Please note that this Content may change.

These boiler training modules, incorporating sections of the

HRA/ORR boiler code of practice, were prepared in 2013 as
part of the HLF funded BESTT training plan project and will be
progressively reviewed and updated by the BESTT Technical
Committee.
 ! Proposed BESTT Syllabus Assessment Plan
!
!"#$%&'()**+',-.*+'
'
(/011'1$2345'"6'("3%&7.'
183.'9"#$%&'3.':"'$.&#'34';"4<$4;:3"4'=3:8'>?@'A$3#B4;&'.8&&:'
(0)**+','-.*+'
!
@39!
"#$%!&'$(!)$**!+$,-!(#-!*-./'-/%!.'!&'0-/%(.'0$'+!12!(#-!2&'3($1'!12!
41$*-/!(&4-%!.'0!#1)!(1!5.$'(.$'!(#-56!
!
-4:7"#$;:3"4!
"#-!$'%7-3($1'!12!41$*-/!(&4-%!$%!.'!$571/(.'(!2&'3($1'!12!41$*-/!
5.$'(-'.'3-6!"&4-%!)$**!'--0!/-7*.3$'+!$2!(#-8!./-!*-.9$'+:!#.,-!
-;3-%%$,-!31//1%$1'!1/!0.5.+-06!
!
"#$%!&'$(!)$**!+$,-!7/.3($3.*!9'1)*-0+-!12<!
• "#-!0$22-/-'(!5-(#10%!12!/-51,$'+!(&4-%!
• =1//-3(!%-*-3($1'!12!/-7*.3-5-'(!(&4-%!
• >-7*.3$'+!(&4-%!
• >-31/0!9--7$'+!
• ?-.(#!@!A.2-(8!
'
C&B74345'D$:;"9&.'
"#-!'&54-/%!$'!7./-'(#-%$%!/-2-/%!(1!(#-!?>B!C&$0.'3-!'1(-!%-3($1'6!!
D-./'$'+!1&(315-!E!31&*0!4-!0-*$,-/-0!$'!.!3*.%%/115!-',$/1'5-'(6!!
!
CD+'
• F'0-/%(.'0$'+!(#-!(-/5!3157-(-'(!7-/%1'!GEH!
• F'0-/%(.'0$'+!12!I-(/$3!.'0!J57-/$.*!%8%(-5%!GKH!
• "#-!31//-3(!&%-!.'0!5.$'(-'.'3-!12!LLM!GNH!
• A7-3$2$3.($1'!12!I.(-/$.*%!GOH!
• >-31/0!P--7$'+!!
CDE'
• "&4-!/-51,.*!!GQH!
• L/-7./.($1'!12!(&4-!7*.(-!#1*-%!GRH!
• >-.5$'+!12!"&4-!L*.(-!?1*-%!GSH!
• F%-!12!4&%#-%:!2-//&*-%!GTH!
• F%-!12!(&4-!7*.(-!*$'-/%!GEUH!
• M;.5$'.($1'!12!(&4-!7*.(-%!GEEH!
• L/-7./$'+!21/!(&4-!$'%(.**.($1'!GEKH!
• A&7-/#-.(-/!2*&-!(&4-%!GENH!
• M;7.'0$'+!(&4-%!!GEVH!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
!
!"#!
!
• "#$%&'(!)*+,!
• -#$.!/#.%&'(!)*0,!
• /#.%&'(!1234#%52#6!)*7,!
• 8#$9!2#4:&;&4$:&3'!)*<,!
• =#6:&'(!)*>,!
!
$
?'!43@1.#:&3'!3;!:A#!@3%5.#!:A#!:2$&'##!6A35.%!B#!$B.#!:3!56#!
4322#4:.C!$'%!6$;#.C!:A#!;3..3D&'(E!
!
• =5B#!45::#26!
• ?FCG$4#:C.#'#H!3FCG1231$'#!45::&'(!#I5&1@#':!
• =5B#!#F1$'%#26!
• J2&'%&'(!DA##.6!
• K'#5@$:&4!#I5&1@#':!
• LA&6#.6!
$
%&&'&&(')*$
!
8#$2'#26!435.%!%#@3'6:2$:#!43@1#:#'4#!&'!:A&6!5'&:!BCE!
!
• M345@#':$.!#N&%#'4#!
• KA3:3(2$1A&4!#N&%#'4#!
• /&:'#66!6:$:#@#':6!#O(O!D2&::#'!32!N#2B$.!6:$:#@#':!;23@!$!
43@1#:#':!1#263'!6:$:&'(!:A$:!:A#C!A$N#!43@1.#:#%!:$696!
6$:&6;$4:32&.CO!
• P'%#21&''&'(!9'3D.#%(#!I5#6:&3'6!#O(O!D2&::#'!I5#6:&3'6H!
@5.:&!4A3&4#!$'6D#2!6A##:6H!3'G.&'#!:#6:6H!$'%!$66&('@#':6O!
• K2$4:&4$.!:2$&'&'(!:$696!
!
!
!
!
!
!"#$$%&'()*+,-./-0%12-%0344*51%*6%12-%7-581&/-%9&8,+&:%;00*'8&18*)%8)%
&,,*+8)/%30%1*%30-%12-85%<38.&)'-%=*1-0%8)%1280%#:,,&>30?%
%
! 6%1!F0K!3C6(NO&&'!
! "##$%!F0K!&'!
! "##$%!P/+%K!)$*$#+!,&&-!
!
!
!

HERITAGE RAILWAY ASSOCIATION

!

GUIDANCE NOTE
!
!
!!!!!!!!!!!
!

TUBING OF LOCOMOTIVE BOILERS

!
!
!
!
!
!
!

Purpose
<=5#!A0:$@%;+!A%#:45B%#!*00A!.4/:+5:%!5;!4%7/+50;!+0!5+#!#$BQ%:+!+0!B%!:/445%A!0$+!B9!3%45+/*%!6/578/9#>!
<4/@8/9#!/;A!#5@57/4!B0A5%#!+0!8=0@!+=5#!A0:$@%;+!/..75%#!

Endorsement
<=5#!A0:$@%;+!=/#!B%%;!A%R%70.%A!/;A!1$779!%;A04#%A!B9!3%4!S/Q%#+9T#!6/578/9!";#.%:+04/+%>!/!A54%:+04/+%!
01!+=%!U115:%!01!6/57!6%*$7/+50;!

Disclaimer
<=%!3%45+/*%!6/578/9!)##0:5/+50;!=/#!$#%A!5+#!B%#+!%;A%/R0$4#!+0!%;#$4%!+=/+!+=%!:0;+%;+!01!+=5#!A0:$@%;+!
5#!/::$4/+%>!:0@.7%+%!/;A!#$5+/B7%!104!5+#!#+/+%A!.$4.0#%G!!308%R%4!5+!@/V%#!;0!8/44/;+5%#>!%W.4%##!04!
5@.75%A>!+=/+!:0@.75/;:%!85+=!+=%!:0;+%;+#!01!+=5#!A0:$@%;+!#=/77!B%!#$115:5%;+!+0!%;#$4%!#/1%!#9#+%@#!01!804V!
04!0.%4/+50;G!!)::04A5;*79!+=%!3%45+/*%!6/578/9!)##0:5/+50;!8577!;0+!B%!75/B7%!104!5+#!:0;+%;+!04!/;9!
#$B#%X$%;+!$#%!+0!8=5:=!+=5#!A0:$@%;+!@/9!B%!.$+G!

Supply
<=5#!A0:$@%;+!5#!.$B75#=%A!B9!+=%!3%45+/*%!6/578/9!)##0:5/+50;!
Y0.5%#!/4%!/R/57/B7%!%7%:+40;5:/779!R5/!0$4!8%B#5+%!888G=%45+/*%4/578/9#G:0@!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
Z#%4#!01!+=5#!C$5A/;:%!F0+%!#=0$7A!:=%:V!+=%!36)!8%B#5+%!+0!%;#$4%!+=/+!+=%9!=/R%!+=%!7/+%#+!R%4#50;G!

Table of Contents
'G ";+40A$:+50; GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG [
,G P5@%;#50;/7!F0+/+50; GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG [
[G M%4#0;/7!M40+%:+5R%!DX$5.@%;+ GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG [
IG ";#.%:+50; GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG [
JG S/+%45/7!\.%:515:/+50;#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG [
HG 6%@0R/7!01!<$B%#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG I
]G Y7%/;5;*!01!<$B%!307%# GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG J
-G 6%/@5;*!01!<$B%!M7/+%!307%#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG J
OG \:4%8%A!<$B%!M7/+%!N$#=%#>!M7$*#!/;A!^%44$7%#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG H
'&G <$B%!M7/+%!?5;%4#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ]
''G <$B%!M7/+%#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ]
',G M4%./45;*!104!<$B%!";#+/77/+50; GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ]
'[G ^7$%!<$B%#GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG -
'IG <$B%!DW./;A5;*GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG O
'JG N%/A5;*GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG '[
'HG \%/7!E%7A5;*!01!<$B%# GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG 'J
']G E%7A5;*!.40:%A$4%GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG 'H
'-G ?%/V# GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG 'H
'OG <%#+5;* GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ']
,&G 6%:04A!L%%.5;* GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ']
,'G )..%;A5:%# GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG ']
!
!
!
!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!,!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

1. Introduction
<=5#!C$5A/;:%!F0+%!5#!0;%!01!/!#%45%#!A%/75;*!85+=!?0:0@0+5R%!N057%4#!+=/+!8%4%!.40A$:%A!B9!+=%!,&&H(-!
@%%+5;*#!0;!_\+%/@!?0:0@0+5R%!N057%4!Y0A%#!01!M4/:+5:%`G!
6/578/9!70:0@0+5R%!B057%4#!/4%!A%#5*;%A!+0!:4%/+%>!#+04%!/;A!A5#+45B$+%!#+%/@!/+!=5*=!.4%##$4%G!<=%!804V5;*!
751%!01!#$:=!/!B057%4!:/;!B%!:0;#5A%4/B79!#=04+%;%A!51!A$%!:/4%!5#!;0+!+/V%;!/+!/77!#+/*%#!01!5;#.%:+50;>!4%./54>!
4$;;5;*!@/5;+%;/;:%!/;A!A/9(+0(A/9!4$;;5;*G!!
";!+=%!./#+!+=%4%!=/R%!B%%;!/!#%45%#!01!/::5A%;+#!/;A!%W.70#50;#!A$%!+0!804V!B%5;*!$;A%4+/V%;!85+=0$+!
=/R5;*!A$%!4%*/4A!+0!+=%!5;=%4%;+!45#V#!5;R07R%AG!"+!5#!85+=!+=/+!5;!@5;A!+=/+!3GSG6G"G!/;A!3G6G)G!#%+!$.!+=%!
#%45%#!01!@%%+5;*#!01!B057%4!.4/:+5+50;%4#!+0!A5#:$##!+=%!5##$%#a!A5#+57!*00A!.4/:+5:%!/;A!:0A519!5+!5;+0!+=5#!
#%45%#!01!C$5A/;:%!F0+%#G!
<=5#!*$5A/;:%!5#!845++%;!104!+=%!/##5#+/;:%!01!.%0.7%!:0@.%+%;+!+0!.%4104@!+=%#%!+/#V#G!";!.7/:%#!+=%!
+%4@5;070*9!$#%A!@/9!B%!#.%:515:!+0!#$:=!.4/:+5+50;%4#G!
<=5#!*$5A/;:%!8577!/7#0!B%!$#%1$7!+0!+=0#%!5;!/!#$.%4R5#049!04!@04%!*%;%4/7!407%>!=08%R%4!;0!804V!#=0$7A!B%!
$;A%4+/V%;!$;7%##!+=%!.%0.7%!:0;:%4;%A!/4%!A%%@%A!:0@.%+%;+!+0!A0!#0G!

2. Dimensional Notation
<=%!045*5;/7!5;104@/+50;!14%X$%;+79!:0@%#!140@!A0:$@%;+#!+=/+!/4%!5;!+=%!5@.%45/7!#9#+%@!0;79G!S%+45:!
%X$5R/7%;+#!=/R%!B%%;!/AA%A!8=%4%!/..40.45/+%G!!!

3. Personal Protective Equipment

N%104%!$;A%4+/V5;*!/;9!804V#!/!45#V!/##%##@%;+!@$#+!B%!:0;A$:+%AG!!
M40+%:+5R%!%X$5.@%;+!5#!+0!B%!#$..75%A!/;A!$#%A!/+!804V!8=%4%R%4!+=%4%!/4%!45#V#!+0!=%/7+=!/;A!#/1%+9!+=/+!
:/;;0+!B%!/A%X$/+%79!:0;+4077%A!5;!0+=%4!8/9#G!!
<=%!%X$5.@%;+!@$#+!B%!
!! ";!/::04A/;:%!85+=!+=%!7/+%#+!M%4#0;/7!M40+%:+5R%!DX$5.@%;+!4%*$7/+50;#G!
!! M40.%479!/##%##%A!B%104%!$#%!+0!%;#$4%!5+!5#!#$5+/B7%G!
!! S/5;+/5;%A!/;A!#+04%A!.40.%479!
!! M40R5A%A!85+=!5;#+4$:+50;#!0;!=08!+0!$#%!5+!#/1%79!
!! Z#%A!:044%:+79!B9!+=0#%!$;A%4+/V5;*!+=%!804VG!
4. Inspection
";!+=%!%R%;+!01!15;A5;*!+=%!+$B%#!/4%!#$#.%:+!#%%V!*$5A/;:%!140@!+=%!B057%4!Y0@.%+%;+!M%4#0;!B%104%!
.40:%%A5;*!85+=!/;9!4%.7/:%@%;+G!!!!

5. Material Specifications.
F0!B057%4!+$B%#!#=0$7A!B%!4%.7/:%A!85+=0$+!.4504!/..40R/7!01!+=%!Y0@.%+%;+!M%4#0;G!)77!+$B%#!0B+/5;%A!/#!
4%.7/:%@%;+#!#=0$7A!B%!+0!N45+5#=!\+/;A/4A!\.%:515:/+50;>!N\!DF!'&,'H('K!,&&,!b\%/@7%##!#+%%7!+$B%#!104!
.4%##$4%!.$4.0#%#c>!N\!DF!'&,']('K,&&,!b8%7A%A!#+%%7!+$B%#!104!.4%##$4%!.$4.0#%#c>!04!/;!%X$5R/7%;+!
#+/;A/4Aa!#%%!+/B7%!B%708!(!
<%;#57%!\+4%;*+=! N6!\.%:515:/+50;! DX$5R/7%;+!
P%+/57! S/+%45/7!!
<0;#!d!#X!_! F$@B%4! C4/A%!
N057%4!<$B%#! N\![H&,([,&!
!!!!!!!!/;A! \+%%7! ,&(,-! ',[!04!',,! N\![&JO!M<'![,&!!
^7$%!<$B%#! 3^\dY^\!04!D6E!
N057%4!<$B%#!! Y0..%4! 'IGJ!@5;! [']/! N\!,-]'!M<[!Y'&](M)[!
!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%![!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
!
!
54$"(
4#8%"0"9(
!"#$%&'(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7(( 4'9(
)*+,"-(
1*:"-0%1&-1(
1%;'4$*-"(
Understanding the meaning Must be able to define
and implications of the roles of the
1 Classroom
“competent person” competent person
! fully and correctly
Show competence in
being able to work in
imperial & metric and
What units can you work Classroom
freely interchange
in? and
between the two
2 Imperial & metric notation is Practical use
performing basic
common of
conversion tasks in
! measurement
weight, length,
temperature, pressure
and volume
Must demonstrate the
ability to equip oneself
Understand the role and in appropriate and In workshops
importance of PPE, how to safe PPE and and other
3
use it and how to look after understand the areas where
it properly storage and appropriate
maintenance issues
associated with PPE
Must be able to
Must have knowledge of demonstrate the
5 what sort of tubes should difference between
Classroom
be used to re-tube a boiler ERW and seamless
and
and ability to recognise the made tubes and be
workshop
types and know what to able to identify BS
inspect for number as right or
wrong for a job.
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
)77!+$B%#!@$#+!B%!.%41%:+79!#0$;A>!8%77!15;5#=%A>!14%%!140@!#$41/:%!A%1%:+#!/;A!4$#+>!/;A!+=%!%;A#!@$#+!B%!
1/:%A!:7%/;!/;A!#X$/4%G!
<=%!+$B%#!@$#+!B%!;04@/75#%A!B%104%!15++5;*G!
<=%!4%#.0;#5B7%!.%4#0;!#=0$7A!4%+/5;!+=%!4%7%R/;+!@/+%45/7!/;A!+%#+!:%4+515:/+%#!104!#$:=!+$B%#!104!/#!70;*!/#!
+=%!+$B%#!/4%!5;!$#%G!

6. Removal of Tubes
<=%4%!/4%!+80!A5#+5;:+!@%+=0A#!01!+$B%!4%@0R/7>!85+=!R/45/+50;#!A%.%;A5;*!0;!+=%!+007#!/;A!#V577#!/R/57/B7%G!
b'c!U;%!@%+=0A!5;R07R%#!700#%;5;*!+=%!+$B%#!140@!B0+=!+$B%!.7/+%#!/;A!4%@0R5;*!%/:=!+$B%!+=40$*=!
5+#!08;!=07%!5;!+=%!140;+!+$B%!.7/+%G!!!!
b,c!";!+=%!0+=%4!.40:%A$4%>!+$B%#!/4%!:$+!/+!%/:=!%;A!/;A!/7708%A!+0!1/77!5;+0!+=%!B057%4!B/44%7>!85+=!
+=%!+$B%#!/;A!:$+!%;A#!4%@0R%A!7/+%4G!
<=%!154#+!@%+=0A!:/;!#$B#+/;+5/779!B%!:/445%A!0$+!85+=!=/;A!+007#!51!#=0.!1/:575+5%#!/;A!.08%4!+007#!/4%!;0+!
/R/57/B7%>!/7+=0$*=!+=%!$#%!01!.08%4!+007#!8577!#.%%A!$.!+=%!.40:%##!/;A!4%X$54%!7%##!.=9#5:/7!%W%4+50;G!!
6%@0R5;*!+=%!+$B%#!+=40$*=!+=%54!08;!=07%#!5#!/7#0!./4+5:$7/479!/AR/;+/*%0$#!51!0;79!/!#@/77!;$@B%4!01!+$B%#!
/4%!+0!B%!4%@0R%A!e!#$:=!/#!8=%;!4%.7/:5;*!/!*40$.!01!+=5;!04!7%/V5;*!+$B%#!/#!/!@/5;+%;/;:%!.40:%A$4%!04!
8=%;!4%@0R5;*!+80!04!@04%!#/@.7%!+$B%#!140@!;%/4!+=%!B057%4!B0++0@!104!%W/@5;/+50;!+0!=%7.!A%+%4@5;%!
*%;%4/7!+$B%!:0;A5+50;G!
E04V!B%*5;#!5;!+=%!154%B0W!8=%4%!+=%!B%/A!b104@%A!B9!45R%+5;*!+=%!%;A!01!+=%!+$B%!0R%4!#0!5+!B%/4#!/*/5;#+!+=%!
.7/+%c!5#!4%@0R%A!140@!+=%!+$B%!%;A!B9!$#5;*!%5+=%4!/!=/;A!:=5#%7>!0W9(/:%+97%;%!:$++5;*!+04:=!04!#.%:5/7!
:=5#%7!5;!/!#@/77!.;%$@/+5:!=/@@%4G!!)!+$B%!A451+!5#!+=%;!5;#%4+%A!5;+0!+=%!+$B%!/;A!+=%!+$B%!A45R%;!1048/4A>!
700#%;5;*!5+#!*45.!8=%4%!5+!=/#!B%%;!4077%A!5;+0!B0+=!+$B%!.7/+%#G!!U;:%!700#%;%A>!+=%!+$B%!5#!%/#579!4%@0R%A!
$;7%##!=%/R579!:0/+%A!85+=!#:/7%>!5;!8=5:=!:/#%!5+!@/9!B%!#75A!B/:V!/;A!104+=!+0!V;0:V!011!+=%!#:/7%G!!!"+!5#!
%/#5%4!+0!A45R%!+=%!+$B%!0$+!51!+=%!#@0V%B0W!%;A!01!+=%!+$B%!5#!154#+!#75+!/70;*!5+#!7%;*+=!104!#%R%4/7!5;:=%#!
$#5;*!/!#X$/4%(%;A%A!_45..5;*`!:=5#%7>!/77085;*!+=%!+$B%!+0!:077/.#%!#75*=+79G!!);!/7+%4;/+5R%!5#!+0!#75+!B0+=!%;A#!
01!+=%!+$B%#!5;!+80!04!@04%!.7/:%#!/;A!1$779!:077/.#%!+=%!%;A#!85+=!:=5#%7#>!+=%;!5;#%4+!/!70;*!B/4!5;+0!+=%!+$B%!
/+!+=%!#@0V%B0W!%;A!/;A!$#%!5+!+0!A4/8!+=%!+$B%!0$+!1/4!%;0$*=!+0!B%!*4/#.%A!B9!=/;AG!
<=%!#%:0;A!@%+=0A!5;R07R%#!:$++5;*!%/:=!+$B%!/+!B0+=!+$B%!.7/+%#!$#5;*!%5+=%4!/!0W9(/:%+97%;%!:$++5;*!+04:=!
04!/;!5;+%4;/7!+$B%!:$++%4!A45R%;!B9!/!.08%41$7!.;%$@/+5:!@0+04G!!"1!+=%!:$++5;*!+04:=!5#!$#%A>!+$B%#!#=0$7A!B%!
:$+!1/4!%;0$*=!B/:V!+0!/R05A!/::5A%;+/7!A/@/*%!+0!+=%!.7/+%G!
Y$+!+$B%#!/4%!4%@0R%A!+=40$*=!/!#.%:5/779!%;7/4*%A!+$B%!=07%!5;!+=%!140;+!+$B%!.7/+%!b+=%!_V5;*!=07%`>!70:/+%A!
;%/4!+=%!B0++0@!01!+=%!:%;+4%!:07$@;!01!+$B%#c>!04!+=40$*=!#$5+/B7%!B057%4!0.%;5;*#!#$:=!/#!/!7/4*%!
#$.%4=%/+%4!17$%!=07%#G!!<=%!4%@/5;5;*!+$B%!%;A#!5;!B0+=!+$B%!.7/+%#!/4%!+=%;!4%@0R%A!B9!:077/.#5;*!+=%@!
85+=!:=5#%7#!/;A!V;0:V5;*!+=%@!0$+!01!+=%54!=07%#G!Y077/.#5;*!:/;!B%!/5A%A!B9!#75++5;*!+=%!+$B%!%;A#!85+=!/!
0W9(/:%+97%;%!+04:=!b$#5;*!/!#@/77!:$++5;*!+5.c>!04!:$++5;*!./4+5/779!+=40$*=!85+=!/;!%7%:+45:!#/8!04!=/:V#/8G!!!
);0+=%4!@%+=0A!5#!+0!=%/+!+=%!%;A!01!+=%!+$B%!+=/+!5#!#+577!5;!+=%!.7/+%a!+=%;!B%;A!5+!/8/9!140@!+=%!+$B%!=07%!B9!
#+45V5;*!85+=!/!:=5#%7G!!!<=%!+$B%!%;A!@/9!+=%;!B%!A4/8;!:7%/4!+=40$*=!85+=!75++7%!45#V!01!A/@/*5;*!+=%!=07%G!
)!1%8!:/$+50;#!/;A!=%7.1$7!=5;+#!104!+$B%!4%@0R/7!#=0$7A!B%!@%;+50;%AG!!
b'c!!DW+4%@%!:/4%!@$#+!B%!%W%4:5#%A!8=%;!$#5;*!/!:$++5;*!+04:=!5;!:/#%!+=%!17/@%!;5:V#!04!*0$*%#!+=%!
#%/+5;*!#$41/:%!01!+=%!+$B%!=07%G!!N%:/$#%!+$B%!@/+%45/7!5#!+=5;>!0;79!/!#@/77!0W9(/:%+97%;%!+04:=!%X$5..%A!
85+=!/!+5.!A%#5*;%A!104!+=5#!+9.%!01!804V!#=0$7A!B%!$#%A!5;!04A%4!+0!4%A$:%!+=%!:=/;:%!01!/::5A%;+/7!A/@/*%G!!
<=%!0.%4/+04!@$#+!B%!#V577%A!e!+=5#!5#!;0+!/!Q0B!104!+=%!5;%W.%45%;:%AG!!Y/4%1$7!804V!/+!+=5#!+5@%!8577!4%A$:%!
+=%!/@0$;+!01!+5@%!/;A!%1104+!;%%A%A!+0!4%./54!A/@/*%A!+$B%!.7/+%!=07%#!7/+%4G!!
b,c!!"1!$#5;*!/;!%7%:+45:!#/8!04!=/:V#/8>!B%!:/4%1$7!+=/+!+=%!#/8!A0%#!;0+!:$+!5;+0!+=%!+$B%!.7/+%!e!+=%!#/@%!
.4%:/$+50;#!*5R%;!104!$#5;*!+=%!0W9(/:%+97%;%!:$++5;*!+04:=!/..79!=%4%G!
b[c!!"1!+$B%#!4%@0R%A!+=40$*=!+=%!V5;*!=07%>!+=4%%!04!10$4!#@/77!Z(#=/.%A!#=5@#!04!:75.#!@/A%!140@!+=5;!#+%%7!
04!B4/##!#=0$7A!B%!.7/:%A!/40$;A!+=%!5;#5A%!01!+=%!=07%!+0!#%4R%!/#!8%/4!.7/+%#G!!<=%!/B4/#50;!8%/4!
.40A$:%A!B9!4%@0R5;*!,&&([&&!+$B%#!+=40$*=!+=%!=07%!:/;!8%/4!+=%!=07%!#0!0$+!01!40$;A!+=/+!5+!8577!=/R%!+0!
B%!4%./54%A!B9!8%7A5;*G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!I!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
!
!"#$%&'(
.,/"#$%0"1(
)*+,"-(
There are two distinct
methods of old tube removal
6 Understanding of both is
essential
! removal on a set of
Use of cutting torch to
remove tubes from tubeplate
made of copper and of steel
and being aware of pitfalls.
Demonstrate how to avoid
6 bending tubeplate by too
many tubes overhanging
having been cut at one end
and unsupported at the
other
!
Seal welds of tubes to
tubeplates must be cut off
6 with care before tube
removal so as to leave the
tubeplate undamaged.
Superheater flues present
their own set of problems
with the flues being thicker
6 Workshop
and less workable making it flues satisfactorily
more difficult to collapse the
ends to facilitate removal
!
(
54$"(
211"11+"'$(3-%$"-%4( 5"6%0"-7( 4#8%"0"9(4'9(
1*:"-0%1&-1(
1%;'4$*-"!
Must be able to
describe theoretical
method and then go Classroom
into workshop and &
perform the tube Workshop
sample tubes
Must demonstrate
theory and ability on
use of oxy acetylene
cutting torch and
ability to remove tube
without nicking the
tubeplate. Also
Workshop
demonstrate how cut
tubes are removed
from inside boiler
Must know how many
in a batch to cut so as
not to risk harming the
old tubeplate
Must demonstrate
cutting off 10 seal
welded tubes with
hammer and chisel or
pneumatic chisel to
leave a tubeplate fit Workshop
and ready to proceed
with to the next stage.
Then cut off a further
10 using mini-grinder
or die grinder
Work with colleague to
remove 5 superheater
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
bIc!!)R05A!:$++5;*!+00!@/;9!+$B%#!011!/+!0;%!%;A!85+=0$+!:$++5;*!+=%@!14%%!/+!+=%!0..0#5+%!%;A>!/#!+=%!=/;*5;*!
8%5*=+!@/9!#+4/5;!+=%!+$B%!.7/+%#!/;A!:/$#%!:4/:V#G!!<=5#!5#!%#.%:5/779!+4$%!8=%;!:$++5;*!011!+=%!=%/R9!
#$.%4=%/+%4!17$%#G!
!
"+T#!/!75++7%!@04%!A5115:$7+!+0!4%@0R%!+$B%#!8=%;!+=%!154%B0W!%;A!B%/A#!=/R%!B%%;!#%/7!8%7A%A!+0!+=%!+$B%!
.7/+%>!B%:/$#%!%5+=%4!+=%!B%/A!04!+=%!8%7A!b04!B0+=c!@$#+!B%!:$+!+=40$*=!+0!.%4@5+!+$B%!4%@0R/7G!!
<=4%%!@%+=0A#!01!8%7A!/;A!B%/A!4%@0R/7!@/9!B%!$#%AK!
'c!C45;A5;*!+=40$*=!+=%!+$B%!B%/A!$#5;*!/!#@/77!A5#V!04!A5%!*45;A%4!
,c!Y=5..5;*!011!+=%!8%7A!/;A!B%/A!85+=!/!#.%:5/7!/;*7%A!:=5#%7!$#%A!5;!/!.;%$@/+5:!=/@@%4!
[c!Y$++5;*!011!+=%!8%7A!/;A!B%/A!85+=!/!0W9(/:%+97%;%!:$++5;*!+04:=G!!<=%!7/#+!+80!.40:%##%#!4%X$54%!
:0;#5A%4/B7%!#V577!+0!4%@0R%!%;0$*=!01!+=%!8%7A!/;A!B%/A!#0!+=%!+$B%!:/;!B%!4%@0R%A!8=57%!/+!+=%!#/@%!
+5@%!/R05A5;*!A/@/*%!+0!+=%!4%/4!+$B%!.7/+%!B9!%5+=%4!$;A%4:$++5;*!85+=!+=%!:=5#%7!04!;5:V5;*!85+=!+=%!+04:=G!
U;:%!+=%!8%7A!/;A!B%/A!=/R%!B%%;!4%@0R%A!+=%!.40:%A$4%!5#!+=%!#/@%!/#!104!;0;(8%7A%A!+$B%#G!
\$.%4=%/+%4!17$%!4%@0R/7!.4%#%;+#!/AA5+50;/7!.40B7%@#!01!5+#!08;G!!^7$%#!/4%!@/A%!01!+=5:V%4>!7%##!804V/B7%!
@/+%45/7!+=/;!/4%!+$B%#!b@/V5;*!:077/.#5;*!A5115:$7+c>!/;A!+=%54!*4%/+%4!8%5*=+!:4%/+%#!=/;A75;*!.40B7%@#G!!
U1+%;!+=%#%!17$%#!/4%!4%@0R%A!+=40$*=!+=%54!08;!=07%#!5;!+=%!140;+!+$B%!.7/+%>!B$+!+=5#!@/9!B%!A5115:$7+!51!
=%/R9!#:/7%!=/#!B$57+!$.!0;!+=%@G!!"+!@/9!B%!;%:%##/49!+0!=/@@%4!011!#$:=!#:/7%!.4504!+0!4%@0R/7!04!+0!
#/:4515:%!+=%!17$%#!/;A!:$+!+=%@!5;+0!.5%:%#!#@/77!%;0$*=!+0!B%!./##%A!+=40$*=!+=%!#+%/@!A0@%G!!

7. Cleaning of Tube Holes

<=%!140;+!/;A!4%/4!+$B%!.7/+%!:0;A5+50;!#=0$7A!B%!:=%:V%A>!.0##5B79!4%R%/75;*!:4/:V#>!:$+#!/;A!*0$*%#!
/40$;A!+$B%!=07%#!;0+!4%/A579!/../4%;+!B%104%=/;AG!)7#0!:=%:V!104!A/@/*%!:/$#%A!B9!+$B%!4%@0R/7>!#$:=!/#!
:=5#%7!04!+04:=!;5:V#!;0+!0;79!0;!+=%!1/:%#!01!+=%!.7/+%#!B$+!/7#0!0;!+=%!#$41/:%#!01!+=%!=07%#!+=%@#%7R%#G!!
Y/4%1$779!*45;A!+=%!154%!#5A%!01!+=%!+$B%!.7/+%!b%#.%:5/779!51!+$B%#!=/R%!B%%;!8%7A%A!+0!+=%!4%/4!+$B%!.7/+%c>!
4%@0R5;*!/#!75++7%!@/+%45/7!/#!.0##5B7%!5;!04A%4!+0!.40R5A%!/!14%#=>!#@00+=!#$41/:%!/*/5;#+!8=5:=!+=%!+$B%#!
:/;!B%!B%/A%AG!!!C45;A5;*!8577!4%R%/7!/!;/4408!B/;A!04!45A*%!/40$;A!%/:=!+$B%!=07%>!/;!5;A5:/+50;!+=/+!+=%!
+$B%!.7/+%!5#!+=5:V%4!8=%4%!+=%!@%+/7!=/#!B%%;!104:%A!0$+8/4A#!B9!+=%!.4%R50$#!%W./;A5;*!.40:%##!/;A!
8=%4%!5+!=/#!B%%;!.40+%:+%A!140@!154%!B9!+=%!B%/AG!!"+T#!;0+!;%:%##/49!+0!4%@0R%!+=%#%!B/;A#!B9!*45;A5;*!
+=%@!A08;!+0!+=%!#/@%!+=5:V;%##!/#!+=%!4%#+!01!+=%!.7/+%G!
<=%!+$B%!=07%#!8577!4%X$54%!:7%/;5;*!/;A!.075#=5;*>!B%#+!A0;%!85+=!/!=5*=!#.%%A!15;%!854%>!17/.!04!#/;A5;*!
8=%%7G!"+!:/;!/7#0!B%!A0;%!85+=!=/71(40$;A!157%#!04!B9!:/4%1$779!@/;5.$7/+5;*!/!.;%$@/+5:!04!%7%:+45:!A5%(
*45;A%4!85+=!/!,J!+0![-@@!b'!+0!'f!c!40$;A!*45;A5;*!+007>!B$+!B%!:/4%1$7!;0+!+0!5;+40A$:%!0$+(01(40$;A;%##!04!
%;7/4*%!+=%!=07%!%W:%##5R%79G!!<=%!%A*%#!01!%/:=!=07%!#=0$7A!B%!40$;A%A!#75*=+79!'GH@@!b'd'H`c!4/A5$#!5#!
#$**%#+%Ac!0;!B0+=!1/:%#!+0!.4%R%;+!+=%!+$B%!140@!B%5;*!:$+!8=%;!5+!5#!%W./;A%A!/;A!B%/A%AG!!<=5#!Q0B!5#!
B%#+!A0;%!$#5;*!/!7/4*%!A5/@%+%4!IJg!*45;A5;*!#+0;%!5;!/!=5*=!#.%%A!*45;A%4G!
F5:V#>!*0$*%#!04!:4/:V#!0;!+=%!+$B%!.7/+%#!04!5;!+=%!+$B%!=07%#!8577!4%X$54%!/++%;+50;!$;7%##!+=%9!/4%!R%49!
@5;04G!b\%%!#%:+50;!0;!6%/@5;*!01!<$B%!M7/+%!=07%#cG!

8. Reaming of Tube Plate Holes

);9!=07%#!104!#@/77!+$B%#!8=5:=!/4%!%70;*/+%A!04!0+=%485#%!0$+!01!40$;A!B9!b&G-@@c!'d[,!!04!@04%!@$#+!B%!
A%/7+!85+=!5;!+=%!1077085;*!@/;;%4K!!
For Copper tube plate.
6%/@!0$+!+0!+/V%!/!;%8!+$B%G!)7+%4;/+5R%79!/1+%4!4%/@5;*!/;!/;;%/7%A!:0..%4!75;%4!:/;!B%!15++%A!+0!B45;*!+=%!
+$B%!=07%!B/:V!+0!+=%!045*5;/7!#5h%G!b6%1%4!+0!#%:+50;!0;!<$B%!M7/+%!?5;%4#c!
DW./;A5;*!01!=07%#!104!+=5#!.$4.0#%!5#!.40=5B5+%AG!
For Steel tube plates.
6%/@!0$+!+0!+/V%!/!;%8!+$B%G!307%#!@/9!B%!B$57+!$.!B9!8%7A5;*!+=%;!%5+=%4!157%A>!4%/@%A!04!B04%A!+0!+=%!
:044%:+!#5h%a!#$BQ%:+!+0!+=%!/*4%%@%;+!01!+=%!Y0@.%+%;+!M%4#0;!/;A!#$5+/B7%!FP<G!U;79!8%7A%4#!.40.%479!
X$/7515%A!/;A!:%4+515:/+%A!104!+=5#!+9.%!01!8%7A5;*!:/;!$;A%4+/V%!+=%!+/#VG!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!J!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7( 1*:"-0%1&-1(
)*+,"-(
1%;'4$*-"!
Knowledge of how the
seal and tube
movement is achieved
Inspection of
is vitally important
tInyyyyspctionhe tubes and
7 And must be Classroom
holes before expanding
demonstrated
!
Explain how to control
the expansion to 7%

Out of round tube holes
must be rectified
8 Reaming copper and steel
tube plates needs different
approaches
! Understand danger of
!
Demonstrate reaming
five tubeplate holes
back to round and to
sized condition
Describe those Workshop
approaches in copper
and steel tubeplates.
“three penny biting”
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
9. Screwed Tube Plate Bushes, Plugs and Ferrules
E=57#+!/!4%./54!B9!:0..%4!8%7A5;*!5#!.4%1%44%A>!14/:+$4%A!+$B%!.7/+%!B45A*%#!@/9B%!4%./54%A!B9!15++5;*!#:4%8%A!
:0..%4!B$#=%#!8=5:=!@$#+!B%!#:4%8%A!5;!+5*=+79!/;Aa!8=%4%!1%/#5B7%a!45R%+%A!0R%4!0;!B0+=!#5A%#!01!+=%!+$B%!
.7/+%G!
<=%!B$#=!5#!+0!B%!@/A%!B9!A45775;*!/;A!0.%;5;*!0$+!0;%!01!+=%!#+/;A/4A!:0..%4!.7$*#!/#!#=08;!5;!A5/*4/@!
B%708G!
"1!:54:$@#+/;:%#!8/44/;+!5+!+=%;!+=%!15++5;*!01!/!@/W5@$@!01!10$4!.7$*#!5;!/;9!0;%!+$B%!.7/+%!5#!.%4@5##5B7%!
.40R5A%A!;0!+80!01!+=%#%!10$4!.7$*#!/4%!/AQ/:%;+!+0!%/:=!0+=%4a!=08%R%4!.7$**%A!/;A!B$#=%A!=07%#!@/9!
/7+%4;/+%G!!
<=%!.7$*#!+0!B%!$#%A>!:0..%4!104!+=%!154%B0W!+$B%!.7/+%!/;A!#+%%7!104!+=%!#@0V%!B0W!+$B%!.7/+%!/4%!#=08;!5;!
+=%!A5/*4/@!B%708G!
<=%!$#%!01!1%44$7%#!+0!.40+%:+!+$B%#!5#!;0+!.%4@5++%A!0+=%4!+=/;!8=%4%!045*5;/779!#.%:515%A!140@!;%8!04!/!
A%#5*;!:=/;*%!=/#!B%%;!/..40R%A!B9!+=%!5;#$4%4G!
^%44$7%#!@$#+!;0+!B%!$#%A!/#!/!4%./54!104!+$B%#!+=/+!/4%!804;!+=5;!04!7%/V5;*!+0!/;!%W+%;+!+=/+!+=%9!:/;;0+!B%!
V%.+!+5*=+!/1+%4!%W./;#50;G!<=%!.$4.0#%!01!+=%!1%44$7%!5#!+0!.40+%:+!+=%!+$B%!%;A!;0+!+0!4%5;104:%!5+G!!

!
!
<=4%/A#!+0!B%!E=5+804+=!104@!;04@/7!+0!+=%!/;*7%!01!+/.%4G!
P5@%;#50;!ijT!+0!R/49!140@!'!]d'H`!+0!,!Od'H`!5;!'d'H`!5;:4%@%;+#!
Plugs for Tubeplates
!
!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!H!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Demonstrate how to tackle
fractured tubeplate bridges
Tubeplate bushes with screwed in bush on five
9 plugs and ferrules Workshop
tube holes having shown on
a drawing how a repair is
done
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

10. Tube Plate Liners

";!04A%4!+0!$#%!#+/;A/4A!+$B%#!5;!+$B%!.7/+%!=07%#!8=5:=!=/R%!B%%;!4%/@%A!0$+>!/;;%/7%A!:0..%4!75;%4#!@/9!
B%!$#%A!5;!/::04A/;:%!85+=!+=%!1077085;*!+/B7%K!
!

! F0@5;/7!5;#5A%!A5/@%+%4! F0@5;/7!0$+#5A%! F0@5;/7!+=5:V;%##!

01!75;%4G!";:=%#! A5/@%+%4!01!75;%4G!";:=%#
\GEGCG!!!!!!!!!!!!!!@@!
^04!<$B%#! 'G'd,!([-G'@@! 'GOd'H!!!(![OGH-@@! ,'! &G-!
'G'd,`b[-G'@@c! 'G'd,!([-G'@@! 'G'Od[,!(I&GI-@@! '-! 'G,!
P5/@%+%4!)+!D;A! 'G'd,!([-G'@@! 'G,'d[,!(I,G&H@@! 'I! ,G&!
^04!<$B%#! 'GJd-!(I'G,@@! 'G''d'H!(I,G-H@@! ,'! &G-!
'GJd-`bI'G,@@c!! 'GJd-!(I'G,@@! 'G,[d[,!(I[GHJ@@! '-! 'G,!
A5/@%+%4! 'GJd-!(I'G,@@! 'G[dI!!!!!(IIGIJ@@! 'H! 'GH!
)+!%;A! 'GJd-!(I'G,@@! 'G,Jd[,!(IJG,I@@! 'I! ,G&!
^04!+$B%#! 'G[dI!(IIGI@@! 'G'[d'H!(IHG&[@@! ,'! &G-!
'G[dI`bIIGI@@c! 'G[dI!(IIGI@@! 'G,]d[,!(IHG-[@@! '-! 'G,!
P5/@%+%4!)+!D;A! 'G[dI!(IIGI@@! 'G]d-!!!!!(I]GH,@@! 'H! 'GH!
! 'G[dI!(IIGI@@! 'G,Od[,!(I-GI,@@! 'I! ,G&!
! 'G[dI!(IIGI@@! 'G'Jd'H!(IOG,'@@! '[! ,G[!
! 'G[dI!(IIGI@@! ,!!!!!!!!!!!(J&G-&@@! '&! [G,!
^04!+$B%#!,`bJ&G-@@c! ,!!!!!!!(J&G-@@! ,G'd-!!!!!(J[GO]@@! 'H! 'GH!
P5/@%+%4!/+!%;A!
E=%4%!5+!5#!:0;#5A%4%A!/!.0##5B575+9!+0!15+!75;%4#>!5+!#=0$7A!B%!%#+/B75#=%A!+=/+!+=%4%!5#!#$115:5%;+!@/+%45/7!+0!
#$..04+!+=%!+$B%#G!<=5#!804V!#=0$7A!;0+!B%!$;A%4+/V%;!85+=0$+!+=%!.4504!:0;#%;+!01!+=%!:0@.%+%;+!.%4#0;G!";!
;0!:54:$@#+/;:%#!#=0$7A!+=%!+=5:V;%##!01!/!75;%4!%W:%%A![G,@@!b'&\ECcG!!
<=%!75;%4#!@$#+!B%!75*=+79!A45R%;!5;!17$#=!85+=!+=%!154%#5A%!01!+=%!+$B%!.7/+%!/;A!+=%;!%W./;A%A!5;!.0#5+50;G!
\+/;A/4A!15R%!4077%4!%W./;A%4#!@$#+!B%!$#%A!104!+=5#!.$4.0#%G!

11. Tube Plates

N08%A!+$B%!.7/+%#!5;!/!.004!:0;A5+50;!@$#+!B%!4%.7/:%A>!B$+!51!#%4R5:%/B7%>!@$#+!B%!7%R%77%AG!

12. Preparing for Tube Installation

N%!:%4+/5;!+=/+!/77!B057%4!4%./54#!8=5:=!:/;!;0+!B%!.%4104@%A!/1+%4!+=%!+$B%#!/4%!5;!=/R%!B%%;!:0@.7%+%AG!!!
DW/@5;%!+=%!5;#5A%#!01!B0+=!+$B%!.7/+%#!104!/;9!$;A5#:0R%4%A!:4/:V#!04!;5:V%A!+$B%!=07%#>!/;A!@/V%!#$4%!
+=%!+$B%!=07%#!/4%!:7%/;G!
<=%!%;A#!01!07A!+$B%#!04!+$B%#!+=/+!=/R%!B%%;!#8/*%A!A08;!8577!4%X$54%!;04@/75#5;*!b=%/+5;*!+=%54!%;A#!+0!!
B45*=+!:=%449!4%A!b-I&!(!-]&!Y!c!/;A!:0075;*!+=%@!#70879c!+0!#01+%;!+=%!@/+%45/7!(!!;0+!0;79!+0!%/#%!40775;*!/;A!
B%/A5;*>!B$+!/7#0!+0!.4%R%;+!:4/:V5;*!A$45;*!+=%!5;#+/77/+50;!.40:%##G!!!)!4%*$7/+%A!*/#!0R%;!5#!+=%!B%#+!
;04@/75#5;*!+007>!B$+!/!104*%!04!=%/+5;*!+04:=!8577!/7#0!804V!51!:/4%!5#!+/V%;!+0!.4%R%;+!B$4;5;*!+=%!+$B%#>!
8=5:=!4%#$7+#!5;!=%/R9!#7/*!B$57A($.>!.5++5;*!/;A!.0##5B7%!B45++7%;%##G!!<=%!+$B%!%;A#!/4%!$#$/779!:007%A!B9!
.7$;*5;*!+=%@!5;+0!/!B%A!01!75@%>!8=5:=!;0+!0;79!5;#$7/+%#>!B$+!/7#0!=%7.#!+0!@5;5@5h%!0W5A/+50;!b#:/7%cG!!!"+T#!
;0+!;%:%##/49!+0!;04@/75#%!+=%!%;A#!01!;%8!+$B%#>!51!+=%9!/4%!A%75R%4%A!5;!/!;04@/75#%A!#+/+%G!!"1!90$!=/R%!
A5115:$7+9!40775;*!;%8!+$B%#>!04!51!:4/:V5;*!0::$4#!A$45;*!40775;*!04!B%/A5;*>!4%Q%:+!+=%!+$B%#!/;A!:0;+/:+!+=%!
+$B%!#$..75%4!104!/;!%W.7/;/+50;G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!]!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Copper liners in
tubeplates
Select theoretical size of
Can be used to bring
liners according to chart Classroom
10 tube holes back to
Fit liners into ten holes in & Workshop
smaller sizes
oversize copper tubeplate
Select liners for ten
holes in oversize
tubeplate
How might tubeplates be
Tubeplates must be bowed? How is that
11 Classroom
straight measured and how is it
corrected?
Explain what you need to do to
Preparation prior to holes and tubes before
12 tubing Classroom
beginning to insert tubes and
expanding
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
<=%!+$B%!%;A#!@$#+!B%!14%%!01!/;9!B$44#!7%1+!0R%4!140@!:$++5;*>!/;A!#=0$7A!B%!75*=+79!.075#=%A!B0+=!5;#5A%!/;A!
0$+!104!/!7%;*+=!01!,`bJ&@@c!+0![`b]J@@c!0;!B0+=!%;A#!+0!4%@0R%!@577!#:/7%!04!#:/7%!4%#$7+5;*!140@!
;04@/75#5;*G!
)1+%4!B%5;*!:$+!+0!7%;*+=>!:7%/;%A!/;A!#8/*%A!b51!;%:%##/49c>!+=%!+$B%#!/4%!4%/A9!+0!B%!.7/:%A!5;+0!+=%!B057%4G!!!
E5.%!+=%!+$B%#!Q$#+!B%104%!5;#%4+5;*!+0!4%@0R%!A54+>!700#%!#:/7%>!/;A!/;9!4%@/5;5;*!057!04!4$#+!.4%R%;+/+5R%a!
+=%;!5;#.%:+!+=%!+$B%#!/!15;/7!+5@%>!4%Q%:+5;*!+=0#%!8=5:=!/4%!A%;+%A>!A%%.79!#:4/+:=%A!04!*0$*%A>!04!=/R%!
A/@/*%A!%;A#G!

13. Flue Tubes

Procedure for new screwed superheater flue tubes and tube plates
M570+!=07%#!+0!B%!A4577%A!5;!+$B%!.7/+%!104!+$B%!=07%#G!<$B%!=07%#!+0!B%!0.%;%A!0$+!/;A!/!4/A5$#!@/:=5;%A!0;!
+=%!154%#5A%!01!%/:=!=07%>!/;A!15;/779!+/..%A!+0!#$5+!+=%!#:4%8%A!%;A!01!+=%!#$.%4=%/+%4!17$%!+$B%G!
<$B%!%;A#!/4%!+0!B%!#:4%8%A!G&&]!b&G'O@@c!+0!G&'J!b&G[-@@c!B%708!+=%!;0@5;/7!A5/@%+%4>!/;A!/+!+=%!#/@%!
#%++5;*!+=%!B04%!@$#+!B%!:7%/;%A!0$+!%W/:+79!:0;:%;+45:!104!/!A%.+=!01![k!b-,@@c!140@!+=%!%;A!01!+=%!17$%!
+$B%G!^40@!+=/+!.05;+!5;8/4A#!+=%!:$+!@$#+!B%!4$;!5;+0!+=%!045*5;/7!40$*=!B04%!01!+=%!+$B%!85+=0$+!/;9!/B4$.+!
:=/;*%!5;!#%:+50;G!"+!5#!.%4@5##5B7%!+0!1/B45:/+%!17$%!+$B%#!B9!8%7A5;*!/!#%./4/+%!#8/*%A!%;A!0;+0!/!.7/5;!
+$B%G!!
U;79!8%7A%4#!.40.%479!X$/7515%A!/;A!:%4+515:/+%A!104!+=5#!+9.%!01!8%7A5;*!:/;!$;A%4+/V%!+=%!+/#VG!
<=%!+$B%!%;A#!@$#+!B%!#+45:+79!:0;:%;+45:!/;A!5;!/::04A/;:%!85+=!+=%!/..40.45/+%!A4/85;*!5;!/77!4%#.%:+#G!
<=%!+=4%/A#!5;!+=%!:0..%4!+$B%!.7/+%!@$#+!B%!:7%/;%A!0$+!85+=!/!#=04+!+/.!4%R07R%A!140@!+=%!#+%%7!+$B%!.7/+%!
%;A!B9!/!70;*!/A/.+04>!+=%!/A/.+04!B%5;*!*$5A%A!B9!/!B$#=!.$+!5;!+=%!:044%#.0;A5;*!#@0V%!B0W!+$B%!.7/+%!
=07%G!
<=%!+$B%!.7/+%!0;!+=%!8/+%4!#5A%!@$#+!B%!75*=+79!1/:%A!8=%;!;%:%##/49!/;A!:0;%A!O&!A%*4%%#!+0!/!A%.+=!01!
/..40W5@/+%79!'d-`!b[G'-@@c>!+=%!:$++%4!B%5;*!@0$;+%A!0;!/!@/;A4%7!#:4%8%A!+5*=+79!5;+0!+=%!:0..%4!.7/+%G!
)+!+=%!154%B0W!%;A!0;!/!#:4%8%A!17$%!+$B%!+=%!8/77!+=5:V;%##!B%708!+=%!+=4%/A%A!.04+50;!01!+=%!+$B%!/+!+=%!
.05;+!01!%W./;#50;!@$#+!B%![d'H`bIG]H@@c!@5;5@$@>!k!!bHG[J@@c!@/W5@$@G!
<$B%#!@/9!B%!#:4%8%A!5;!$#5;*!+=%!#+/;A/4A!+007>!#%%!#V%+:=!B%708>!04!51!+=%9!=/R%!B%%;!04A%4%A!0R%4!
7%;*+=!+=%9!@/9!B%!#:4%8%A!5;+0!.7/:%!$#5;*!+=%!8/#+%!%;A!/;A!+=%;!:$+!+0!7%;*+=!5;!#5+$G!Y/4%!@$#+!B%!
+/V%;!+0!%;#$4%!+=/+!+=%!%;A!5#!:7%/;!/;A!#X$/4%!B%104%!%W./;#50;G!

!
Tool for inserting flue tubes

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!-!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Demonstrate
understanding of Fit ten small tubes correctly
how steel into both tubeplates and
superheater flues position correctly
are ended and Must have assisted actively in
prepared for joining the preparation and insertion of
13 into tubeplate. How 10 new superheater flues Workshops
to support tap and including tapping,
tube during countersinking, winding home,
insertion and how to beading and cutting off at
tighten flues fully smoke box
home and cut off
!
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

14. Tube Expanding

<=%!+9.%!01!%W./;A%4!$#%A!8577!B%!A%+%4@5;%A!B9!+=%!045*5;!01!+=%!B057%4G!
<9.5:/779! +=%! D/#+%4;! /;A! \0$+=%4;! 4%*50;#! $#%A! 154%#5A%! %W./;#50;! /;A! +=%! E%#+%4;! 4%*50;! /;A! ?0;A0;!
S5A7/;A!6%*50;!$#%A!8/+%4#5A%!%W./;#50;G!S0A%4;!5;A$#+45/7!.4/:+5:%!5#!+0!$#%!./4/77%7!5;+%4;/7!%W./;#50;G!

!
);!0R%4(#:/7%!#V%+:=!01!+=%!%11%:+#!01!+=%!+80!104@#!01!%W./;A%4!5#!*5R%;!/B0R%K!

!
<0!4%(%W./;A!+$B%#!85+=!/;!%W./;A%4!=/R5;*!/!A511%4%;+!A54%:+50;!01!%W./;#50;!+0!+=/+!.4%R50$#79!%@.709%A!
8577!:/$#%!#%R%4%!A5#+04+50;!/;A!5#!+=%4%104%!.40=5B5+%AG!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!O!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Demonstrate
Be able to illustrate
understanding of
satisfactorily a full
different types of
understanding of types of
expanders and
14 expanders and matching Classroom
different types of
mandrels with pros and cons
expansion with pros
for each. How to achieve and
and cons
monitor 7% expansion
!
How to avoid “pull Explain what options are
in” on first available to keep tubes from
14 Classroom
expansion moving longitudinally during
! expansion process

Demonstrate
understanding of Manually expand twenty tubes
why sequence of satisfactorily plus a test piece.
expanding in a Section test piece and check
14 tubeplate is so theoretical expansion figures Workshop
important Draw diagram of expansion
sequence and why your
method is satisfactory

Demonstrate the Expand tubes using expander

use of stops on an stop to control movement
14 Workshop
expander producing evidence of no
! movement afterwards
Different mandrels
produce different
results within the Be able to identify the right
14 same expander. mandrel for a certain expansion Classroom
Demonstrate and explain why
understanding of
this
Demonstrate correct
Knowing when to completion of expanding to
14 stop expanding Workshop
correct limits of 7%

!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
<$B%!%W./;#50;!B%*5;#!5;!+=%!154%B0WG!![!4077%4!%W./;A%4#!#=0$7A!;0+!B%!$#%A!5;!:0..%4!+$B%.7/+%#!A$%!+0!+=%!
.0+%;+5/7!104!A%104@/+50;G!Y$44%;+!.4/:+5:%!1/R0$4#!+=%!J!4077%4!%W./;A%4!/#!5;!A4/85;*!B%708!

!
J!4077%4!%W./;A%4!104!Y0..%4!<$B%!'!k`!+0![!k`!
H!4077%4!%W./;A%4!104!\+%%7!<$B%#!
Expanders for small tubes
!
D/:=!+$B%!@$#+!.40Q%:+!140@!+=%!+$B%!.7/+%!/!4%X$54%A>!.4%(A%+%4@5;%A!/@0$;+>!$#$/779!B%+8%%;![d'H`!
bIG]H@@c!+0!Jd'H`!b]GO[@@cG!!b)#!+=%!+$B%#!/4%!A45R%;!5;+0!.0#5+50;>!V%%.!/!#@/77!.7/+%!@%+/7!*/$*%!=/;A9cG!!
<=%!.40Q%:+50;!01!+=%!+$B%!/+!B0+=!+=%!154%B0W!/;A!#@0V%B0W!%;A#!@$#+!B%!:=%:V%A!+0!R%4519!:044%:+!+$B%!
7%;*+=G!!!)!75++7%!%W:%##!7%;*+=!5#!/7708%A!5;!+=%!#@0V%B0W>!B$+!#=04+!+$B%#!#=0$7A!B%!4%Q%:+%AG!!<=%!4077%4!
%W./;A%4!+%;A#!+0!.$77!+=%!+$B%!5;+0!+=%!154%B0W!/#!8%77!/#!40+/+%!5+>!#0!+=%!+$B%!@$#+!B%!/;:=04%A!+0!+=%!140;+!
+$B%!.7/+%G!!)!*00A!@%+=0A!5#!+0!*4/#.!+=%!.40Q%:+5;*!.04+50;!01!+=%!+$B%!/+!+=%!#@0V%B0W!%;A!85+=!+80!./54!01!
70:V5;*!.75%4#>!#0!+=/+!+=%!75.#!01!+=%!.75%4#!4%#+!/*/5;#+!+=%!+$B%!.7/+%!8=%;!+=%!+$B%!5#!5;!5+#!.40.%4!.0#5+50;!
b/#!*/$*%A!5;!+=%!154%B0Wca!!+=%!.75%4#!/7#0!.4%R%;+!+=%!+$B%!140@!#.5;;5;*G!
<=%!%W./;A%4!#=0$7A!B%!7$B45:/+%A>!B$+!B%!:/4%1$7!;0+!+0!*%+!057!B%+8%%;!+=%!+$B%!/;A!=07%>!8=5:=!:/;!:/$#%!
/!=9A4/$75:!70:V!.4%R%;+5;*!+=%!+$B%!140@!#%/75;*!.40.%479G!!!Z#%!8/+%4(#07$B7%!057!#0!+=/+!+=%!%W./;A%4!:/;!
B%!8/#=%A!.%450A5:/779G!Y0@.4%##%A!/54!@/9!B%!$#%A!+0!B708!A54+!140@!+=%!5;+%4504!01!+=%!+$B%!/;A!140@!
B%+8%%;!+=%!+$B%!/;A!5+#!=07%G!
<0!/R05A!A5#+04+50;!01!+=%!+$B%!.7/+%#>!5+!5#!/AR5#/B7%!+0!107708!#0@%!#9#+%@/+5:!@%+=0A!5;!+=%!15++5;*!01!+=%!
17$%#G!!
<=%!#%X$%;:%!5;!8=5:=!+$B%#!/4%!+0!B%!%W./;A%A!8577!B%!7/5A!A08;!/;A!#=0$7A!B%!/A=%4%A!+0a!=08%R%4>!51!+=%!
045*5;/7!04A%4!A4/85;*#!/4%!;0!70;*%4!/R/57/B7%!0;%!+=%!1077085;*!@%+=0A#!@/9!B%!/A0.+%AK!
Method 1.
^5;5#=!/!R%4+5:/7!:%;+4/7!408>!107708%A!B9!/!=045h0;+/7!:%;+4/7!408G!<=%;!15;5#=!%/:=!X$/A4/;+>!#$::%##5R%79!
804V5;*!140@!+=%!0$+#5A%!+08/4A#!+=%!:%;+4%G!
Method 2.
\+/4+!%W./;A5;*!/+!+=%!0$+#5A%!408#!/;A!804V!5;8/4A!5;!/!#.54/7!@/;;%4!+0!15;5#=!5;!+=%!:%;+4%!01!+=%!+$B%!
.7/+%G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'&!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
Method 3.
<=%!0$+%4!/;A!B0++0@!+$B%#!/4%!%W./;A%A!154#+!*4/A$/779!804V5;*!5;8/4A#!/;A!$.8/4A!804V5;*!+08/4A#!+=%!
:%;+4%!01!+=%!+$B%!.7/+%a!+=%!0BQ%:+!B%5;*!+0!A5#+45B$+%!+=%!:0@.4%##5;*!/:+50;!01!+=%!%W./;A%4!/#!%R%;79!/#!
.0##5B7%!0R%4!+=%!%;+54%!.7/+%!85+=0$+!A5#+04+5;*!+=%!+$B%!.7/+%G!
<=%!%W./;A%4!#=0$7A!B%!
1$779!5;#%4+%A!5;+0!+=%!+$B%G!!
DW./;A%4#!85+=!+=4$#+!
:077/4#!=/R%!/!_B45A*%`!8=5:=!
%W+%;A#!./#+!+=%!0$+#5A%!01!
+=%!+$B%>!/;A!8=5:=!@$#+!
4%#+!#%:$4%79!/*/5;#+!+=%!
+$B%!.7/+%G!);!%W/@.7%!5#!
#=08;!5;!A4/85;*!+0!+=%!
45*=+K!
!
!
!
!
!
Adaptor for small tube expanders
!
N%!#$4%!+0!#%7%:+!+=%!+/.%4%A!@/;A4%7!+=/+!8577!1$779!%;*/*%!+=%!4077%4#!/+!+=%!#+/4+G!!<=%!@/;A4%7!@/9!B%!
+$4;%A!B9!=/;A!8=%;!;%:%##/49>!B$+!5#!*%;%4/779!A45R%;!B9!%5+=%4!.;%$@/+5:!04!%7%:+45:!_4077!@0+04#`G!!!Z#5;*!
+=%#%!@0+04#!5;!+=%!:0;15;%#!01!%5+=%4!+=%!154%B0W!04!#@0V%B0W!5#!=/h/4A0$#!B%:/$#%!+=%!=5*=!+04X$%!
A%R%70.%A!:/;!%/#579!:/$#%!+=%!0.%4/+50;!+0!70#%!:0;+407!01!+=%!@/:=5;%G!!E=%;%R%4!.0##5B7%!B4/:%!+=%!
@0+04!/*/5;#+!+=%!#5A%!04!:408;!.7/+%>!04!$.0;!/!B/4!5;#%4+%A!5;+0!/!:0;R%;5%;+!+$B%>!/;A!=07A!0;+0!+=%!
@0+04T#!+45**%4!5;!#$:=!/!8/9!/#!+0!/R05A!.5;;5;*!+=%!:0;+40775;*!=/;A!5;!+=%!%R%;+!01!/!.40B7%@G!
U;:%!+=%!@/;A4%7!=/#!B%%;!.7/:%A!5;!+=%!%W./;A%4!/;A!+=%!@0+04!:0;;%:+%A!/;A!#85+:=%A!0;>!8/+:=!+=%!
/:+50;!01!+=%!4077%4#!/*/5;#+!+=%!+$B%!8/77!/#!#+4%+:=5;*!B%*5;#G!!!!S0#+!4077%4#!/4%!A%#5*;%A!+0!#%71(1%%A!+=%!
+/.%4%A!@/;A4%7>!@/V5;*!5+!$;;%:%##/49!+0!.$#=!5+!5;+0!+=%!%W./;A%4G!!)#!+=%!@/;A4%7!5#!1%A!+=%!+$B%!8577!
#70879!*408!5;!A5/@%+%4!/;A!1577!+=%!=07%G!!!<=%!45..75;*!/:+50;!01!+=%!+$B%!8577!#70879!A5@5;5#=!/;A!+=%;!#+0.>!
/::0@./;5%A!B9!/!#75*=+!#+4/5;5;*!01!+=%!@0+04>!B0+=!5;A5:/+50;#!+=/+!+=%!+$B%!=/#!+5*=+%;%A!5;!5+#!=07%G!
DW.%45%;:%!5#!;%:%##/49!+0!A%+%4@5;%!51!40775;*!#=0$7A!B%!:0;+5;$%A!B%90;A!+=5#!A%*4%%!01!+5*=+;%##G!!
\0@%+5@%#!/!#+/;A/4A!#$:=!/#!_0;%(=/71!+$4;!@04%`!04!_0;%!+$4;!@04%`!5#!/..75%Aa!/7+%4;/+5R%79!+=%!A%*4%%!01!
%W./;#50;!:/;!B%!:/7:$7/+%A!/#!107708#K!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!''!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
!
!
\+%.!)!(!S%/#$4%!<$B%!M7/+%!307%!
\+%.!N!(!S%/#$4%!<$B%!UP! !
\+%.!Y!(!Y/7:$7/+%!Y7%/4/;:%!b)eNc!
\+%.!P!e!S%/#$4%!<$B%!"P!
\+%.!D!e!Y/7:$7/+%!<0+/7!E/77!<=5:V;%##!bNePc!
\+%.!^!e!Y/7:$7/+%!]l!E/77!6%A$:+50;!bG&]!m!Dc!
\+%.!C!e!Y/7:$7/+%!^5;5#=%A!6077%A!<$B%!"P!bYnPn^c!
^04!#+%%7!+$B%#!+=%!+$B%!8/77!#=0$7A!B%!4%A$:%A!B9!/..40W5@/+%79!]l!+0!-l!104!0.+5@$@!+$B%!Q05;+#G!E=%;!
40775;*!:0..%4>!:0;#5A%4!/..40W5@/+%79!-l!+0'&l!8/77!4%A$:+50;!+0!.40A$:%!/!.40.%4!+$B%!Q05;+G!
Y0;#5A%45;*!+=%!R/45/+50;#!8=5:=!0::$4!5;!#$:=!5+%@#!/#!+$B%!8/77!+=5:V;%##!/;A!A5/@%+%4!01!+$B%!=07%>!+=%!
804V!5;R07R%A!5;!@%/#$45;*!/;A!4%!@%/#$45;*!%/:=!Q05;+!80$7A!@/V%!:0#+!%W:%##5R%G!!
U;:%!+=%!+$B%!5#!+5*=+>!4%R%4#%!+=%!A54%:+50;!01!+=%!@0+04!/;A!.$77!+=%!@/;A4%7!B/:V!8=57%!+$4;5;*>!4%7%/#5;*!5+!
140@!+=%!4077%4#G!!"1!+=%!@0+04!8577!;0+!4%R%4#%>!4%@0R%!+=%!@/;A4%7!B9!+$4;5;*!5+!85+=!/!#./;;%4G!
E=%;!+=%!154%B0W!%;A!5#!15;5#=%A>!.40:%%A!+0!+=%!0+=%4!%;AG!!N%*5;!/*/5;!/+!+=%!:%;+4%!+0!B4/:%!+=%!.7/+%G!!N%!
:/4%1$7!01!+=%!.$775;*!/:+50;!0;!+=%!154#+!+$B%#>!B%:/$#%!+=%!+$B%!.7/+%#!@/9!B%!.$77%A!:70#%4!+0*%+=%4!/+!+=%!
:%;+4%>!B%:0@5;*!A5#=(#=/.%AG!!);!%W./;A%4!85+=0$+!/!+=4$#+!:077/4!8577!=%7.!4%A$:%!+=5#!.$775;*!+%;A%;:9G!
\$.%4=%/+%4!17$%#!4%X$54%!7/4*%4!4077%4#>!/;A!@/9!A%@/;A!=%/R5%4!@0+04#G!!"+T#!#/1%4!+0!70:/+%!=%/R5%4!@0+04#!
5;!+=%!@04%!#./:50$#!#@0V%B0W!04!0;!+%@.04/49!.7/+104@#!5;!140;+!01!+=%!B057%4G!!!S/;9!7/4*%!%W./;A%4#!=/R%!
A45R%!B0##%#!04!:0;;%:+50;#!/+!B0+=!%;A#!01!+=%!+/.%4%A!@/;A4%7a!8=%;!40775;*!/+!+=%!4%/4!+$B%!.7/+%a!+=%#%!
:0;;%:+!+=%!4077%4!+0!+=%!@0+04!R5/!/!A45R%!#=/1+!#75A!+=40$*=!+=%!17$%G!!
^$4+=%4!:0;#5A%4/+50;!8577!#=08!+=/+!4%*/4A7%##!01!+=%!R/45/+50;!5;!:7%/4/;:%!B%+8%%;!+=%!0$+#5A%!A5/@%+%4!01!
+=%!+$B%!/;A!+=%!+$B%!=07%>!+=%!804V!A0;%!5;!%W./;A5;*!+=%!+$B%!$.!+0!+=%!5;#5A%!A5/@%+%4!01!+=%!=07%!5#!
4%7/+5R%79!#@/77!:0@./4%A!85+=!+=%!804V!5;!/:+$/779!4%A$:5;*!+=%!8/77!+=5:V;%##G!3%;:%!+=%!A%*4%%!01!
%W./;#50;!:/;!B%!:0;+4077%A!B9!/:+$/779!@%/#$45;*!+=%!/@0$;+!01!804V!;%:%##/49!+0!*5R%!+=%!4%X$54%A!
/@0$;+!01!8/77!+=5;;5;*!b8=5:=!5#>!5;!1/:+>!A54%:+79!4%7/+%A!+0!+=%!+04X$%!%W%4+%A!B9!+=%!@/;A4%7!5+#%71!104!/;9!
#.%:515:!#5h%!01!+$B%!Q05;+cG!U;:%!+=%!5;5+5/7!Q05;+!5#!/:+$/779!@%/#$4%A!/;A!4%7/+%A!+0!+=%!+04X$%!0;!+=%!
@/;A4%7>!+=%;!+=%!%W./;#50;!01!+=%!0+=%4!Q05;+#!+0!+=%!#/@%!+04X$%!4%/A5;*!*5R%!:0;#5#+%;+!4%#$7+#!5;!75;%!85+=!
+=/+!01!+=%!154#+!%W./;#50;G!
L%%.!5;!@5;A!+=/+!+=%!A%#54%A!4%#$7+!5#!+0!#%/7!+=%!+$B%#!8=57%!.40A$:5;*!+=%!7%/#+!/@0$;+!01!#+4%##!5;!+=%!
+$B%!.7/+%G!!)!+$B%!8=5:=!=/#!B%%;!%W./;A%A!#75*=+79!7%##!+=/;!1$779!=/#!/!@$:=!B%++%4!B0;A!+=/;!/!+$B%!
8=5:=!=/#!B%%;!#+4%##%A!B9!0R%4%W./;#50;G!"+!5#!B%++%4!+0!$;A%4(4077!+=/;!0R%4(4077G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!',!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

15. Beading
U;:%!/77!+$B%#!/;A!17$%#!/4%!.40.%479!%W./;A%A>!+=%!%;A#!/4%!*%;%4/779!_B%/A%A`>!04!45R%+%A!0R%4!/*/5;#+!+=%!
+$B%!.7/+%#G!!N%/A5;*!B%*5;#!5;!+=%!154%B0W!/;A!#=0$7A!107708!+=%!#/@%!./++%4;!$#%A!8=%;!%W./;A5;*!+=%!
+$B%#G!!<=%!.40Q%:+5;*!%;A!01!%/:=!+$B%!@$#+!154#+!B%!_B%77%A`!04!17/4%A!+0!/B0$+!IJg!bS5;![JgcG!!!
"1!+=%!%W./;A%4!$#%A!=/A!%W+4/!_17/45;*`!4077%4#>!B%775;*!8/#!A0;%!/#!+=%!+$B%#!8%4%!%W./;A%AG!!"1!;0+>!$#%!/!
:0@@%4:5/7!04!=0@%(@/A%!B%775;*!+007>!A45R%;!B9!=/;A!04!.;%$@/+5:!=/@@%4#G!)#!#=08;!5;!A5/*4/@!B%708K!

!
First operation, pneumatic tool for flaring tubes
<=%!#%:0;A!0.%4/+50;!5#!+0!B%/A!0R%4!+=%!%A*%!01!+=%!17/4%A!+$B%>!85+=!/!B%/A5;*!+007!/#!#=08;!B%708K!!

Beading tool for small tubes.

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'[!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers
!
216 mm radius

19

22 mm octagon steel

Dia
Hand Tool To Chain Dot Lines

19

1.5

Example of a beading tool for large flue tubes.

!
)!B%/A5;*!04!_+=$@B`!+007!:/;!B%!$#%A!B9!=/;A!04!5;!/!#@/77!+0!@%A5$@!.;%$@/+5:!=/@@%4G!!N%/A5;*!1$4+=%4!
#%/7#!04!:/$7V#!+=%!%W./;A%A!Q05;+a!+0!.40A$:%!+=%!:044%:+!B%/A>!=/@@%4!;0+!0;79!+=%!%;A!01!+=%!+$B%>!B$+!
/7#0!+=%!+$B%!5;+%4504>!B%;A5;*!+=%!+$B%!0$+!/*/5;#+!+=%!=07%!5;!+=%!.7/+%G!)#!#=08;G!

!
Incorrect use of beading tool (left) Correct use of beading tool (right)
!
\+/4+!+=%!/54!1708!+0!+=%!=/@@%4!#70879>!/;A!804V!+=%!B%/A5;*!+007!/40$;A!+=%!+$B%!#%R%4/7!+5@%#>!*4/A$/779!
=/@@%45;*!+=%!B%77%A!+5.!0R%4!/;A!.40A$:5;*!+=%!15;5#=%A!B%/AG!!<=%!B%/A!@$#+!B%!104@%A!85+=0$+!/77085;*!
+=%!+5.!01!+=%!+=$@B!+0!:$+!5;+0!+=%!.7/+%G!!)#!+=%!+007!8%/4#>!+=5#!+5.!8577!;%%A!+0!B%!*40$;A!B/:VG!!!\%7%:+!+007#!
85+=!+=%!.40.%4!4/A5$#!104!+=%!+$B%!+=5:V;%##!/;A!/7708%A!.40Q%:+50;>!/;A!:=/;*%!+007!#5h%!/#!;%:%##/49!51!+=%!
.40Q%:+5;*!7%;*+=!01!+$B%#!R/45%#G!!
";!+=%!#@0V%B0W!5+!5#;T+!/78/9#!;%:%##/49!+0!B%/A!/77!+=%!+$B%#G!C%;%4/779!/!1%8!408#!01!#@/77!+$B%#!/+!+=%!
B0++0@!/4%!B%/A%A!104!%/#%!01!:7%/;5;*a!+=%!+$B%#!/40$;A!+=%!8/#=0$+!.7$*#!/4%!B%/A%A!+0!.4%R%;+!A/@/*%!
140@!#./;;%4#!/;A!+=%!#@/77!+$B%#!5;!+=%!/4%/!/40$;A!+=%!17$%#G!<$B%#!8=5:=!4%X$54%!B%/A5;*!B$+!.40Q%:+!+00!
1/4!140@!+=%!.7/+%!#=0$7A!B%!+45@@%A!011!85+=!/!*45;A%4!04!:=5#%7!B%104%!B%/A5;*G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'I!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Understanding
purpose of beading Draw correctly executed
15 and how to achieve beading and explain why Classroom
it
!
Demonstrate ability
Create satisfactory bead on
to bead superheater
15 ten superheater flues Workshop
flues
!
Be able to explain wrong ways
Understanding that
of beading and consequences
beading badly done
15 satisfactorily and demonstrate Classroom
can do great harm
same

!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

16. Seal Welding of Tubes

<=%!@%+=0A!+0!B%!$#%A!#=0$7A!B%!/*4%%A!85+=!+=%!:0@.%+%;+!.%4#0;!.4504!+0!:0@@%;:%@%;+G!<=%!+$B%#!
@$#+!B%!%W./;A%A!B%104%!8%7A5;*!/;A!75*=+79!4%(%W./;A%A!/1+%4!8%7A5;*!+0!=%7.!4%75%R%!#+4%##%#!/;A!.4%R%;+!
7%/V/*%!:/$#%A!B9!+=%!8%7A5;*!=%/+G!!
";!04A%4!+0!0R%4:0@%!.40B7%@#!:/$#%A!B9!@0R%@%;+!01!+=%!+$B%#!/;A!.7/+%#!0;!#+%%7!154%B0W%#!+=%!154%B0W!
%;A#!01!+=%!+$B%#!:/;!B%!8%7A%AG!N%104%!8%7A5;*!+=%!+$B%!.7/+%!@$#+!B%!:7%/;>!A49!/;A!14%%!140@!057G!
<=%!1077085;*!A5/*4/@#!577$#+4/+%!8%7A5;*!/7+%4;/+5R%#G!<=%!#%:0;A!@%+=0A!%75@5;/+%#!B%/A5;*G!E=%;!
A%:5A5;*!8=5:=!@%+=0A!+0!$#%!+=%!1077085;*!#=0$7A!B%!:0;#5A%4%AK!!
E=%;!$#5;*!@%+=0A!0;%!+=%!#%/7!8%7A!@/9!:4/:V!/40$;A!+=%!B%/A5;*>!/7+=0$*=!+=5#!:/;!+=%;!B%!:=5..%A!0$+!
/;A!+=%!+$B%!%;A!4%(8%7A%A!+0!+=%!+$B%!.7/+%G!!
<=%!#%:0;A!@%+=0A!%75@5;/+%#!B%/A5;*!+=%4%104%!+=%!:4/:V#!/40$;A!+=%!B%/A5;*a!=08%R%4>!0R%4!/!.%450A!
:4/:V#!:/;!A%R%70.!140@!+=%!8%7A!5;+0!+=%!+$B%!7%;*+=8/9#!:/$#5;*!+$B%!1/57$4%G!
U;79!8%7A%4#!.40.%479!X$/7515%A!/;A!:%4+515:/+%A!104!+=5#!+9.%!01!8%7A5;*!:/;!$;A%4+/V%!+=%!+/#VG!

Method 1 Beaded tubes Method 2 Unbeaded tubes

8%7A!+0!B%!15;5#=%A
17$#=!85+=!B%/A
[d'Ho

\$.%4=%/+%4!17$%!+$B%

\$.%4=%/+%4!17$%!+$B%

'dIo!+0!Jd'Ho!8%7A

\%/75;*
8%7A

\%/75;*
8%7A

\@/77!B057%4!+$B%

\@/77!B057%4!+$B%

[d'Ho

!
!
!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'J!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Although you would
not be seal welding
16
tubes yourself you Underpinning knowledge
Classroom
need to understand questions
17
who would do it and
how
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

17. Welding procedure

)!8%7A5;*!.40:%A$4%!@$#+!B%!/*4%%A!85+=!+=%!Y0@.%+%;+!M%4#0;!B%104%!:0@@%;:%@%;+G!U;79!8%7A%4#!
.40.%479!X$/7515%A!/;A!:%4+515:/+%A!104!+=5#!+9.%!01!8%7A5;*!:/;!$;A%4+/V%!+=%!+/#VG!<=%!:0@.7%+%A!8%7A!+0!B%!
#$BQ%:+%A!+0!#$5+/B7%!FP<>!$;7%##!/*4%%A!0+=%485#%!B9!+=%!Y0@.%+%;+!M%4#0;G!
)!*$5A%!+0!+=%!04A%4!01!8%7A5;*!5#!*5R%;!B%708G!
!
!
!
!
!
U6PD6!U^!ED?P"FC!
\+/4+!8%7A!/+!_)`!/;A!804V!5;!+=%!A54%:+50;!01!_j`!
+0!_N`G!!
<=%;!4%+$4;!+0!_)`!/;A!8%7A!5;!+=%!A54%:+50;!01!_p`!
+0!_N`>!7/..5;*!0R%4!+=%!%;A!01!+=%!154#+!8%7AG!
!
!
!
!
!

18. Leaks
";!04A%4!+0!/R05A!+$B%!7%/V#>!5+!5#!%##%;+5/7!+0!4%/75#%!+=/+!+=%!+$B%!@0R%#!70;*5+$A5;/779!5;!+=%!+$B%!.7/+%!/#!
+=%!+%@.%4/+$4%!R/45%#>!/;A!+=%4%104%!:044%:+!@/;5.$7/+50;!01!+=%!154%(=07%!A004!/;A!+=%!A%17%:+04!.7/+%!@$#+!
B%!$;A%4#+00A!+0!.4%R%;+!:07A!/54!140@!#+45V5;*!+=%!+$B%!.7/+%G!)#!+=%4%!5#!@0R%@%;+!B%+8%%;!+=%!+$B%!/;A!
.7/+%>!+=%!B%/45;*!#$41/:%#!01!+=%!+$B%!/;A!.7/+%!@$#+!B%!1/5479!#@00+=G!)!40$*=!=07%!/;A!+$B%!#$41/:%!80$7A!
:%4+/5;79!B%!#+%/@!+5*=+!104!/!#=04+!+5@%!B$+!4%7/+5R%!@0R%@%;+!#00;!8%/4#!+=%!=5*=!#.0+#!/;A!7%/V/*%!
0::$4#G!
!Y0;+5;$%A!%W./;#50;!A5#+04+#!+=%!+$B%!.7/+%!/;A!+=5;#!+=%!+$B%!@%+/7a!5;!B/A!:/#%#!5+!5#!.0##5B7%!+0!5@.45#0;!
#:/7%!B%+8%%;!+=%!+$B%!/;A!+=%!.7/+%!4%#$7+5;*!5;!1$4+=%4!7%/V/*%#G!"+!5#!#0@%+5@%#!B%;%15:5/7!5;!B/A!:/#%#!+0!
%W./;A!+=%!+$B%#!#$440$;A5;*!+=%!A%1%:+5R%!0;%!154#+>!+=%4%B9!:70#5;*!+=%!@%+/7!0;+0!+=%!+$B%!/;A!4%A$:5;*!
+=%!/@0$;+!01!%W./;#50;!104!+=%!0;%!+$B%G!
6$#+!#=0$7A!;0+!B%!/7708%A!+0!4%@/5;!0;!+=%!B0A9!01!+=%!+$B%!04!.5++5;*!5#!/7@0#+!:%4+/5;!+0!4%#$7+G!
"1!7%/V/*%#!0::$4#!/40$;A!+=%!+$B%!%;A#!4%@0R%!+=%!8/+%4!140@!+=%!B057%4!/;A!4%(B%/A!+=%!7%/V5;*!+$B%#>!+=5#!
5#!;04@/779!#$115:5%;+!/;A!/R05A#!+=%!;%%A!104!4%(%W./;A5;*G!
)!#5*;515:/;+!7%/V!+=/+!A0%#!;0+!4%/A579!#%/7!@/9!5;A5:/+%!/!:4/:V%A!+$B%!04!/!:4/:V!A%R%70.5;*!5;!+=%!+$B%!
.7/+%!75*/@%;+!;%W+!+0!+=%!+$B%G!!!
"1!7%/V/*%!0::$4#!140@!+=%!5;#5A%!01!+=%!+$B%!5+!5#!@0#+!75V%79!A$%!+0!:0440#50;!04!:4/:V5;*G!";!+=5#!#5+$/+50;!/!
+=040$*=!%W/@5;/+50;!01!ALL!+=%!+$B%#!@$#+!B%!:/445%A!0$+!/;A>!85+=!+=%!/..40R/7!01!+=%!4%#.0;#5B7%!.%4#0;>!
+=%!A%1%:+5R%!+$B%b#c!@$#+!B%!4%.7/:%AG!
<=%!$#%!01!/;9!+9.%!01!+$B%!.7$*!04!B7/;V!5#!;0+!.%4@5++%A!$;7%##!#.%:515:/779!/*4%%A!85+=!+=%!Y0@.%+%;+!
M%4#0;G!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'H!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
!
!
54$"(
!"#$%&'( 4#8%"0"9(4'9(
.,/"#$%0"1( 211"11+"'$(3-%$"-%4( 5"6%0"-7((
)*+,"-( 1*:"-0%1&-1(
1%;'4$*-"(
Give reasons why freshly
How to deal with
expanded tubes may leak.
18 and remedy leaks Classroom
Under what circumstances
after expansion!
would you re-expand and why?
!
!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

19. Testing
"1!+=%!N057%4!=/#!B%%;!4%(+$B%Aa!04!+=%!+$B%#!=/R%!B%%;!4%(%W./;A%Aa!%5+=%4!./4+5/779!04!1$779!/;A!;0!0+=%4!
4%./54!804V!=/#!B%%;!$;A%4+/V%;G!U;!:0@.7%+50;!01!+=%!+$B%!4%.7/:%@%;+>!%W./;#50;>!B%/A5;*!/;A!#%/7!8%7A!
0.%4/+50;#!+=%!B057%4!#=/77!B%!#$BQ%:+%A!+0!/!#+/+5:!:07A!8/+%4!=%/A!.4%##$4%!+%#+!85+=!+=%!B057%4!5;!/!E/+%4!
E%A*%A!Y0;A5+50;!b1577%A!85+=!;0!/54!#./:%c!104!/!A$4/+50;!;0!#=04+%4!+=/;!',!=0$4#G!
<=%!#+/+5:!=%/A!.4%##$4%!+%#+!=/#!/!#+5.$7/+%A!A$4/+50;!01!',!=0$4#!+0!%;#$4%!#$115:5%;+!#0/V!+5@%!104!+=%!+%#+G!
Y/4%!#=0$7A!B%!+/V%;!+0!%;#$4%!+=/+!+=%!8/+%4!+%@.%4/+$4%!85+=5;!+=%!B057%4!5#!@/5;+/5;%A!/B0R%!]!A%*4%%#!
Y%7#5$#!/+!/77!+5@%#!+0!/R05A!+=%!.0##5B575+9!01!Y07A!N45++7%!^4/:+$4%G!!bN\,]O&!\%:+50;!H!"##$%![c!
Z;A%4!:%4+/5;!:54:$@#+/;:%#!=9A4/$75:!+%#+5;*!@/9!#$..7%@%;+!+=%!#+/+5:!:07A!8/+%4!=%/A!.4%##$4%!+%#+!51!
A54%:+%A!B9!+=%!Y0@.%+%;+!M%4#0;!

20. Record Keeping

"+!5#!%##%;+5/7!+=/+!/::$4/+%!4%:04A#!/4%!V%.+!01!/77!804V!:/445%A!0$+G!)!104@!#$:=!/#!+=/+!5;!6\MH!5#!5;:7$A%A!
/#!/;!%W/@.7%!5;!)..%;A5W!)!/;A!:/;!B%!$#%A!+0!4%:04A!804V!:/445%A!0$+!0;!+$B%#G!!

21. Appendices
)G!!!6%:04A!L%%.5;*!
qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq %;A!01!@/5;!A0:$@%;+ qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq!
!

! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!']!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
HGR-B9001-Is01____________________________ Tubing of Locomotive Boilers

Appendix A
Record Keeping

!
qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq %;A!01!/..%;A5W qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq!
!
! ! !
"##$%!&'(!)$*$#+!,&&-! ./*%!'-!01!'-! 2!3%45+/*%!6/578/9!)##0:5/+50;!,&&-!
<=%!3%45+/*%!6/578/9!)##0:5/+50;>!?5@5+%A!B9!C$/4/;+%%>!5#!6%*5#+%4%A!5;!D;*7/;A!/;A!E/7%#!F0G!,,,H,IJ!
6%*5#+%4%A!0115:%K!,!?5++7%#+0;%!60/A>!F%8!60@;%9>!L%;+>!<F,-!-M?!
 ! Proposed BESTT Syllabus Assessment Plan
!
BESTT%
Tubing%of%Boilers%1%Module%9001%Is01%
!
Assessment%Record%for:%% %%% Training%Centre:%% % Year:%August%14%–%July%15%
!
LO1% 1% 2% 3% 4% 5% ! ! ! !
Supervisor* ! ! ! ! ! ! ! ! !
Initials*and* !
date*when* !
completed* !
LO2% 1% 2% 3% 4% 5% 6% 7% 8% 9%
Supervisor* ! ! ! ! ! ! ! ! !
Initials*and*
date*when*
completed*
LO3% 1% 2% 3% 4% 5% ! ! ! !
Supervisor* ! ! ! ! ! ! ! ! !
Initials*and*
date*when*
completed*
!
Witness%Statement%
%
The!trainee!! ! ! ! has!completed!the!Learning!outcomes!to!a!satisfactory!standard!
!
Signed:!!Internal!!Supervisor! Print%Name:!!Internal!Supervisor! Date:!December!14!
!
Verified%by%BESST%Assessor%% Name:!! TBC! ! Assessor%Number:!12345!! Date:!December!14!
*