Form FRA-4 Boiler Specification Card

OMB No. 2130-0505

FRA Form 4

BOILER SPECIFICATION CARD

Locomotive No._____________; Boiler No.______________________; Date built________________________

Boiler built by:______________________________________________________________________________

Owned by:_________________________________________________________________________________

Operated by:_______________________________________________________________________________

Type of boiler:_____________________________; Dome, where located:_____________________________

BOILER SURVEY DATA

Where condition is called for, use: New - New material at the time of the boiler survey; Good - Little or no wear and/or corrosion; Fair - Obvious wear and/or corrosion.

Boiler Shell Sheets

Material: Type of Material Carbon Content Condition

(wrought iron, carbon steel, or alloy steel)

1st course (front) _________________________ ______________ ___________________________

2nd course _________________________ ______________ ___________________________

3rd course _________________________ ______________ ___________________________

Rivets _________________________ n/a n/a

Documentation of how material was determined shall be attached to this form.

Measurements: At Seam Thinnest

Front flue sheet, thickness n/a ________

1st course, thickness ________, ________, ID________________,ID________________

2nd course, thickness ________, ________, ID________________,ID________________

3rd course, thickness ________, ________, ID________________,ID________________

When courses are not cylindrical give ID at each end

Is boiler shell circular at all points?__________

If shell is flattened, state location and amount________________________________________________

Are all flattened areas of shell stayed adequately for the pressure allowed by this form?______________

Water Space at Mud Ring: Sides________, Front________, Back________

Width of water space at sides of fire box measured at center line of boiler: Front________, Back_________

Firebox and Wrapper Sheets

Firebox sheets: Thickness Material Condition

Rear flue sheet _________ ____________________ ___________________________ Crown _________ ____________________ ___________________________

Sides _________ ____________________ ___________________________

Door _________ ____________________ ___________________________

Combustion chamber _________ ____________________ ___________________________

Inside throat _________ ____________________ ___________________________

Wrapper sheets:

Throat _________ ____________________ ___________________________

Back head _________ ____________________ ___________________________

Roof _________ ____________________ ___________________________

Sides _________ ____________________ ___________________________

Steam Dome

Dome is made of ____________pieces (not including seam welts, if any), Top opening diameter___________

Middle cylindrical portion - ID__________ , Opening in boiler shell, longitudinally - _____________________

Dome sheets: Thickness Material Condition

Base _________ ____________________ ___________________________

Middle cylindrical portion _________ ____________________ ___________________________

Top _________ ____________________ ___________________________

Lid _________ ____________________ ___________________________

Boiler shell liner for

steam dome opening: _________ ____________________ ___________________________

Is liner part of longitudinal seam?____________

Arch Tubes, Flues, Circulators, Thermic Siphons, Water Bar Tubes, Superheaters, and Dry Pipe

Arch tubes: OD___________, wall thickness___________; number __________; condition________________

Flues:

OD________, wall thickness_________, length_____________; number_________; condition______________

OD________, wall thickness_________, length_____________; number_________; condition______________

OD________, wall thickness_________, length_____________; number_________; condition______________

Circulators: OD___________, wall thickness___________; number __________; condition________________

Thermic siphons: number______; plate thickness____________; condition________________

neck OD____________, neck thickness____________; condition________________

Water bar tubes: OD__________, wall thickness____________

Superheater units directly connected to boiler with no intervening valve:

Type______________, Tube OD_______, wall thickness___________; number________; condition__________

Dry pipe subject to pressure:

OD_________, wall thickness__________, material________________; condition________________________

Stay Bolts, Crown Bar Rivets, and Braces

Stay bolts:

Smallest crown stay diameter_________, avg. spacing__________X__________; condition_________________

Smallest stay bolt diameter_________, avg. spacing__________X__________ ; condition__________________

Smallest combustion chamber stay bolt dia.________,

avg. spacing__________X__________; condition_____________________

Measurement at smallest diameter

Crown bar bolts & rivets:

Roof sheet rivets, smallest dia._______, ave. spacing_________X_________; condition______________

Roof sheet bolts, smallest dia._______, ave. spacing_________X_________; condition______________

Crown sheet rivets, smallest dia.________, ave. spacing_________X_________; condition_________________

Crown sheet bolts, smallest dia.________, ave. spacing_________X_________;condition__________________

Braces: Total Cross Sectional Area of Braces

Number Total Area Stayed Actual Equivalent Direct Stay

Backhead _______ ______________ _____________ ___________________________

Throat sheet _______ ______________ _____________ ___________________________

Front tube sheet _______ ______________ _____________ ___________________________

_____________ _______ ______________ _____________ ___________________________

_____________ _______ ______________ _____________ ___________________________

Safety Valves, Heating Surface, and Grate Area

Safety valves: Total number of safety valves on locomotive____________

Valve Size Manufacturer No. valves of this size and manufacture

__________ __________________________ _________________________________

__________ __________________________ _________________________________

__________ __________________________ _________________________________

__________ __________________________ _________________________________

Heating Surface:

Heating surface, as part of a circulating system in contact on one side with water or wet steam being heated and on the other side with gas or refractory being cooled, shall be measured on the side receiving heat.

Firebox and Combustion Chamber __________________ square feet

Flue Sheets (less flue ID areas) __________________ square feet

Flues __________________ square feet

Circulators ` __________________ square feet

Arch Tubes __________________ square feet

Thermic Siphons __________________ square feet

Water Bar Tubes __________________ square feet

Superheaters (front end throttle only) __________________ square feet

Other __________________ square feet

Total Heating Surface __________________ square feet

Grate area:___________square feet

Water Level Indicators, Fusible Plugs, and Low Water Alarms

Height of lowest reading of gauge glasses above crown sheet:_________________ ___________________

Height of lowest reading of gauge cocks above crown sheet:____________

Is boiler equipped with fusible plug(s)? _______________, number________________________

Is boiler equipped with low water alarm(s)? _______________, number________________________

Calculations

Staybolt stresses:

Stay bolt under greatest load, maximum stress _________________psi

Location____________________________________________

Crown stay under greatest load, maximum stress _________________psi

Location____________________________________________

Combustion chamber stay bolt under greatest load, maximum stress _________________psi

Location____________________________________________

Braces:

Round or rectangular brace under greatest load, maximum stress __________________psi

Location____________________________________________

Gusset brace under greatest load, maximum stress __________________psi

Location____________________________________________

Shearing stress on rivets:

Greatest shear stress on rivets in longitudinal seam ________________psi

Location (course #)_________________ ; Seam Efficiency___________

Boiler shell plate tension:

Greatest tension on net section of plate in longitudinal seam ________________psi

Location (course #)_________________ ; Seam Efficiency___________

Boiler plate and components, minimum thickness required @ tensile strength:

Front tube sheet _________@__________ Rear flue sheet _________@__________

1st course at seam _________@__________ 1st course not at seam _________@__________

2nd course at seam _________@__________ 2nd course not at seam _________@__________

3rd course at seam _________@__________ 3rd course not at seam _________@__________

Roof sheet _________@__________ Crown sheet _________@__________

Side wrapper sheets _________@__________ Firebox side sheets _________@__________

Back head _________@__________ Door sheet _________@__________

Throat sheet _________@__________ Inside throat sheet _________@__________

Combustion chamber _________@__________ Dome, top _________@__________

Dome, middle _________@__________ Dome, base _________@__________

Arch tubes _________@__________ Dome, lid _________@__________

Water bar tubes _________@__________ Thermic siphons _________@__________

Dry pipe _________@__________ Circulators _________@__________

Notes. 1. If tensile strength used is greater than 50,000 psi for steel or greater than 45,000 psi for wrought iron, supporting documentation must

be furnished.

2. Any shell dimension less than 1/4" in thickness may not be adequate for support of or by other structures, particularly where threads or staybolts are concerned. Applicable codes should be consulted.

Boiler Steam Generating Capacity: ________________________pounds per hour

The following may be used as a guide for estimating steaming capacity:

Pounds of Steam Per Hour Per Square Foot of Heating Surface:

Hand fired 8 lbs. per hr.

Stoker fired 10 lbs. per hr.

Oil, gas or pulverized fuel fired 14 lbs. per hr.

Record of Alterations

Description of Alteration Date of Alteration

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Record of Waivers

Section No.

Waiver No. Affected Scope and Content of Waiver

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Calculations done by:__________________________; Verified by:_____________________________

Data used to verify the foregoing specifications is current and accurate. Based upon the information contained in this document and all necessary calculations, this boiler of Locomotive (Initial & number)____________ is safe for a working pressure of _________psi.

__________________________ Date__________; __________________________ Date__________

Locomotive Owner Locomotive Operator

Make working sketch here or attach drawing of longitudinal and circumferential seams used in shell of boiler, indicating on which courses used and give calculated efficiency of weakest longitudinal seam.

Public reporting burden for this information collection is estimated to average 30 minutes per response. This estimate includes the time for completing the inspection, filling-out the form, and sending the form back to FRA. According to the Paperwork Reduction Act of 1995, no persons are required to respond to a collection of information unless it displays a valid OMB control number. The valid OMB control number for this information collection is 2130-0505.

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