tions inspection. 91.449 Filing of specification. 91.450 91.451 Filing of inspection reports. 91.452 Transfer between inspection districts. Retirement or change of unit numbers. 91.453 Extension of time for inspections 91.454 91.455 and tests. Reporting of accidents. Changes in construction. 91.456 Safety appliances. 91.457 Body structure. 91.458 Report forms. AUTHORITY: The provisions of this Part 91 issued under secs. 2, 5, 36 Stat. 913, 914; 45 U.S.C. 23, 28, unless otherwise noted. § 91.0 Definition of locomotive. A locomotive is a self-propelled unit of equipment designed for moving other equipment and includes a self-propelled unit designed to carry freight and/or passenger traffic. [19 F. R. 4375, July 16, 1954] Subpart A-Boilers and SOURCE: The provisions of this Subpart A contained in Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I.C.C., June 2, 1911, unless otherwise noted. The railroad company will be held responsible for the general design and construction of the locomotive boilers under its control. The safe working pressure for each locomotive boiler shall be fixed by the chief mechanical officer of the company or by a competent mechanical engineer under his supervision, after full consideration has been given to the general design, workmanship, age, and condition of the boiler, and shall be determined from the minimum thickness of the shell plates, the lowest tensile strength of the plates, the efficiency of the longitudinal joint, the inside diameter of the course, and the lowest factor of safety allowed. § 91.2 FACTOR OF SAFETY The lowest factor of safety for locomotive boilers which were in service or under construction prior to January 1, 1912, shall be 3.25. Effective October 1, 1919, the lowest factor shall be 3.5. Effective January 1, 1921, the lowest factor shall be 3.75. Effective January 1, 1923, the lowest factor shall be 4. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenance, I. C. C., June 2, 1911, as amended Apr. 7, 1919] § 91.3 Maximum allowable stress on stays and braces. (a) For locomotives constructed after January 1, 1915, the maximum allowable stress per square inch of net cross sectional area on fire box and combustion chamber stays shall be 7,500 pounds. The maximum allowable stress per square inch of net cross sectional area on round, rectangular, or gusset braces shall be 9,000 pounds. (b) For locomotives constructed prior to January 1, 1915, the maximum allowable stress on stays and braces shall meet the requirements of § 91.2 except that when a new fire box and wrapper sheet are applied to such locomotives they shall be made to meet the requrements of this section. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended June 9, 1914] STRENGTH OF MATERIAL § 91.4 Tensile strength of shell plates. When the tensile strength of steel or wrought-iron shell plates is not known, it shall be taken at 50,000 pounds for steel and 45,000 pounds for wrought iron. § 91.5 Maximum shearing strength of rivets. The maximum shearing strength of rivets per square inch of cross sectional area shall be taken as follows: § 91.7 Responsibility for inspection and repair. The mechanical officer in charge at each point where boiler work is done will be held responsible for the inspection and repair of all locomotive boilers and their appurtenances under his jurisdiction. He must know that all defects disclosed by any inspection are properly repaired before the locomotive is returned to service. § 91.8 Term "inspector." The term "inspector" as used in the rules and instructions in this subpart, unless otherwise specified, will be held to mean the railroad company's inspector. INSPECTION OF INTERIOR OF BOILER § 91.9 Time of inspection. The interior of every boiler shall be thoroughly inspected before the boiler is put into service and whenever a sufficient number of flues are removed to allow examination. § 91.10 Flues to be removed. All flues of locomotive boilers in service, except as otherwise provided, shall be removed at least once every 4 years for the purpose of making a thorough examination of the entire interior of the boiler and its bracing. After the flues are taken out, the inside of the boiler must have the scale removed and be thoroughly cleaned and inspected. The removal of flues will be due after 48 calendar months' service, provided such service is performed within 5 consecutive years. Portions of calendar months out of service will not be counted. Time of service must be properly accounted for by out of service reports and notations of months claimed out of service made on the back of each subsequent inspection report and cab card. The period for removal of flues, upon formal application to the director, may be extended, if investigation shows that conditions warrant it. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended Apr. 7, 1919] § 91.11 Method of inspection. The entire interior of the boiler must then be examined for cracks, pitting, grooving, or indications of overheating and for damage where mud has collected, or heavy scale formed. The edges of plates, all laps, seams, and points where cracks and defects are likely to develop or which an exterior examination may have indicated, must be given an especially minute examination. It must be seen that braces and stays are taut, that pins are properly secured in place, and that each is in condition to support its proportion of the load. Any boiler developing cracks in the barrel shall be taken out of service at once, thoroughly repaired, and reported to be in satisfactory condition before it is returned to service. § 91.13 Lap-joint seams. Every boiler having lap-joint longitudinal seams without reinforcing plates shall be examined with special care to detect grooving or cracks at the edges of the seams. § 91.14 Fusible plugs. If boilers are equipped with fusible plugs they shall be removed and cleaned of scale at least once every month. Their removal must be noted on the report of inspection. INSPECTION OF EXTERIOR OF BOILER § 91.15 Time of inspection. The exterior of every boiler shall be thoroughly inspected before the boiler is put into service and whenever the jacket and the lagging are removed. § 91.16 Lagging to be removed. The jacket and lagging shall be removed at least once every 5 years and a thorough inspection made of the entire exterior of the boiler while under hydrostatic pressure. The jacket and lagging shall also be removed whenever on account of indications of leaks the United States inspector or the railroad company's inspector considers it desirable or necessary. The modification granted in this section in the Commission's order of September 20, 1917, on account of the war in which the date for removal of jacket and lagging was advanced for a period equivalent to the duration of the war, such advanced period shall be considered 2 years. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended Apr. 7, 1919] Every boiler, before being put into service and at least once every 12 months thereafter, shall be subjected to hydrostatic pressure 25 percent above the working steam pressure. § 91.18 Removal of dome cap. The dome cap and throttle standpipe must be removed at the time of making the hydrostatic test and the interior surface and connections of the boiler examined as thoroughly as conditions will permit. In case the boiler can be entered and thoroughly inspected without removing the throttle standpipe the inspector may make the inspection by removing the dome cap only, but the variation from the rule must be noted in the report of inspection. § 91.19 Witness of test. When the test is being made by the railroad company's inspector, an authorized representative of the company, thoroughly familiar with boiler construction, must personally witness the test and thoroughly examine the boiler while under hydrostatic pressure. and the boiler and appurtenances carefully examined. All cocks, valves, seams, bolts, and rivets must be tight under this pressure and all defects disclosed must be repaired. § 91.21 STAYBOLT TESTING Time of testing rigid bolts. All staybolts shall be tested at least once each month. Staybolts shall also be tested immediately after every hydrostatic test. § 91.22 Method of testing rigid bolts. The inspector must tap each bolt and determine the broken bolts from the sound or the vibration of the sheet. If staybolt tests are made when the boiler is filled with water, there must be not less than 50 pounds pressure on the boiler. Should the boiler not be under pressure, the test may be made after draining all water from the boiler, in which case the vibration of the sheet will indicate any unsoundness. The latter test is preferable. § 91.23 Method of testing flexible staybolts wtih caps. (a) Except as provided in paragraph (b) of this section, all staybolts having caps over the outer ends shall have the caps removed at least once every 2 years and the bolts and sleeves examined for breakage. Each time the hydrostatic test is applied the hammer test required by §§ 91.21 and 91.22 shall be made while the boiler is under hydrostatic pressure not less than the allowed working pressure. (b) When flexible staybolts are provided with a telltale hole not less than three-sixteenths inch nor more than seven thirty-seconds inch in diameter, extending the entire length of the bolt and into the head not less than one-third of its diameter, and are opened and tested each time the hydrostatic test is applied, with an electrical or other instrument approved by the Bureau of Locomotive Inspection, that will positively indicate when the telltale holes are open their entire length, the caps will not be required to be removed. When this test is completed, the hydrostatic test must be applied and all staybolts removed which show leakage through the telltale hole. The inner ends of the telltale holes must be kept closed with a fireproof porous material that will exclude foreign matter and permit leakage of steam or water, if the bolt is broken or fractured, into the telltale hole. When this test is completed the ends of the telltale holes shall be closed with material of different color than that removed and a record kept of colors used. (c) The removal of flexible staybolt caps and other tests shall be reported on the report of inspection Form No. 3, and a proper record kept in the office of the railroad company of the inspections and tests made. (d) Fire-box sheets must be carefully examined at least once every month for mud burn, bulging, and indication of broken staybolts. (e) Staybolt caps shall be removed or any of the above tests made whenever the United States inspector or the railroad company's inspector considers it desirable in order to thoroughly determine the condition of staybolts or staybolt sleeves. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended July 28, 1925, and at 6 F.R. 3648, July 23, 1941] § 91.24 Method of testing flexible staybolts without caps. Flexible staybolts which do not have caps shall be tested once each month, the same as rigid bolts. Each time a hydrostatic test is applied such staybolt test shall be made while the boiler is under hydrostatic pressure not less than the allowed working pressure and proper notation of such test made on Form No. 3. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended June 9, 1914] § 91.25 Broken staybolts. No boiler shall be allowed to remain in service when there are two adjacent staybolts broken or plugged in any part of the fire box or combustion chamber, nor when three or more are broken or plugged in a circle 4 feet in diameter, nor when five or more are broken or plugged in the entire boiler. Every gauge shall have a siphon of ample capacity to prevent steam entering the gauge. The pipe connection shall enter the boiler direct and shall be maintained steamtight between boiler and gauge. The siphon pipe and its connections to the boiler must be cleaned each time the gauge is tested. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended Sept. 12, 1912] § 91.30 Time of testing. Steam gauges shall be tested at least once every 3 months and also when any irregularity is reported. der any conditions of service, an accumulation of pressure more than 5 percent above the allowed steam pressure. § 91.35 Setting of safety valves. Safety valves shall be set to pop at pressures not exceeding 6 pounds above the working steam pressure. When setting safety valves, two steam gauges shall be used, one of which must be so located that it will be in full view of the persons engaged in setting such valves; and if the pressure indicated by the gauges varies more than 3 pounds they shall be removed from the boiler, tested, and corrected before the safety valves are set. Gauges shall in all cases be tested immediately before the safety valves are set or any change made in the setting. When setting safety valves the water level in the boiler shall not be above the highest gauge cock. [Rules and instructions for inspection and testing of locomotive boilers and their appurtenances, I. C. C., June 2, 1911, as amended Sept. 12, 1912] § 91.36 Time of testing. Safety valves shall be tested under steam at least once every 3 months, and also when any irregularity is reported. WATER GLASS AND GAUGE COCKS § 91.37 Number and location. Every boiler shall be equipped with at least one water glass and three gauge cocks. The lowest gauge cock and the lowest reading of the water glass shall be not less than 3 inches above the highest part of the crown sheet. Locomotives which are not now equipped with water glasses shall have them applied on or before July 1, 1912. § 91.38 Water glass valves. All water glasses shall be supplied with two valves or shutoff cocks, one at the upper and one at the lower connection to the boiler, and also drain cock, so constructed and located that they can be easily opened and closed by hand. § 91.39 Time of cleaning. The spindles of all gauge cocks and water glass cocks shall be removed and cocks thoroughly cleaned of scale and sediment at least once each month. § 91.40 Tests required before each trip. All water glasses must be blown out and gauge cocks tested before each trip and gauge cocks must be maintained in such condition that they can be easily opened |