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Steam Stationary Engines, Traction Engines, Steam Boats

Boiler Fabrication


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  #1  
Old 11-02-2005, 01:14:58 PM
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Dan Donaldson Dan Donaldson is offline
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Default Boiler Fabrication

I started this thread to document the progress of the boiler I am building for my 26 Advance Straw Burner. I bought this engine in January of 2005 from Norm Stevens of Bellevue, Michigan. I new before I bought the engine that boiler was in need of some major repair. The outside wrapper, under the axle castings, were thin and the firebox sheets were thin around each of the stay bolts. One option would be to replace the firebox and the plate under the axle castings but since I work for a steel fabrication shop that has an ASME “U” stamp I decided to buy the steel to do the entire boiler. I would be able to use the shops machinery to cut the plates, drill the holes for the rivets and stay bolts and form the parts. I want to build a boiler that is as much like the original within reason so I am going to use riveted construction with the exception of the longitudinal seam of the barrel and the steam dome. The firebox will also be of welded construction. A boiler fabricator in Ohio will be doing the welding, riveting and stay bolt installation so that the boiler can receive an “S” stamp.

Now, on to the pictures. This first set is of the engine as it looked after it arrived at my house in Florida.
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Old 11-02-2005, 01:16:56 PM
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Default Re: Boiler Fabrication

The first thing I had to do was create drawings of the boiler. Since I work as a draftsman at the steel fabrication shop I work at I did this myself. Because of the size restraints for posting pictures on this message board this image does not look clear at all. If you are interested I can email you better quality full size .jpeg or .pdf files.

Email me at ddonaldson@tampatank.com

In order to create these drawings I had to measure everything on the old boiler. This included removing the grates and crawling inside the firebox. Most boiler shops dismantle the engine before making measurements but I want to keep the engine assembled until the boiler is completed.
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Last edited by Dan Donaldson; 11-02-2005 at 01:27:55 PM.
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Old 11-02-2005, 01:20:04 PM
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Dan Donaldson Dan Donaldson is offline
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Default Re: Boiler Fabrication

The first photo in this set is of the outside and firebox wrappers just after they were cut on the CNC burning machine.

The Second photo shows the firebox back head, the back head and firebox wrapper after the stay-bolt holes have been drilled.

The third and fourth photos show the drilling process. I used two automatic feed, magnetic drills at the same time to speed up the work. It takes 30 seconds to drill a hole which is just enough time to set up the other drill and get it started.
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Last edited by Dan Donaldson; 11-02-2005 at 01:26:33 PM.
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Old 11-02-2005, 01:21:01 PM
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Default Re: Boiler Fabrication

These two pictures are of the barrel being rolled.
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Old 11-02-2005, 01:21:54 PM
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Default Re: Boiler Fabrication

These two pictures are of the outside wrapper being rolled.
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Old 11-02-2005, 01:24:00 PM
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Default Re: Boiler Fabrication

The first picture here is of the water leg being formed in the brake press. The second picture is the firebox wrapper after it was broke in the brake press. In order to get the firebox wrapper in and out of the brake press the crown sheet had to be “back broke”. We are using the plate roll to remove the bend in the crown sheet.
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Old 11-02-2005, 01:25:25 PM
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Default Re: Boiler Fabrication

Here are the misc. parts after they were formed
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Old 11-02-2005, 03:01:31 PM
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Default Re: Boiler Fabrication

Wow! I wish I could do that. I have an A&T pre-code non-code boiler and wonder at times if this might be financially feasable for the an average guy without access to the heavy fab equipment to have this work done. I assume not and you are lucky to have access to the shop so you can cut your expenses. Look at all the heavy new plate, drool.....

What does it mean to be s-stamp for riveting? I assume the boiler is not asme code and that repairs or fabrication should still be documented and up to some standard? what rules cover this vintage boiler rebuild? is this now covered in the new apendix c, being discussed in other threads? Would it make sense to keep the origional dome, both for cosmetic reasons and you could claim to have repaired the origional boiler? Curious, did you drill the rivet holes undersize prior to rolling? Lots of questions, sorry, its very interesting project to watch.
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Old 11-02-2005, 04:28:48 PM
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Default Re: Boiler Fabrication

Quote:
Originally Posted by Peter
What does it mean to be s-stamp for riveting? I assume the boiler is not asme code and that repairs or fabrication should still be documented and up to some standard? what rules cover this vintage boiler rebuild? is this now covered in the new apendix c, being discussed in other threads? Would it make sense to keep the origional dome, both for cosmetic reasons and you could claim to have repaired the origional boiler? Curious, did you drill the rivet holes undersize prior to rolling? Lots of questions, sorry, its very interesting project to watch.
The "S" stamp is for riveting and welding. It means the the vessel meets the ASME code for fired boilers. If it were a repaired boiler you would want to have it repaired to the National Board appendix C and get an "R" stamp for repair. There are other ASME stamps like the "U" stamp for unfired pressure vessels and many others. My boiler will receive an ASME "S" stamp per the current code and the 1971 code which cover riveted construction. If I were to re-use and portion of the old boiler it would get an "R" stamp.

The rivets holes are drilled to 3/4" dia. and will be reamed to 13/16" dia. before the 3/4" rivets are installed. The stay bolts are also drilled undersize and the each pair of holes will be reamed to line-up with each other and threaded to match the pitch of the stay bolts.

Dan Donaldson
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Old 11-02-2005, 09:33:36 PM
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Default Re: Boiler Fabrication

Awesome job Dan, I hope you are doing this on your coffee breaks!!! (G)
Joe Kelley
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