Steam Boiler Regulations

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SOUTHERN FEDERATION Of

MODEL ENGINEERING SOCIETIES

20th November 2005

To all affiliated Clubs/Societies

REVISED BOILER TEST CODE AND NEW STYLE CERTIFICATES

As you are aware, the Southern Federation along with other similar organisations, i.e the Midlands Federation, the Northern Association and the 71/4 Gauge Society under the umbrella of the Miniature Railways Liaison Group, has for a number of years been reviewing the Boiler Test Code. This revision arose because of anomalies between the various Test Codes currently in existence and the need to bring our test procedures more in line with the requirements of the Pressure Systems Safety Regulations. While the Regulations do not normally apply to those operating pressure systems as a hobby activity it is considered good practice to provide the same level of precaution as if we were duty holders under the Regulations.

Originally the Health and Safety Executive (HSE) wanted us to operate a scheme similar to `full size' practice. whereby each boiler had its own Written Scheme of Examination and accompanying documentation. This we vigorously opposed, as being unworkable. Through negotiation with both the HSE and our Insurers we have arrived at a scheme which, although it creates slightly more paperwork than current practice, we hope. will be workable and understood by all involved.

It is a requirement that any club/society testing boilers in the 500 -1100 bar life category has to notify to the insurers the names of their inspectors who will be testing such boilers. See details in the December edition of Southern Federation News.

This scheme will come into operation from 1st January 2006. From that date old style Boiler Certificates may no longer be issued. However, boilers with remaining time on existing certificates may run their course under the old scheme and will only be required to be tested under the new scheme once their current certificate expires. Old style certificates may no longer have additional entries made to them after the commencement of the new scheme.

Owing to the ease with which the old style certificates can be forged or doubtful entries made therein, the new certificates are to be issued each time a test is undertaken and have been printed in a manner that will show if copied. The new certificates are uniquely numbered and therefore should be traceable.

At last we are able to supply you with a copy of the revised Test Code, samples of the documentation, and details of how the scheme will operate. We apologise for the delay In presenting this information; the printing of the booklet and other documentation was held up owing to the Northern Association not being able to verify its acceptance until late October.

1 The Examination and Testing of Miniature Steam Boilers (New Edition 2006) This is the new Test Code and will be issued by all of the organisations that administer the affairs of our hobby. It has been agreed and approved by Royal and Sun Alliance, the principle insurer for the hobby. In fact it is a requirement of Royal and Sun Alliance that we adhere to its content. It also has been approved by the HSE, who have issued the following statement:

"The HSE welcomes and supports the manner in which the various Clubs, Societies, Associations and Federations representing Miniature and Model Engineering have worked in their own time to produce this Test Code for the Examination and Testing of Miniature Steam Boilers. This Code should ensure that boilers are constructed, maintained and operated safely, and that when applicable, compliance is achieved with the relevant legislation. This is another good example of the HSE principles of working in partnership, and acknowledges that the people best placed to make an activity safe are the people who are most closely involved in it. This is an important step for the industry (sic) in ensuring the high safety standards they set are maintained and improved. The HSE commends this Code and is confident that it will assist the organisations involved to continue to Improve standards of safety.”

Some of you may already have obtained a version of this booklet, which was being distributed at a recent model engineering exhibition. Please note that those copies are incorrect and that alterations were made to the final document before being published in the present form.

It is recommended that everyone in the hobby who owns or uses a boiler should obtain a copy of this booklet.

2. Report of Examination and Certificate of Hydraulic Test. This form/certificate will be issued each time the boiler is examined/tested. Because of the requirement that a report is made of the condition of the boiler at each test the top part will have to be filled-in irrespective of whether the boiler passes or fails its hydraulic test. If the boiler fails either at examination or the hydraulic test, the lower, certificate-part of the form should be struck through thus,

The bar-litre capacity of the boiler will have to be shown on the certificate. Bar-litre is the total internal water volume (in litres) multiplied by the working pressure (in bars).

A boiler register/database is to be set up by the Federation similar to the existing scheme operated by the Northern Association. This will enable us to: 1) ascertain the number and sizes of boilers, with valid certification, in circulation, 2) aid the tracing of owners should their models be stolen and recovered, and 3) identify boilers/models and their historic records should they change hands without the necessary paperwork, thus enabling their continued use. The inspector is to complete the tear off slip (Block capitals) each time the boiler is hydraulically tested and forward it to the Southern Federation Boiler Registrar. If the boiler has failed the examination/test in such a way that it cannot be repaired please show the reason on the reverse of the slip. Details of where to send the slips will be issued with the certificates

These certificates are Issued as pads of 50 certificates/copies and are printed on NCR paper (no carbon required). Complete the form with a ball pen to enable the writing to transfer to the copy sheet. To prevent the writing being transferred through the whole pad, Insert a sheet of stiff card or flap the cover of the pad below the top two sheets (the Certificate and its copy). The certificate shall be handed to the owner, and the copy retained by the issuing club/society.

Full instructions for filling-in the forms are clearly printed inside the cover of each pad.

3. Certificate of Annual Examination and Steam Test. Each boiler will have to undergo an annual examination and steam test.

Details of what the examination entails are shown in the Test Code and the steam test is nothing more than we are customarily used to. Correct operation of the following items shall be verified: a) Boiler water feed arrangements - by at least two independent means (hand pump, injectors, mechanical pump - two Injectors count as two independent means of supplying water to a boiler). b) Pressure gauge - the gauge should be clearly marked to indicate the working pressure of the boiler, c) The water gauge(s) -which should be blown down and the water should be seen to recover to its level without delay.

These certificates are also Issued as pads of 50 certificates/copies, are printed on NCR paper and should be used in the same fashion as described above for the Hydraulic Test Certificates.

For both types of certificates, periods of validity count from the date of the test. Certificates are punched to enable storage in a ring binder.

The boiler may only be used if the owner Is in possession of both a valid Hydraulic Test Certificate and a valid Steam Test Certificate

4. Boiler Test Record. Used to record the various tests and over the ensuing years will form a historic record of the boiler. The very first entry on the record card should show details and date (If known) of the initial test the boiler was subjected to, thus establishing a record of the age of the boiler.

This Boiler Record is NOT proof that valid certificates exist and therefore MUST NOT BE ACCEPTED IN LIEU OF CERTIFICATES when their presentation is required.

The Boiler Test Record card, current and expired certificates, along with any certificates issued under the old scheme, should be retained, and must be passed-on to the new owner should the model/boiler change hands.