at 22:54 #248729
julian atkins
Participant
@julianatkins58923
Hi John,

Duncan and Steve are absolutely correct, and having seen one pic of your 5"g Tich boiler in your album I would highly recommend you get it hydraulically tested by your club boiler inspector! He may refuse to issue a certificate if he has not seen all stages of construction, but at least a proper hydraulic test might suggest whether you want to sit so close behind or allow anyone else near and dear or not so dear so close to a potential 'bomb' (as all boilers are, potentially, of course).

Cheers,

Julian
31 July 2016 at 11:38 #248763
John Lintorn
Participant
@johnlintorn87585
Are there many instances of model boilers going boom?
31 July 2016 at 12:43 #248770
Maurice Cox 1
Participant
@mauricecox1
No there aren't, This is because the builders perform a hydraulic test to twice the working pressure, and a steam test to ensure that the safety valves can cope with the maximum output the the boiler is capable of. John, you say you have no certificate, but have you at least tested it yourself? If not, please do so!

Maurice
31 July 2016 at 13:22 #248771
JasonB
Moderator
@jasonb
John, it looks like you may be using a compressor to test your poiler going by teh air hose fitting. If so make sure teh boiler is brimmed with water as if something did let go it won't be as explosive as a boiler full of compressed air.

As Maurice says with the boilers being checked at intervals during construction, on completion and regularly after that luckily there have been few failures in public. Probably would not hear about one going bang in a back garden unless it was fatal.
31 July 2016 at 13:26 #248772
John Lintorn
Participant
@johnlintorn87585
Yeah I have tested it up to 130psi but that’s as far as my compressor goes. I really do need to take my work to my local club but, being in the navy it’s not easy to find time to do so.
31 July 2016 at 17:31 #248793
duncan webster 1
Participant
@duncanwebster1
Testing on air is really asking for trouble. Even if the boiler is full of water the interconnecting pipework and compressor reservoir are not, so there is a fair bit of stored energy. Fortunately copper is very ductile so is not likely to go off with a bang, but if a joint does start to unzip, it will go a lot further than if all water, when it would just spray a bit of water out
31 July 2016 at 17:46 #248795
S.D.L.
Participant
@s-d-l
Posted by John Lintorn on 31/07/2016 13:26:09:
Yeah I have tested it up to 130psi but that's as far as my compressor goes. I really do need to take my work to my local club but, being in the navy it's not easy to find time to do so.

If you are making a hand pump for the loco use that, it will test that the pump works as well. A gauge bought from a hydraulic hose factors will do for a look see but it won't be calibrated but would allow you to check before going to your club inspector.

Steve
1 August 2016 at 11:05 #248864
John Lintorn
Participant
@johnlintorn87585
I guess this is what comes of building a boiler during a 9 month deployment to the middle east haha! My next boiler will be better quality I’m sure XD
27 December 2016 at 23:15 #273979
John Lintorn
Participant
@johnlintorn87585
Well I have managed to get my boiler it’s initial hydraulic test. Next step the second hydraulic test with all the fittings installed.
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