I worked at a generating plant cleaning boilers for just two weeks before taking a job I really wanted as a mechanic. They had three massive boilers and one was always down for cleaning and maintenance. I was 6ft 170lbs and could barely fit inside the tubes, but I squeezed in and scraped for an hour at a time with a 10 minute breather each time. There was no other way to do it, and despite all the stuff they did to purify and demineralize the water the tubes still got scale that was as hard as concrete. Come to think of it, lime scale is concrete! Tough dirty work, but everyone who started at the company had to clean boilers (a test of character maybe?). Anyway, I did okay and my boss said he was going to miss me, which surprised me because I never indicated I liked cleaning boilers!
The last time I punch tubes out a Boiler (the term used in industry for cleaning them) there were 330 tubes in each boiler and there were three boilers and then two chiller units with 440 tubes each. We also welded hinges on the chillers so we could open them like boilers instead of removing them with block and tackle. Thankfully that was long in the past.
Many years ago I worked for a company that did commercial boiler work. We retubed a large and ancient (~ 80 - 90 years old) commercial unit for a school. One of the most labor intensive and all around crappy jobs I have ever done in my life. If it wasn't rusted solid it was packed so full of scale on the inside it was like pulling the tubes out of solid concrete. They guy who ran the company thought he was the worlds greatest engineer. After about 2 months of working there I was pretty sure he was the world biggest idiot. If anyone could find the hardest way to do something, he did. I do have to admit I learned a load about how boilers and general fluid based heating systems worked for him though, mostly just by seeing how not to do it the wrong way.
@@keithappleton ok good. I ask because I acquired a partial built case replica steam traction engine. The boiler is about half done. I’ve never seen a welded boiler. So I had to ask. I’ll also be needing to build a hydro tester like yours.. could you do a video covering it so I can make one too? I’ve had really small steam toys. This is my first big one.. it’s got about a 4 foot long boiler.
@@keithappleton Seriously? I'll be honest, that hadn't occurred to me at all. Also, thanks for uploading a hydraulic boiler test video - I've used what snippets of your test rig I've seen to get the parts to make my own rig, luckily the boiler I acquired came with 2 M10 blanking plugs, so I'll be modifying one for the test.
Keith, been meaning to ask how the sale and move went? Thought you would have kept us up with the backround stuff. More curious about a new shop location for you and how you set up the new shop.. Still thanks for sharing the videos. Stay well..
@@keithappleton Yeah, it's amazing how much "stuff" one collects over even a short time let alone several years in one place. Well good luck on a successful move** (**that's where everything gets from point A to point B without being lost or broken). Hope your going to have more space in the new place for a really nice little shop..Good Luck Sir..
Never pressure tested a girlfriend before. (Probably should have) I however, got shit tested a bunch over the years, but always passed with plenty of working overhead. (much to their dismay.) :P
I worked at a generating plant cleaning boilers for just two weeks before taking a job I really wanted as a mechanic. They had three massive boilers and one was always down for cleaning and maintenance. I was 6ft 170lbs and could barely fit inside the tubes, but I squeezed in and scraped for an hour at a time with a 10 minute breather each time. There was no other way to do it, and despite all the stuff they did to purify and demineralize the water the tubes still got scale that was as hard as concrete. Come to think of it, lime scale is concrete! Tough dirty work, but everyone who started at the company had to clean boilers (a test of character maybe?). Anyway, I did okay and my boss said he was going to miss me, which surprised me because I never indicated I liked cleaning boilers!
Great straightforward nonsense instructional video & that certainly is a beautiful model cheers from the land of 7 & 1/2 inch gauge California
The last time I punch tubes out a Boiler (the term used in industry for cleaning them) there were 330 tubes in each boiler and there were three boilers and then two chiller units with 440 tubes each. We also welded hinges on the chillers so we could open them like boilers instead of removing them with block and tackle. Thankfully that was long in the past.
Many years ago I worked for a company that did commercial boiler work. We retubed a large and ancient (~ 80 - 90 years old) commercial unit for a school.
One of the most labor intensive and all around crappy jobs I have ever done in my life. If it wasn't rusted solid it was packed so full of scale on the inside it was like pulling the tubes out of solid concrete.
They guy who ran the company thought he was the worlds greatest engineer. After about 2 months of working there I was pretty sure he was the world biggest idiot. If anyone could find the hardest way to do something, he did.
I do have to admit I learned a load about how boilers and general fluid based heating systems worked for him though, mostly just by seeing how not to do it the wrong way.
So why do they rivet boilers and not weld them? Or do they weld them now? And rivets are just what was available in early boilers?
You answered your own question. Welding techniques and quality of metal is much better now, and welding seems to be the most popular method.
@@keithappleton ok good. I ask because I acquired a partial built case replica steam traction engine. The boiler is about half done. I’ve never seen a welded boiler. So I had to ask. I’ll also be needing to build a hydro tester like yours.. could you do a video covering it so I can make one too? I’ve had really small steam toys. This is my first big one.. it’s got about a 4 foot long boiler.
I have an Accucraft boiler to test. Trying to find M5 x 0.5 blanking plugs is basically impossible, so that's been fun.
Use tapered wooden dowel plugs, they will work fine for a Hydraulic test. I made a video about this when I briefly worked at "The Steam Workshop"
@@keithappleton Seriously? I'll be honest, that hadn't occurred to me at all. Also, thanks for uploading a hydraulic boiler test video - I've used what snippets of your test rig I've seen to get the parts to make my own rig, luckily the boiler I acquired came with 2 M10 blanking plugs, so I'll be modifying one for the test.
As I previously mentioned, small wooden Dowels do work perfectly well . . . . . I have done this many times.
hi Keith, do you know off hand the thread type of the safety valve for a stuart 501 boiler ?
You need to watch some more of my videos . . . . . . 5/16" x 26 TPI if I remember rightly ......
@@keithappleton ill try that, thanks
Keith with a model steam boiler due you have a chart recorder connected during the test to document it? or is it not required.
not required.
Keith, been meaning to ask how the sale and move went? Thought you would have kept us up with the backround stuff. More curious about a new shop location for you and how you set up the new shop.. Still thanks for sharing the videos. Stay well..
The sale completes on Friday and I haven't moved yet - well not everything - it is a BIG job . . . .
@@keithappleton Yeah, it's amazing how much "stuff" one collects over even a short time let alone several years in one place. Well good luck on a successful move** (**that's where everything gets from point A to point B without being lost or broken). Hope your going to have more space in the new place for a really nice little shop..Good Luck Sir..
I live in hopes . . . . should be OK.
very yes . . . we do not like *BANG*
You inspire me one day I'll give this a wack and try live steam
I test my aircraft gas cylinders to 7500psi in a hydrostatic test rig
Polypropylene is what is usually used in the plastic brushes. Useless information.. but it’s information anyway.. lol
Are you going to charge a premium on your old house because it comes with a garden railroad?
}:-)))
Never pressure tested a girlfriend before. (Probably should have) I however, got shit tested a bunch over the years, but always passed with plenty of working overhead. (much to their dismay.) :P