29 Jan 04 Boiler Maint. Further thoughts 2.04
John,
Generally, this condition indicates a not-up-to- standard boiler washing & inspection, no bombarding of sheets during major boiler inspections to remove hard scale build up and importantly, the lack of a proper water testing and treatment program.
1. It is unknown if this condition was discovered because of the 1472 day boiler inspection or because the firebox sheets indicated a bulge or burned condition.
2. But the condition indicates a possible problem with the previous washout and inspection of the boiler. This is not to point a finger at shop forces (See #s 5 & 6 below). But perhaps more to a false notion of what is "OK" or “it will make another trip” or the “it was done that way in the past” attitudes. This philosophy can effect management as well as shop forces and commonly comes from lack of engines, budget or people.
3. Conditions like this can take place (as Linn M. pointed out) in only a few days service and occur from (but not limited to):
A. Water from pond or lake bottom (sucking up mud/dirty water),
B. Well or town supply to water tank by pumping very dirty or treated with ??? water.
C. Lack of proper cleaning of tender cistern.
4. Apparent lack of or incorrect use of water treatment.
5. Use of boiler blow downs do not remedy this condition, washout and water change is the best course of action. Again, Linn M. noted this condition.
6. Unless one knows that the water supplied to the tender cistern is dirty, this condition may not be readily determined until the bulged or burned condition becomes apparent during daily inspection or during the 31 day boiler wash.
Except, if water testing is performed on a daily basis. In this case, the testing would have indicated a severe change in water condition.
Then, how is the problem resolved is the question.
7. Once a problem (with boiler or supply water) of condition is known, that hopefully, good practices would be instituted to:
A. Blow down boiler, inspect & change water.
B. Re-inspect the mud ring after a day or two to insure that this condition has not continued.
C. Drain & flush the tender cistern.
D. If water is taken at stand pipe, flush standpipe to clean piping from the supply before taking water in tender cistern.
E. It may well take more the one or two water changes to resolve the condition.
8. Total the costs to perform these firebox patches. Compare the costs to:
A. A properly administered water treatment program.
B. Additional washouts necessary to protect the boilers and the overtime required to perform this work at night, in-between trips, especially when only one engine is available.
C.The real question here is: What if the locomotive had continued in service without this condition being discovered? How does one calculate the cost of this condition where the sheet bulged, failed and the possible injuries to employees or the public, not including costly boiler repairs.
9. I hope all of this is received and learned, not as a condemnation but to better the maintenance without incurring half the national debt or more importantly, any personnel injuries.
Chris
