FALL 2012 VOLUME 67 David A. Douin CONTENTS NUMBER 3 Executive Director Richard L. Allison Assistant Executive Director – Administrative Test lab staff hosts Charles Withers Assistant Executive Director – Technical representatives from Weir Paul D. Brennan, APR 22 Power & Industrial who were Director of Public Affairs Wendy White on hand to witness their steam Publications Editor valve testing on August 1. Brandon Sofsky Manager of Publications

BOARD OF TRUSTEES Jack M. Given Jr. Chairman Joel T. Amato First Vice Chairman Gary L. Scribner Second Vice Chairman David A. Douin Secretary-Treasurer John Burpee Member at Large Christopher B. Cantrell Member at Large Donald J. Jenkins Member at Large Milton Washington Member at Large COVER STORY On the Cover: ADVISORY COMMITTEE Powered up and ready to go: the test lab’s new three-in-one “everyday workhorse” air George W. Galanes, P.E. 22 Testing... Testing... 1, 2, 3... Representing the welding industry Expansion Project Complete, It's Full testing system is a highlight of the 2012 Lawrence J. McManamon Jr. expansion project. Representing organized labor Speed Ahead at the National Board Kathy Moore Representing National Board stamp holders Test Lab Brian R. Morelock, P.E. Representing boiler and pressure vessel users Peter A. Molvie Representing boiler manufacturers Departments Michael J. Pischke FEATURES Representing pressure vessel manufacturers Robert V. Wielgoszinski 2 Executive Director’s Representing authorized inspection agencies (insurance companies) 3 2012 Registrations Message

The National Board of Boiler and Pressure 6 Inspector’s Insight Vessel Inspectors was organized for the pur- 4 Safety on Trial pose of promoting greater safety by securing 75-Ton Bottle Rocket Case Study concerted action and maintaining uniformity 20 Pressure Relief Report in the construction, installation, inspection, and repair of boilers and other pressure vessels and their appurtenances, thereby 8 Phased Array Ultrasonics 30 Updates & Transitions ensuring acceptance and interchangeability among jurisdictional authorities empowered Now Replacing Radiography to ensure adherence to code construction and 32 Profile in Safety repair of boilers and pressure vessels. for Small Bore Piping Welds The National Board BULLETIN is published three times a year by The National Board of 34 Training Matters Boiler and Pressure Vessel Inspectors, 1055 12 A Collection for the Gages Crupper Avenue, Columbus, Ohio 43229- 1183, 614.888.8320, nationalboard.org. 35 Training Courses Postage paid at Columbus, Ohio. 14 and Seminars Points of view, ideas, products, or services Testing... What's Not to featured in the National Board BULLETIN do Love? not constitute endorsement by the National 36 The Way We Were Board, which disclaims responsibility for A tough world needs tough tests authenticity or accuracy of information con- tained herein. Address all correspondence to the Public Affairs Department, The National nationalboard.org Board of Boiler and Pressure Vessel Inspec- 16 Boiler External Piping (BEP) tors, at the above address. Part 2 – Feedwater Piping © 2012 by The National Board of Boiler and Pressure Vessel Inspectors. All rights re- Please Recycle served. Printed in the USA. ISSN 0894-9611. This Magazine CPN 4004-5415. Remove Cover And Inserts Before Recycling DEPARTMENT Executive Director's Message

Performing Under Pressure The Validation of Valves by david A. Douin, EXECUTIVE DIRECTOR

In this issue, we are and tested, and that a company’s quality system has been pleased to bring our readers audited. More important, it means the certified equipment meets a story long overdue. I say internationally‑recognized standards. long overdue because many Recently, demand for National Board lab services has been in our profession don’t often such that it became necessary to expand the testing area by think of the Test Lab as being nearly 3,000 square feet. The addition of new test components a component of the National and upgrades to support equipment will accommodate increased Board. work volume and accelerate response to certification customers. Fact is, it is a very important While testing is the primary focus, the lab also actively component. supports industry research and development by testing new I subscribe to the notion designs. Additionally, it validates new concepts and serves as the safety valve and other a comparative standard for other laboratories. pressure relief devices are the most critical parts of all pressure- The lab has also been instrumental in assisting jurisdictions containing items. Without these devices, pressure equipment with accident investigations by providing important testing to becomes potential bombs. With these elements, operators today evaluate equipment failure. can be assured there is little guessing when operating controls The article on page 22 is the most comprehensive yet on the fail and pressures reach critical levels. Test Lab. Readers will not only gain insight regarding the testing Yet, curiously, these equipment devices are often overlooked. process, they will get a rare look at what takes place behind the When invented by Denis Papin in the late 1600s, the safety walls of this vital National Board facility. valve was revolutionary. Although materials and designs have When Papin created the first safety valve nearly four evolved over centuries, Papin’s basic concept has endured. The centuries ago, it was to protect him from the potential explosion fact pressure relief devices are today employed on just about of a digester he constructed. While his action addressed an every piece of pressure equipment underscores universal and immediate problem (i.e., his safety), little did he understand the critical importance. impact his new invention would have on the world. And that’s why the National Board Lab is integral to the The safety valve is the one component that often determines pressure equipment industry. Since 1974, it has tested thousands whether a pressurized device continues to perform the work upon thousands of pressure-relief devices, thus helping to ensure for which it was intended, or becomes an instrument of the quality of safety valve manufacture and repair. unharnessed energy. Each year hundreds of manufacturer representatives visit While the National Board Test Lab fully embraces its coveted the lab in Worthington, Ohio, to measure the performance of role as one of the world’s most vital testing facilities, its function their company's pressure-relieving equipment. can never be understated. Here, pressure relief devices are independently evaluated The work performed here touches the lives of anyone who for function and capacity. Devices meeting standards and comes into close proximity of pressure equipment. specifications of new construction allow the manufacturer to And that is all of us. Every day. apply the National Board NB capacity certification mark for new equipment. Testing is also conducted to assess a company’s skill and aptitude in repairing pressure relief valves. Qualifying organizations become accredited to stamp the National Board VR symbol on repair nameplates. Capacity certification by the National Board Test Lab denotes equipment designs have been independently reviewed

2 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org FEATURE BULLETIN

2012 Registrations

ational Board Certificate of Authorization to Register file by manufacturer name and National Board number. ensures a third-party inspection process, provid- The list below identifies boiler, pressure vessel, and ing for uniform acceptance of pressure-retaining nuclear vessel registrations by size for the past five fis- Nequipment by member jurisdictions. This important safety cal years. The National Board fiscal year is from July 1 to process is documented via submission of data reports by June 30. the manufacturer to the National Board. These are the only The total number of registrations on file with the reports carrying the National Board registration number. National Board at the end of the 2012 reporting period Once registered, each report is maintained in a permanent was 48,582,839.

SIZE FY 2012 FY 2011 FY 2010 FY 2009 FY 2008 BOILERS square feet of heating surface ≤ 55 (A) 163,189 154,964 156,129 161,041 156,766 > 55 and ≤ 200 (B) 28,591 28,823 30,884 32,371 39,115 > 200 and ≤ 2,000 (C) 8,281 8,362 8,032 9,084 10,680 > 2,000 and ≤ 5,000 (D) 607 557 420 720 689 > 5,000 (E) 475 572 650 766 1,021 TOTAL 201,143 193,278 196,115 203,982 208,271 PRESSURE VESSELS in square feet < 10 (A) 927,192 788,752 680,873 774,899 819,791 > 10 and ≤ 36 (B) 207,621 202,902 183,449 214,107 338,811 > 36 and ≤ 60 (C) 44,401 40,017 35,798 43,648 59,371 > 60 and ≤ 100 (D) 16,162 12,924 11,039 14,714 14,983 > 100 (E) 21,189 16,784 13,783 18,509 18,239 TOTAL 1,216,565 1,061,379 924,942 1,065,877 1,251,195 NUCLEAR VESSELS in square feet ≤ 10 (A) 443 482 481 494 700 > 10 and ≤ 36 (B) 79 51 30 38 98 > 36 and ≤ 60 (C) 9 14 7 13 19 > 60 and ≤ 100 (D) 6 18 5 5 27 > 100 (E) 169 94 14 9 19 TOTAL 706 659 537 559 863

ATTACHMENTS* 103,175 92,158 90,117 86,961 103,336 GRAND TOTAL 1,521,589 1,347,474 1,211,711 1,357,379 1,563,665

*An attachment is any type of additional information to be submitted with the primary data report.

For more information on the Authorization to Register Program, access the National Board website at

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 3 BULLETIN FEATURE

Safety on Trial 75‑Ton Bottle Rocket Case Study

By Rick Smith, P.E.

n autoclave is a device in which objects are heated other. The steam inlet was on top of the door end, and the valved predominantly by steam, but sometimes electrically, exhaust vent on the closed end. The door was hinged on the right for sterilization, cooking, or curing, among other as one enters the clave, and was supported by large davits not uses.A Large autoclaves are used in many industries, including unlike those seen on large firetube boilers commonly in service. aerospace, medicine, food and beverage, and concrete block The main hinge was about 3” in diameter. The door‑locking manufacturing. Inspectors frequently encounter autoclaves mechanism consisted of a square metal bar bent into a circular of all shapes and sizes during routine inspections. From the shape. A steam valve and cylinder on the locking mechanism local tattoo parlor, dentistry office, or manufacturing plant, expanded the metal bar into matching grooves in the door and to a hospital or veterinary clinic, autoclaves are utilized every the “jamb” located on the autoclave body. day in society. Because of the powerful pressures at which autoclaves operate – typically 35 pounds force per square inch gage (PSIG) to 150 PSIG – they must be carefully inspected and maintained for obvious safety reasons. The following account is a case study of a large autoclave that malfunctioned and caused substantial property damage in a Southern city in early May of 1988. The unit, approximately 11 feet in diameter, 97 feet long, and enclosing a volume of about 9,200 cubic feet, was used for curing concrete blocks. Concrete blocks can be air-cured or cured in a steam autoclave, which greatly shortens the curing time and reportedly improves the mechanical properties of the blocks.

Cause and Effect Damage as seen from railroad tracks.

The incident occurred during the late evening/early To load the autoclave, fork trucks would drive over the morning hours. The locking mechanism of the autoclave’s threshold and move the pallets of uncured blocks into the main loading door failed while the unit was pressurized with unit. The most probable cause of this explosion was that the 125 PSIG steam. The autoclave instantly became a 75‑ton bottle operator/loader did not completely clean debris from the rocket and launched itself out of the building, destroying it. It bottom of the locking groove in the autoclave body. This traveled approximately 100 feet down an embankment and prevented the locking ring from completely engaging, and the landed straddling some railroad tracks. Fortunately, this incident pressure (125 PSIG) / force (1.7 MM lbs.) acting on the door happened during non-working hours and no one was injured distorted the ring enough so that it yielded. The force of the or killed. Neighbors reported the explosion sounded like a door blowing off sheared the hinge pin at the top and bottom. bomb going off and that their houses shook. Damage included The energy content of the steam in the autoclave was about one destroyed autoclave and the building it was housed in, 3.4 MMBtu, equivalent to nearly 2,000 pounds of dynamite. collateral damage to adjoining equipment, and minor damage The owner filed an insurance claim for the property damage to the railroad tracks. One can only imagine if a tanker filled and resultant production and revenue losses. The insurance with anhydrous ammonia, nitrile, or liquefied natural gas was carrier denied the claim based upon an explosion clause in the sitting on the tracks at time of impact. policy. Interestingly, this case revolved more around the definition The autoclave looked like a large steel test tube with the of the word “explosion” than what actually caused the explosion. loading door on one end and a semi-hemispherical head on the My involvement in the case consisted of trying to determine the

4 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org cause of failure and to determine if this was an explosion. Since litigation occurred before Internet use was widespread, I spent several hours at the Columbus Metropolitan Library researching all the dictionaries I could find on the definition of explosion. Even though it has been over 20 years, this definition is burned into my memory: Explosion – the sudden, violent release of energy whether chemical, electrical, mechanical, or nuclear. In my mind, this event was clearly an explosion. The explosion is what caused all of the damage. But what caused the explosion – most likely debris left on the bottom of the locking groove due to Damage as seen from the side street. operator carelessness – was another issue entirely. However, the cause of the explosion was not adjudicated in this case because Additionally, the safety valve inlet should not be occluded the parties settled before it went to trial. by pallets or product during operation. Large autoclaves also have a somewhat unique operational Importance of Inspection issue that can have a huge negative effect on boilers. When a large autoclave is filled with cool or cold product and closed Regular inspection and maintenance of pressure equipment up, the operator typically does not alert the boiler house that a is the first line of defense for preventing this type of incident from huge load swing is coming. The operator will typically open a happening and for ensuring a safe work environment. This case 2” or 3” high pressure steam valve as quickly as possible – in study is a sobering reminder of the devastating consequences some cases this is a quarter turn ball or butterfly valve. The of unchecked pressure equipment and careless operation and resulting instantaneous load spike can easily shut the boiler(s) maintenance. It is extremely fortunate this was a property damage down on low water, as well as cause serious water hammer due incident only and that people were not hurt or killed. Had there to carryover and priming. been a railroad tanker full of hazardous, toxic, or flammable materials when the autoclave launched on its horizontal trajectory, There are four ways to prevent this type of boiler upset: this incident could have caused mass casualties. 1. Train and supervise the autoclave operators to open the main steam valve slowly. This may be very difficult in When inspecting large pressure vessels, such as the autoclave actual practice. involved in this case, inspectors will typically: 2. Put slow-opening valves on the steam inlet to the autoclave. closely examine the vessel and safety valve(s). 3. Make sure the boiler level controls are VERY well-tuned, inspect the closing, locking, and hinge mechanisms for wear particularly on the feed forward signal from the steam flow and corrosion. meter. carefully check any locking grooves, cutouts, or similar fea- 4. Use a differential pressure or flow control valve on the tures for debris build‑up or unusual wear patterns. boiler header to limit the instantaneous steam flow.

It is imperative that operators and management be informed Rick Smith has been working with boilers for 35 years. He is about the importance of: president of Applied Thermal Engineering, Inc., a central Ohio firm keeping locking grooves clean. specializing in industrial utilities and forensic engineering. He has been properly cleaning, lubricating, and maintaining locking an expert witness in numerous boiler explosion and carbon monoxide mechanisms. cases and has taught hundreds of boiler and HVAC classes. He can be frequently checking the lock integrity. reached through his website at www.ate-inc.com.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 5 DEPARTMENT INSPECTOR’S INSIGHT

It's Just a Fillet Weld by Robert Schueler, Senior Staff Engineer

illet welds are very basic to most industries, but especially to the Example 1: world of pressure-containing items. FEvery code we follow has rules defining fillet Typical sample of a code-required fillet weld sizing calculation. welds. They are to be found on every welded (See Section I, Fig. PW-16.1 (d), Section IV, Fig. HW-731(d), and nozzle, slip-on flange, socket welded fitting, Section VIII, Div. 1, Fig. UW-16.1(l) ). and lap joint.

Why do we use fillet welds? tn

The ASME Boiler and Pressure Vessel Code (ASME t = vessel shell B&PVC) places considerable importance on fillet tn = nozzle wall welds. They are not something to cover gaps or hide a t and t = fillet t1 1 2 groove weld. Fillet welds serve a number of important weld throat purposes, which when done correctly, greatly improve t dimensions construction. In ASME Section I, PW-15.1.2, for example, the t2 fillet weld strength is based on one-half the area subject to shear forces, computed on the average diameter of the weld. In addition, PW-15.2 provides a value of 49% for a fillet weld in shear to be used in establishing the allowable stress value for the weld metal. t1+ t2 ≥ 1¼ tmin. Even small seal welds used on rolled tubes provide considerable added strength. The size and shape of fillet welds used to attach nozzles provides t1 and t2 shall each be not less than

the additional benefit of controlling local stress the smaller of ¼ in. (6 mm) or 0.7 tmin. intensification within the nozzle.

For the most part, fillet welds are 45° right tmin. = minimum (t, tn, 0.75) triangular-shaped welds defined by two legs measured from the weld root or intersection point. The ASME B&PV codes calculate the weld throat, Let: t = 0.5 in. (13 mm) and tn = 0.375 in. (10 mm) which is then used to calculate the weld leg, as shown tmin = minimum( t, tn, 0.75) = minimum( 0.5, 0.375, 0.75) = 0.375 in. in Example 1. . 0.7 tmin = 0.7 0.375 = 0.2625 in.

t2 = minimum(0.25, 0.7tmin) = 0.25 in. . . t1 = maximum( (1.25 tmin) – t2), 0.25) = maximum((1.25 0.375) – 0.25), 0.25) = 0.25 in.

6 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Example 2: Right Triangle Once the weld size is determined, the required information is (typical fillet weld shape) then transmitted to the welder, who is expected to produce the weld of the proper size. This brings us to the main question at A hand. How do we know this is done correctly? The simple answer is to measure the weld, but how?

c 45° Example 4: Typical Weld Gage b 45° 90° B C Weld Throat a

A b Weld Leg C c a B Photo courtesy of G.A.L. Gage Company

2 2 2 2 Example 4 shows one type of weld gage that measures c = a2 + b2 a = c - b b = c - a fillet weld legs and weld convexity. The following illustrations Let a = b =1.0 Then c = 2 = 1.4142 demonstrate how simple it is to use a weld gage like the one shown in Example 4. The first and second illustrations measure fillet Weld Leg = Weld Throat . 1.4142 weld legs. The third illustration measures the throat dimension Weld Throat = Weld Leg / 1.4142 of the weld.

In Example 2, both t1 and t2 have solved a 0.25 in. (13 mm) minimum throat dimension. Measurement of Measurement of Measurement of

Solving the minimum weld leg for either t1 or t2 will solve Vertical Fillet Weld Horizontal Fillet Weld Fillet Weld 0.25 • 1.4142 = 0.354 in. or round up to 3/8 in. (10 mm) leg. The Leg Dimension Leg Dimension Throat Dimension weld size information is normally transmitted to the welder in the form of a welding symbol shown in Example 3, which in this case would look like the following:

Example 3: 3/8 Leg t and t shall each be not less than 1 2 Measured Dimensions the smaller of ¼ in. (6 mm) or 0.7 tmin. 3/8 Leg Why take the time to measure the welds?

Isn’t it just good enough to look at the weld? A practiced eye is a good thing; however, should a weld prove to be 3/8 Leg undersized, this would result in considerable added costs for additional welding and possibly additional postweld heat Cross-section through nozzle, treatment. In the case of fillet welds, larger is not better. The shell, and welds showing fillet 3/8 Leg addition of extra weld metal is both expensive and could weld legs. lead to the introduction of defects. Either condition should justify having and using fillet weld gages on a regular basis. They are quick and easy to As normally shown on a detailed drawing in the use and can eliminate problems. form of an AWS standard welding symbol.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 7 BULLETIN FEATURE

Phased Array Ultrasonics Now Replacing Radiography for Small Bore Piping Welds By Mark Carte and Michael Moles, Olympus NDT

hased array ultrasonics is to 10 MHz. A phased array system a serious competitor to radiography steadily replacing radiography will also include a sophisticated testing (RT) for welds. for construction weld computer-based instrument that is Radiography testing has been the inspections,P in particular, using encoded capable of driving the multi-element standard for weld inspections for the scanning. An encoder is a device that probe, receiving and digitizing the last several decades; however, it has coordinates distance with recorded returning echoes, and plotting that known limitations. Specifically, RT digital data for storage in a computer, echo information in various standard has major safety issues from radiation, unlike conventional ultrasonics. formats. In general, performing a PA licensing issues from the same problem, Encoding permits auditable, repeatable inspection is fairly straightforward. work disruptions, environmental and scanning with additional sizing Equipment and training are available, chemical wastes, large volumes of film, capabilities. The encoder has a resolution so the major emphasis is on correct and film deterioration. Defect analysis of 32 steps/mm, which is plenty for setups and interpreting the results. can be subjective and quite slow. In inspection of welds. Portable phased The ASME Boiler and Pressure addition, RT is unable to reliably size arrays offer significant advantages Vessel Code Section V, Article 4, has defects in the vertical plane for structural over radiography for detection, sizing, published rules for performing integrity, and is poor at detecting planar imaging, and characterization of phased array ultrasonic inspections of defects. In contrast, there are no safety defects in welds. Unlike conventional welds. Besides being safer and more or licensing issues, film deterioration, or ultrasonics, phased arrays (PA) use repeatable, PA systems are faster for storage issues with PA. Phased arrays can electronically-controlled time delays to high-volume weld inspections. These size defects in the vertical plane, within sweep, steer, and focus beams. Arrays inspection devices can be used for known errors. The inspection speed are similar to conventional transducers, a number of different applications is generally a lot higher when using but are sliced into small elements for where small bore piping placed in encoded linear scanning. Probability phasing. It is easy to change either arrays close proximity creates an inspection of detection (POD) is improved using or the contoured wedges. challenge. In many cases, defects can multiple angles and imaging, and results Phased array probes typically be clearly identified and characterized, are fully auditable when encoded. (1, 2) consist of a transducer assembly with and locations mapped. This article Time-of-flight diffraction (TOFD) is anywhere from 16 to as many as 256 will describe some results obtained the other common automated ultrasonic small individual elements that can during testing. testing (AUT) technology and has been each be pulsed separately. These may covered by ASME (3) since 2004. TOFD be arranged in a strip (linear array), a Advantages of PA over uses two transducers in a pitch-catch ring (annular array), a circular matrix Traditional Ultrasonic arrangement and measures arrival (circular array), or a more complex Techniques times and defect sizes to high accuracy. shape. As is the case with conventional However, the main problem with transducers, phased array probes may Phased arrays offer significant scanning small-diameter pipes occurs be designed for direct contact use, advantages in speed, imaging, when wall thicknesses are less than as part of an angle beam assembly data auditing, and flexibility over ~10 mm (3/8”). When this happens, with a wedge, or for immersion use traditional ultrasonic techniques. TOFD becomes less useful as the dead with sound coupling through a water Not surprisingly, encoded phased zones at the outside diameter (OD) and path. Transducer frequencies are most arrays, either mechanically or semi- inside diameter (ID) dominate the wall commonly in the range from 2 MHz mechanically driven, have become thickness.

8 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Industry Awareness

Most design engineers, procurement personnel, and outage planners have not recognized that compared to RT, PA has the ability to reduce overall cost in manufacturing facilities and at plant sites. Those who are using PA technology have recorded significant cost savings in all facets of construction, but even more so in reduction of downtime during outages of boilers, furnaces, and other projects involving small bore piping in close proximity to other pipes and obstructions. Inspection service providers have reported that more than 120 welds of 3” pipe butt welds can be scanned in one eight‑hour shift. Scanning can occur very soon after welding when the metal is sufficiently cool. Additionally, testing of small bore pipe welds using ultrasonic testing instruments and manually driven, semi-automated scanners do not require A/C power. This adds a tremendous complement to safety.

Codes

One major issue facing automatic Figure 1: Small, hand-held scanner in action. ultrasonic testing (AUT) is code acceptance, but that improved three AUT Mandatory Appendices vessel codes can call for ultrasonics and significantly in July 2010, when ASME effectively replace Code Case 2235(7). use these set-up rules, e.g., ASME B31.1 published three Mandatory Appendices The two Mandatory Appendices and B31.3. on AUT (4) and two on phased arrays (5). on phased arrays cover both manual The three Mandatory Appendices on and encoded scanning. The Mandatory Equipment AUT should allow operators to inspect Appendix for encoded scanning welded components using AUT with requires fully automated or semi- Industry demand for off-the- more clearly defined inspection criteria. automated scans, with appropriate shelf equipment to provide complete In addition, ASME recently published data recording, displays, reporting, application solutions for small-diameter a Code Case on calibration for pipes (6), and scanning conditions. Section V, pipes has driven manufacturers to which permits much greater flexibility Article 4, can be called upon by any design and produce small scanners (see in pipe diameter (0.9 to 1.5 times the number of ASME referencing codes, Figures 1 and 2). These scanners are nominal) and in wall thickness (+ 25%), which includes Sections I, VIII, and semi-automated (encoded and hand- in keeping with other global codes. The XII. In addition, other non-pressure pushed around the weld).

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 9 BULLETIN FEATURE

Hand-propelling saves costs, is technically easier, and provides ultra- low-profile design, which makes scanning between tubes convenient. The scanner itself can be adapted to a range of sizes matched to the pipe diameter. As it is spring-loaded, it can inspect both carbon steel and non-magnetic materials (e.g., stainless steels). Field experience has shown that the scanner provides good coupling for 360o around the pipe, which is essential. These low-profile scanners can inspect pipe diameters from 21 mm (0.84”) OD to 115 mm (4.5”) OD. Clearance, including the low-profile array, is only 12 mm, which permits it to inspect most small-diameter welds in most configurations. It is waterproof, rust-free, and CE compliant. Scanners Figure 2: Two-sided scan being performed on small-diameter vertical pipe. can be configured to inspect both sides of unobstructed circumferential welds. For welds with one-sided access (See Figure 2.) only (flanges or pipes-to-component), the scanner can be re-configured for single access. (See Figure 3.)

Weld Quality Review “On the Fly”

In an effort to streamline weld inspection, the latest portable ultrasonic instruments are capable of viewing images of a weld using S-scans (side or swept angle scans) and C-scan (plan) views simultaneously. Such features allow inspectors to determine go/no-go very quickly; therefore, production of welds is not impacted due to inspection. In many cases, anomalies produced due to welding procedures are identified

Figure 3: Phased array probes and scanner positioned to scan a weld with single-sided access.

10 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org and corrected very early, which helps reduce the quantity of repairs and lost production. Another major advantage of using PA is that there is no disruption to the production schedule. PA is “safe,” so no clearing or local shutdowns are required to minimize safety issues. Multigroup scanning (scanning up to eight channels of data at the same time), is yet another time-saving feature of PA. Multigroup effects are where two separate images are shown, one from each side of the weld. These images consist of two A-scans (waveforms), S-scans, and C-scans. The A-scans show the time-corrected gain (TCG) and angle-corrected gain Data display with S-scan and C-scan (side and plain views). (ACG) data, such that all points above the recording threshold at any scanning structural integrity. The traditional References angle show the same color/palette. method of amplitude drop-off gives 1. Olympus NDT, “Introduction to Phased Array Technology Applications,” by R/D Tech, 2004. This is very convenient for analyzing a reasonable estimate of defect depth. 2. Olympus NDT, “Phased Array Testing: Basic Theory results quickly. Devices such as Zooming the image and recording for Industrial Applications,” November 2010. Olympus' NDT portable PA instrument the depth will give better defect sizing 3. ASME Section V, Article 4, Mandatory Appendix III, “Time-of-Flight Diffraction (TOFD) Technique,” OmniScan have linked cursors, so any and more precise defect location. Both 2004. item selected by a cursor in one image can be recorded in the defect tables. 4. ASME Boiler & Pressure Vessel Code, Section V, Article will link to other images automatically. Sizing defects can also be based on 4, Mandatory Appendices VI-VIII. diffraction rather than amplitude. 5. ASME Boiler & Pressure Vessel Code, Section V, Article 4, Mandatory Appendices IV-V. Measuring Defect Length 6. ASME Code Case 2638, “Alternative Piping Conclusions Calibration Blocks: Section V,” January 20, 2010. Measuring weld defect length is 7. ASME Code Case 2235-9, “Use of Ultrasonic Examination in Lieu of Radiography.” Section I; generally straightforward, as signal Instruments, software, and Section VIII, Divisions 1 and 2; and Section XII”, amplitude drops of 50% are usually scanners are available off-the-shelf October 11, 2005. selected. This follows the basic concept for performing standard PA weld Additional References that defects are generally smooth and inspections on small-diameter pipes. 1. ASME Section V, Article 4, NonMandatory flat, although this is not always the case. Phased arrays can be performed Appendices N and O, “Time of Flight Diffraction (TOFD) Interpretation” and “Time-of-Flight manually or by using automated Diffraction (TOFD) Technique: General Examination Measuring Defect Depth scanners. Codes are published Configurations.” and available for PA and TOFD if 2. F. Jacques, F. Moreau and E. Ginzel, “Ultrasonic Measuring weld defect depth required. Interpreting the results can Backscatter Sizing Using Phased Array – Developments in Tip Diffraction Flaw Sizing,” on thin-walled pipes is not always be challenging, but there is potential Insight, Vol. 45, No. 11, November 2003, p. 724. required by code. This type of for better defect detection and accurate 3. J. Mark Davis and M. Moles, “Resolving Capabilities inspection is usually more challenging, sizing because of this new technology of Phased Array Sectorial Scans (S-Scans) on Diffracted Tip Signals,” Insight, Vol. 48, No. 4, but also more critical for ensuring for weld inspection. April 2006, p. 1.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 11 BULLETIN FEATURE A Collection for the Gages Step into Villa Nova Italian restaurant in Columbus, Ohio, and your senses come alive – from the savory aroma of pizza and pasta wafting from the kitchen, to the lively banter

of loyal patrons gathered around tables. But The collection belongs to the patriarch of there are a few more reasons – around 300 of the family-owned restaurant, Frank Colleli, who is by far the most unique attraction in them – why Villa Nova appeals to the senses. the establishment. If you ask him about his gages, he will likely take you by the sleeve and rilliantly displayed across the back walls of the restaurant is lead you into the hallway outside the kitchen an eclectic collection of antique gages. where gages line the walls. He’ll tell you a The polished, stately instruments, many 100 years old or little something about each gage while busy older, offer patrons a rare visual treat, but are also reminders wait staff maneuver around him balancing of past technology – before the digital age – when shiny faces trays of spaghetti and lasagna. of gages once warned engineers and technicians if pressure was reaching dangerous levels. Gauging the Past

Frank was a boy when he encountered his first steam gage. His father was a locomotive B engineer and he recalls climbing up into the locomotive cab and watching his father work – and check the gages. As a young merchant marine, Frank was stationed in New Orleans. When he wasn’t on the ship, he worked at an antique shop on Bourbon Street. There he learned how to clean old and tarnished relics – a skill he has since mastered, as evidenced by his burnished collection. He later obtained a stationary engineer and boiler operator’s license. “Everything was run on gages. I was always looking at gages; had to check them every day,” he remembers. PHOTOS BY GREG SAILOR “They don’t make them like this anymore.”

12 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org He also restores each copper kettle. Once a customer asked Frank if he “dipped” his kettles to get them shining. His swift reply: “You don’t know the half of it! “See that kettle over there,” he says, pointing to a giant, cauldron-like kettle, “it took me three days to clean that cockroach!” The kettle was completely black and tarnished when he got it. Today, it is shiny copper, in like-new condition. A sign next to it says, “The world’s largest copper tea kettle.” “None of my gages or kettles will tarnish,” he explains. After going through several steps to restore the items to the best condition possible (often involving steel wool, acid, and a sander), Frank adds 2-3 How it All Began “They don’t make them coats of polyurethane. like this anymore.” The result? Preservation of 19th and “When Frank does something, he – Frank Colleli early 20th century safety instruments rarely does it 200%,” says Donna, Frank’s wife seen on equipment today. of 30 years. “It drives me crazy, but I do enjoy it.” And that’s a good thing, because air-water, pressure, altitude, locomotive, Happy Endings – it was Donna who unwittingly started tank pressure, and compound gages. and Beginnings Frank’s collecting. Some come from Great Britain and Japan. “I ordered a few antique copper tea In 1986 the Collelis sold Villa Nova and kettles on Ebay then told Frank I’d like to Handiwork moved to Florida for retirement. Twelve have a few more,” she says. Those “few years later, in 1998, they were wooed back more” accumulated to over 350 copper Ninety percent of Frank’s gages are to central Ohio by their son, John (who tea kettles and 300 gages. The couple’s in working condition – many due to his now runs the restaurant), to repossess the tea kettle collection is also on display in meticulous cleaning and repair work. “I business. And that’s just what Frank and the restaurant and includes the world’s strip apart every gage; each and every Donna did. smallest tea kettle, which was made from screw. I take it all apart. Then I polish up “Frank’s not good at retirement,” a single penny and featured on PBS’ all the pieces and put them back together.” Donna explains. Her husband, surrounded popular Antiques Roadshow in 2009. They On average it takes Frank two by customers who make it a point to greet also have an extensive collection of license hours to thoroughly clean a single gage. him as they come and go, grins and nods plates. “If Frank had not discovered Ebay, If one has a hand missing, no problem: at his wife’s surmise. we wouldn’t have half of this collection,” Frank cuts a fitting from metal Venetian It’s not too surprising. When asked his Donna says. blinds and affixes it to the instrument. philosophy on life, the 83-year-old quickly The first gages Frank bought were He has six workshops at home where he replies, “Keep going. Keep moving. Never two 14” steam gages the seller claimed painstakingly restores rusted, dull gages sit in the cabbage.” came from a paddle boat. They were into bright pieces of art. placed over the entrance to the kitchen, “I like to take things that are screwy where they remain, and his collection has and make them nice,” Frank says, Frank’s gage collection is the featured grown from there. All types of gages are glancing around at his treasures. “I look backdrop of Executive Director David on display: steam, water temperature, for old and different gages.” Douin’s picture in the Executive Message.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 13 BULLETIN FEATURE

Testing... What's Not to Love? A tough world needs tough tests By James R. Chiles

testing is to ensure daily use will be hen writing my book Inviting boringly serene. Passengers and other Disaster, I devoted an entire customers don’t want the kind of scenes Wchapter to the subject, ironically titled, Reader’s Digest calls “Drama in Real Life.” “Doubtless: Testing is Such a Bother.” There you’ll find a rogue’s gallery of Testing… What’s Not to Love? insufficiently tested products such as the US Navy’s Mark 14 torpedo and its I understand if readers of the Mark 6 magnetic exploder, a weapon BULLETIN regard this issue’s theme that went off to the WWII Pacific theater as so much preaching to the preachers. with three major design defects that took Certification testing on ASME code almost two years to fix before submarine pressure products is not just a good commanders could rely on it for war idea, it’s a requirement, says Tom Beirne, patrols. I also profiled Boeing’s 767, which National Board senior staff engineer. “If went into service with a hazardous glitch you are putting a stamp on a valve, you in its thrust-reverser interlocks. (Thrust Illinois.) Heavy trucks operated by Army must have it tested. And every six years reversers are the scoops that swing out recruits were driven around five loops of the certification needs renewal.” But a from jet engines after a jet has touched pavement and bridges, plus a sixth loop great many valves and tanks are outside down and needs to slow on the runway.) as a control. Operations went on night the domain of government-backed safety The Federal Aviation Administration and day, employing more than a hundred codes (see “Non-ASME Pressure Vessels permitted Boeing to do abbreviated testing trucks. Some bridges failed early, but other at Risk,” in the winter 2011 BULLETIN, on on the risks of reverser deployment in types held up so well that the organizers the risks of concrete trucks’ pressurized flight, so the real danger wasn’t detected had to run super-heavy loads across the water tanks). until the accidental deployment of the spans to hasten their destruction as the Further, even this long-regulated reversers on an airliner over Thailand in two-year test drew to a close. In just 14 field doesn’t sit still. Are you watching 1991. That crash killed everyone on board. lane miles, the arrangement offered more out for risks emerging from the rapid pace And failure-to-test scandals continue than 800 combinations of pavement and of change? Brandan Ashbrook, National apace, from cars to drugs to computers. foundations. Board lab manager, points out that some But there are plenty of testing hall-of- As chief of the Navy’s electrical long-time valve manufacturers are feeling famers who show that even the toughest section, Captain Hyman Rickover would competitive pressure to expand their problems will give way to rigorous testing. bang electrical gear against a radiator, or product line to cover a much broader Every road trip you take benefits from an even throw it out a window, to remind range of machinery and processing experimental blitz that began in 1958, which visiting factory reps that everything environments. Informational testing still stands as the most comprehensive aboard a submarine had to be designed prior to the certification process can help highway test ever undertaken. The US for extreme shocks from depth charges. A indicate when a company needs to build Army Corps of Engineers worked with the test pilot with Douglas Aircraft checked up some specialized expertise first. American Association of State Highway the toughness of its DC-8 airliner in 1961 Some manufacturers and assemblers Officials to try out a huge variety of by putting it into a supersonic dive over also request informational tests from highway bridges in Illinois, in preparation Edwards Air Force Base. the National Board laboratory when for building the nation’s interstate highway Dramatic stuff. While testing pondering a change in key component system. (Remnants of the road test can generates its share of exciting anecdotes, suppliers, to verify there won’t also be be seen today, just off I-80 near Ottawa, “lab rats” know the real point of tough a change in a valve’s relief rating during

14 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org its six-year certification period. “As an Techno-Commandments check whether all critical components example,” explains Beirne, “a manufacturer shut down, switched over, and started per might have purchasing people who can get I was touring a naval museum specifications. (Such as: did ventilation a better price on springs. The spring is an in Buffalo, New York, recently and a louvers to gensets in the penthouse open as important part of a valve. Say the new placard reminded me that the Navy they were supposed to? If not, the engines source is from overseas. It isn’t the 40-year has long taught its submariners the Ten will overheat.) Often such a test identifies supplier the manufacturer is used to. If Commandments of Damage Control, such some fixes for the punch list. As hundreds the metal is different, perhaps in how it as Know Your Way Around, Even in the Dark, of building owners discovered during was heat treated, there will be a different and Keep Cool: Don’t Give Up the Ship! the 2003 Northeast Blackout, having an spring rate.” Seasoned safety professionals, emergency generator and UPS battery What’s in the future? Perhaps new forensic experts, and product testers bank on site is not the same as having types of tests for makers of industrial could no doubt chisel out their own them work. valves not currently covered by ASME tablets of techno-commandments related One final word about complex systems codes (for example, choke valves at a to testing. How about this one: Thou Shalt tested in place. Even the enthusiastically refinery, which are now under American Not Ignore the Annoying Anomaly. One of pro-testing person can think of examples Petroleum Institute guidelines), who want multiple root causes behind the Deepwater where a test went seriously wrong due to to verify that their models won’t fail due Horizon blowout and explosion was a flawed planning or somebody’s failure to damage in long service, such as from botched well test as an inexperienced to complete a checklist. In particular, stress-corrosion cracking. Many products Transocean drilling crew finished work on take extra care when testing single-point- that looked peachy under lab conditions a cement plug at the Macondo well, before failure machines in the field. Watch out later failed due to chemicals common delatching the rig. While the drilling crew for what seasoned testers call the second- to today’s environment, such as engine- knew that a “negative pressure test” after order consequence – the unanticipated compartment fuel lines that leaked due cementing hadn’t returned the expected side-effect. Compared to quality tests to ozone damage and caused deadly fires. results, they found other tests reassuring. at the factory, where equipment is new One of the biggest class-action lawsuits in Not knowing the inherent danger of and tested in isolation, inservice tests can history arose out of leaky plastic pipes and the situation or how several on-the-fly spring second-order surprises any time fittings. That cracking was due to oxidation procedures had increased the danger of from setup all the way through to restoring caused by chlorine – a common sanitizing a blowout, they set aside the anomaly all normal connections. agent in domestic water supplies. Another as unimportant. Yielding to BP’s subtle While earthly geographic frontiers element metallurgists know to watch pressure to finish the abandonment job don’t last for long, complex machines out for is hydrogen, which turns some sooner rather than later, they didn’t pause get more complicated and spring new grades of steel brittle over time. Without to check with seasoned experts – some of surprises. Good testing helps map safe special care and advance testing, hydrogen whom were coincidentally aboard the rig routes through the machine frontier. embrittlement could be an obstacle to in a group of Transocean VIPs, present It’s not just good citizenship; it’s good widespread use of hydrogen in vehicles. to hand out safety awards, of all things. business. Another assault on valves can come Here’s another for the stone tablet: from vibrations, such as resonant chatter. Thou Shalt Not Regard a Half-Test as a James R. Chiles, author of Inviting Energy may be transmitted into the Full Test. This refers to a very common Disaster and The God Machine has been valve via the steel of long piping runs, sin of omission. One example of the full writing about technology and history for or as pressure waves traveling down a test comes from the field of new, high- over 30 years. He has appeared multiple pipe’s liquid contents. Ashbrook says that tech buildings: an exhaustive, day-long times on the History Channel and has written chemical processing plants have reported procedure called the Whole-Building for Smithsonian, Air & Space, Popular occasional catastrophic failures of large Shutdown. With many witnesses in place Science, The Boston Globe, Aviation control valves. At its worst, a spindle with and data recorders running, the tester Weekly, Mechanical Engineering, and its hand-wheel can entirely blast off of a throws a switch that cuts the building off Invention & Technology. He maintains a valve body, spewing flammable vapors from the grid, simulating an area power blog called Disaster-Wise and can be reached into the middle of a refinery complex. failure. Observers at strategic locations at [email protected].

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 15 BULLETIN FEATURE

Boiler External Piping (BEP) Part 2 – Feedwater Piping

By Steve Kalmbach

his is the second in a three-part series on steam, feedwater, and blowoff piping. Previous articles in this series on Tboiler external piping (BEP) appeared in the winter (introduction) and summer (part 1, steam piping) 2012 issues. Feedwater piping for steam boilers is composed of this design pressure is based on the MAWP and not the various different configurations to meet boiler plant re- pressure‑relieving device setting or operating pressure. quirements. There are differences between a single-boiler There are additional design rules that apply to all types installation with a simple on and off feedwater pump ar- of boiler feedwater piping. The code requires the installa- rangement and complex feedwater systems for multiple tion of a stop valve located at the boiler feedwater connec- boilers with feedwater economizers. Each of these differ- tion. Piping from the stop valve to the boiler feedwater ing systems has distinct ASME Power Piping B31.1 termina- connection shall be the same size as the boiler feedwater tion points for ASME Boiler and Pressure Vessel Code, Section connection. From this stop valve to the BEP termination I, code-required piping limits. This article will look at the point, piping may be reduced to the size required to supply various requirements for feedwater systems. the boiler with feedwater. Unlike the well-defined ASME Section I and ASME Feedwater piping not part of BEP is classified as non- B31.1 requirements for steam and blowoff piping, the ter- boiler external piping (NBEP). The ASME Section I code mination points for feedwater piping are determined by requires this piping be able to supply the required amount the arrangements used for supplying feedwater to the of feedwater to the boiler when the highest set pressure- boiler. These rules are found in ASME Section I, Figure PG- relieving device, plus 3%, is operating. Unlike the pressure 58.3.1(a), paragraphs PG-59.3.3 through PG-58.3.5; PG-61; requirements for BEP, this rule may allow the use of pipe and ASME B31.1, Figure 100.1.2(B), paragraphs 122.1.3 and fittings of a different class than the BEP design requirement 122.1.7(B.1). The following basic rules will apply for all if the pressure-relieving devices installed are less than the feedwater systems discussed in this article. MAWP of the boiler. The ASME B31.1 code specifically states the required Design Requirements stop valve shall be the first valve off the boiler with the check valve located upstream. The only exception to this Design requirements for all feedwater piping classi- rule is in ASME B31.1, paragraph 122.1.7 (B2), for feedwa- fied as BEP are as follows: ter piping used on a single boiler turbine unit system where • Design pressure: the maximum allowable work- the check valve may be the first valve off of the boiler with ing pressure (MAWP) plus 25% or MAWP plus 225 the stop valve located upstream. It is permissible to have a pounds per square inch (psi), whichever is lower, plus different size check valve and stop valve. the applicable static head (rule 101.2.2). Let’s start our discussion about feedwater piping with a • The transition pressure at which one switches from very basic feedwater system found on the majority of small- adding 25% of the MAWP to adding 225 psi occurs at to-medium-sized boilers: the on-off feedwater system. the 900 psi level, plus the applicable static head. • If the design pressure is less than or equal to 900 psi, Basic On-Off Feedwater Systems add 25% plus the applicable static head. If the design pressure is greater than 900 psi, add 225 psi, plus the Basic feedwater systems for small and moderately 16 applicable static head. sized boilers utilize a boiler-mounted level control which ­ energizes the feedwater pump when the boiler water level The design temperature is based on the saturation reaches a low point and then will stop the feedwater pump temperature of steam at the MAWP of the boiler. Note that when the normal operating water level is reached. This

16 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org arrangement requires the minimum of a stop valve located limits. Caution should be used if pressure-relieving devices at the boiler and a check valve installed before or upstream are changed to the MAWP rating of the boiler to ensure fit- of this valve. The stop valve and its piping connecting to tings are suitable for use at the new pressure requirement. the boiler feedwater connection shall be the same size as the boiler connection. The remaining piping in the BEP lim- Feedwater-Regulating Control Valves its may, however, be reduced to the size required to supply the boiler, if needed. The design pressure for piping from The next arrangement gaining in popularity is the use of the termination point to the feedwater source is subject to a feedwater-regulating valve controlled by variation in the ASME Section I, which requires this piping to be able to sup- boiler water level. This type of system provides better and ply the required amount of feedwater to the boiler when the more consistent boiler water level control, and is becoming highest set pressure-relieving device, plus 3%, is operating. standard as larger firetube boilers are being installed. In the case where these pressure-relieving devices are lower than the boiler MAWP, it may allow the use of fittings with Example of one pump supplying two or more boilers utilizing a three- a lower class rating than for the piping used within BEP valve bypass around the regulator valve.

Boiler feed water connection

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 17 BULLETIN FEATURE

This system is also used for multiple boiler installations the economizer inlet connection. The economizer pressure- where there is a common feedwater header with multiple relieving requirements are now met by the boiler pressure- feedwater pumps. ASME Section I code compliance relieving valves and additional protection is not required requires that the feedwater system be able to supply the for the economizer. required amount of feedwater to the boiler when the highest A problem will arise when code-required feedwater set pressure-relieving device, plus 3%, is operating. Good piping and valves are located between the economizer out- engineering practice requires feedwater valves and piping let connection and the boiler feedwater inlet connection. meet this requirement for safe boiler operation. Caution The economizer can now be isolated from the boiler and should be used if pressure-relieving devices are installed become a fired pressure vessel requiring pressure-relieving using a setting less than the MAWP, and then changed valves. This piping now must meet the ASME B31.1 code at a future date to the MAWP of the boiler. Feedwater rules for BEP piping. pumps and valves should be checked and confirmed that The BEP design rules are now defined by the MAWP they are still in code compliance if changes are made. of the economizer, or the shutoff pressure of the feedwater When using a feedwater valve, close examination of system pump, not by the boiler MAWP. It is permissible to the feedwater arrangement should be performed to deter- install pressure-relieving devices on the economizer based mine BEP termination points. As noted earlier, the required on the MAWP of the economizer, even if it exceeds the check valve and stop valve are also included in this piping. boiler MAWP. To guarantee feedwater flow to the boiler, When a feedwater valve is installed without a bypass, it these valves should be carefully selected so that the boiler becomes the termination point and is subject to the design pressure-relieving valves operate before the economizer rules for feedwater piping. As for the basic feedwater sys- pressure-relieving devices. Since the economizer MAWP tems mentioned earlier, this feedwater valve and piping is generally much higher than the boiler’s MAWP, there is to the required stop valve may be reduced in size to what the possibility that the BEP will be exposed to this higher is required to feed the boiler. When a feedwater regulator pressure. It is possible for a boiler with a MAWP of 150 valve is equipped with a three-valve bypass, the BEP ter- psi and with feedwater piping designed for 188 psi that mination points are relocated. The new locations will be incorporates an economizer designed for a MAWP of 400 the outboard face of the block and bypass valves (see Fig- psi, with pressure-relieving devices with a setting of 400 ure 100.1.2(B) of ASME B31.1). In this case the feedwater psi, now subjecting this 188 psi piping to 400 psi. An econo- valve is only subject to the design requirement of 3% over mizer located upstream (pump side) of the required BEP the highest set pressure-relieving device. All valves and boundaries will require a design pressure compatible with the feedwater control valve must be sized to provide the the feedwater pressure at the location installed. This will required amount of feedwater to be code compliant. normally be considerably higher than any of the design pressures employed within the scope of the BEP. Feedwater Economizers Feedwater Pumps Another installation becoming more common is the use of a feedwater economizer that is mounted in the boiler When an inspection is performed on a boiler and it is stack. Installing these systems can present problems in de- noted that the operating pressure is substantially lower fining the termination points and other requirements for than the pressure-relieving valve setting, the feedwater compliance with ASME B31.1. ASME Section I states spe- pump should be checked to ensure it meets the require- cifically that if an economizer is installed without any inter- ments of ASME Section I, which says feedwater pumps vening valves between the economizer outlet connection should be able to supply the required amount of feedwater and the boiler feedwater connection, it is the responsibility to the boiler when the highest set pressure-relieving device, of the ASME Section I code committee. The required valves plus 3%, is operating. If the pressure-relieving devices are for BEP compliance only apply to the piping installed on set for 150 psi and the boiler is operating at 60 psi, there is

18 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org

12 This system is also used for multiple boiler installations a possibility the feedwater pump is not sized properly. For • The design pressure for feedwater piping subject to where there is a common feedwater header with multiple the pump to stay within the performance curve at 60 psi, BEP requirements is MAWP plus 25% or MAWP plus feedwater pumps. ASME Section I code compliance it is doubtful the pump can supply the required feedwater 225 psi, whichever is lower. NOTE: This is based on requires that the feedwater system be able to supply the at 150 psi plus 3%; however, if a pump is installed that is the MAWP, not the operating or pressure-relieving required amount of feedwater to the boiler when the highest sized for 150 psi plus 3%, it will probably be off the perfor- device pressure setting. set pressure-relieving device, plus 3%, is operating. Good mance curve at 60 psi. Pump flow is inversely related to • The design temperature for this piping is based on engineering practice requires feedwater valves and piping the output pressure. As pressure increases, flow decreases. the saturation steam temperature at the MAWP of the meet this requirement for safe boiler operation. Caution When the operating pressure and the pressure-relieving set boiler. should be used if pressure-relieving devices are installed pressures are closer together, the pump will probably per- • When a feedwater level control valve is installed using a setting less than the MAWP, and then changed form properly. It is still wise to confirm the pump meets the without a bypass, the valve itself becomes the BEP at a future date to the MAWP of the boiler. Feedwater requirements and is in compliance with the ASME Section termination point. pumps and valves should be checked and confirmed that I code. • When a feedwater level control valve is installed with they are still in code compliance if changes are made. isolation valves and a bypass, the bypass and the iso- When using a feedwater valve, close examination of Pressure-Relieving Devices lation valve (located downstream of the feedwater the feedwater arrangement should be performed to deter- control valve) become the BEP termination point. mine BEP termination points. As noted earlier, the required Sometimes it may become necessary to lower the set • When using an economizer without any intervening check valve and stop valve are also included in this piping. pressure of pressure-relieving devices so the feedwater valves between the economizer and the boiler feed- When a feedwater valve is installed without a bypass, it pump is within design and operating parameters and in water connection, BEP rules apply to the inlet of the becomes the termination point and is subject to the design conformance with ASME Section I code rules. This is per- economizer and pressure-relieving valves are not re- rules for feedwater piping. As for the basic feedwater sys- missible within code requirements as long as the required quired on the economizer. tems mentioned earlier, this feedwater valve and piping pressure-relieving capacity is provided. As the set pressure • Use caution when installing feedwater level control to the required stop valve may be reduced in size to what of the pressure-relieving device is lowered, the device will valves between the economizer outlet connection and is required to feed the boiler. When a feedwater regulator become larger to provide the required capacity. There may the boiler feedwater inlet connection. This piping now valve is equipped with a three-valve bypass, the BEP ter- be a limitation as to how much the pressure may be low- may be subject to the economizer MAWP, not the boil- mination points are relocated. The new locations will be ered, as the size of the pressure-relieving devices will be er MAWP. Pressure-relieving valves are now required the outboard face of the block and bypass valves (see Fig- limited by the size of the openings in the boiler. on the economizer. ure 100.1.2(B) of ASME B31.1). In this case the feedwater • The feedwater source must be capable of supplying valve is only subject to the design requirement of 3% over In Conclusion the required amount of feedwater to the boiler at 3% the highest set pressure-relieving device. All valves and over the highest set pressure-relieving device. the feedwater control valve must be sized to provide the The installation and inspection of feedwater piping required amount of feedwater to be code compliant. subject to ASME Section I and ASME B31.1 rules for BEP Part 3 in this series will discuss the correct and code- requires a detailed examination of each system to ensure compliant installation and inspection of an often over- Feedwater Economizers code compliance. Each feedwater system is unique and looked and improperly installed boiler piping system – will have to meet specific requirements to be in code com- blowoff valves and piping. Another installation becoming more common is the pliance. This examination will determine the BEP termina- use of a feedwater economizer that is mounted in the boiler tion points and the items subject to these rules. The follow- stack. Installing these systems can present problems in de- ing items should be checked to ensure code compliance: Steve Kalmbach has been involved in the boiler repair, fining the termination points and other requirements for maintenance, and service industry for 30 years. His company, compliance with ASME B31.1. ASME Section I states spe- • The code requires at minimum a stop valve located at Kasco, has a National Board R Certificate of Authorization cifically that if an economizer is installed without any inter- the boiler feedwater connection and a check valve in- for repairs and alterations and an ASME Certificate of vening valves between the economizer outlet connection stalled upstream of this valve. Authorization with S and U designators controlled by the and the boiler feedwater connection, it is the responsibility • The stop valve and piping to the boiler feedwater con- office in Golden, Colorado. He can be reached at skalmb4427@ of the ASME Section I code committee. The required valves nection shall be the same size as the boiler feedwater aol.com. for BEP compliance only apply to the piping installed on connection.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 19

12 DEPARTMENT Pressure relief Report

Implementing the New ASME Code Stamp Challenges for Pressure Relief Devices by Joseph F. Ball, P.E., Director, Pressure Relief Department

The ASME same method as for any other nameplate For most code stamp holders Boiler and Pressure markings or stampings. addition of the new mark is relatively Vessel Code 2011 straightforward. To apply the new addenda included mark, ASME is in the process of a new, single ASME providing stamps to certificate-holding certification mark organizations. Certificate holders will that will replace all need to plan for a space on their nameplate 25 Code Symbol Stamps included in the for the designator. ASME Boiler and Pressure Vessel Code, as Applying the new mark on well as stamps and marks used for other XX pressure relief devices (PRDs) can be ASME programs and equipment outside (XX = designator) challenging. Space on pressure relief of the boiler code. device nameplates has always been at Implementation of the new mark Because this is a significant change, a premium. The code has long made an was necessitated by ASME’s need to ASME Certificate Holders were provided exception for the minimum size of letters protect its symbols in countries all over an extra year to administer the new mark. and numbers for pressure relief device the world, which includes the costly legal This new stamp and designator must be markings, and a common complaint by registration of trademarked symbols implemented by the end of 2012. Extra inspectors is that the PRD markings are wherever they could be used. Because time was formalized by Code Cases 2710 hard to read. The new ASME stamp is ½” ASME has a large number of symbols, and and 2714. by ½” (12.7 mm x 12.7 mm) which is larger is continuously expanding the locations than the previous pressure relief device where ASME-stamped equipment code stamp. (Another version, ¾” x ¾”, might be supplied, maintaining control is also available.) With the larger stamp, over them had become more and more plus the new designator, addition of the burdensome. Therefore, the new single mark has become very difficult due to mark was developed to protect the space restrictions. trademark in the future. On larger pressure relief valves The certification mark consists of the there is room for bigger nameplates, so letters “ASME” positioned diagonally some organizations are enlarging their inside the traditional cloverleaf symbol, nameplates to make room for the new and must be accompanied by one or mark and designator; however, this is more letters, called the “designator.” not an option on smaller devices. For The designator describes the object in smaller valves, organizations have used more detail and consists of the letters an alternate marking method for applying previously used with the old Code the current code stamp. Symbol Stamp. The designator is Fortunately, there is an acceptance descriptive of the device being marked, procedure available to organizations but is not actually part of the mark itself. who want an alternative to the new steel A method for applying the designator is stamp issued by ASME. Alternative not included with the new ASME stamp, methods of applying the stamp must be so it will be applied separately using the accepted by ASME, which will be done

20 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org upon recommendation from the National manufacturers and assemblers should 1. A drawing or other method of Board, the ASME-designated organization be well into the planning process for how documenting the arrangement of the for pressure relief devices. they will implement the new mark. The new stamping. In some cases this may For the alternative method to be remaining time this year should include be a CAD or drafting file identification. considered, it must meet the following plans to use up existing nameplate stock The drawing or file must beapproved criteria: while the current code stamp can still be and controlled by the Certificate used to minimize the effect on inventory Holder’s quality system.

1. The mark must be an acceptable when new nameplates are needed. This 2. A sample of the actual stamping facsimile of the ASME mark. may be an opportunity to upgrade and method on a nameplate, tag, valve modernize marking methods, allowing body, or rupture disk holder shall be 2. The size of the markWATER is not specified, for increased efficiency and improved supplied. A large detailed picture can but it must be legibleTEST and permanent.SYSTEM accuracy in the process. be used for this purpose. The mark will most likely be smaller For acceptance of an alternative than the steel stamp issued by ASME. 3. A copy of the procedure for marking method, please provide the controlling use of the stamp. 3. The procedure for controlling the use following information: of the alternative stamping method must be documented and addressed This information can be sent to the Pressure Relief Department at: in the organization’s quality program. National Board Pressure Relief Department Alternative methods that have been 7437 Pingue Drive used include: roll stamping with a die, Worthington, OH 43085 laser marking, photosensitive etching, E-mail to: [email protected] and metal pin scribing or metal dot matrix printing. These marking methods After the information is reviewed and accepted, the National Board will forward can be automated and allow all required a recommendation to ASME that the alternative marking method be accepted. ASME nameplate information to be applied at should then provide an acceptance letter before the time when implementation is the same time. These processes are often required. integrated into a company’s business system, allowing information stored in PRD Designators for Pressure Relief Devices computer files to be directly applied to Designator Service the nameplate (such as model number, V Section I pressure relief valves for boilers set pressure, capacity, serial number, etc.). NV Section III pressure relief valves for nuclear equipment The alternative marking method can HV Section IV pressure relief valves for heating boilers and hot be seen as an improvement over using a water heaters hammer to strike a metal stamp onto a UV Section VIII pressure relief valves for unfired pressure vessels PRD, as PRDs can be considered precision UD Section VIII pressure relief devices for unfired pressure vessels instruments that should be handled with (usually rupture disks) extreme care until they are installed. TV Section XII pressure relief valves for transport tanks The implementation deadline, 2013, TD Section XII pressure relief devices for transport tanks will be here before we know it. PRD

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 21 BULLETIN COVER STORY

Testing... Testing...1,2, 3... Expansion Project Complete, It’s Full Speed Ahead at the National Board Testing Lab

22 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Bulletin photographs by Brandon Sofsky NATIONAL BOARD

2012 is a landmark year for the National Board Testing Laboratory (NBTL). It marks the 75th anniversary of its existence (in multiple locations) and a year of substantial growth and change.

Testing...1,2, 3... Expansion Project Complete, It’s Full Speed Ahead at the National Board Testing Lab

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 23 BULLETIN COVER STORY

compressors were replaced with a liquid nitrogen storage and he National Board Testing Lab vaporizing system. And there’s been an overall increase in flow is an independent ASME-certified flow lab and pressure capacity. where staff conducts tests on pressure-relieving All of this is to the client’s advantage. “It’s a win-win devices from valve manufacturers, assemblers, and repair situation,” says National Board Lab Manager Brandan facilitiesT around the globe. Currently, the lab performs over 180 Ashbrook. “The process is quicker and there is less wait time tests a month and hosts approximately 300 people representing between tests. We can test more than one customer at a time. 130 companies and 20 countries each year. Nearly half of all Our new data automation system captures and records test tests are witnessed by the customers. results with greater accuracy, and international clients will be To accommodate a record number of tests in recent years, able to view recorded test data as if 'live' without traveling to the lab has undergone a major expansion of its facilities. What the lab, which means tremendous travel cost savings for them.” started as a need for additional storage morphed into a nearly 3,000 square foot addition to the southeast side of the building. New Air Testing System But it didn’t stop there. We have the option of The extra 3,000- square-foot add-on to running three different the lab made it possible jobs on one system: a 2,500- for the installation of a “ brand new air testing psi line, a 1,350-psi line, system, which was high on the wish list to and rupture disk tests.” help meet the growing demand for air tests.

LEFT: The crane used to install two vaporizers. RIGHT: New nitrogen tank and both vaporizers at work. BELOW: Setting up the new air testing system inside the 3,000-square- foot addition.

With the support and foresight of National Board senior management and the Board of Trustees, staff also looked at ways they could improve the existing test systems and equipment. "National Board leadership recognizes the importance of investing in the future of pressure relief testing. The expansion project is our commitment to safe, efficient, and accurate testing now and for years to come," says Executive Director David Douin. In light of newer technologies and different methods of recording and measuring data, significant upgrades were made on the existing air and steam test systems. Digital automation was installed on every steam, air, and water testing console to electronically capture and record test results in the most accurate and efficient means possible. An entirely new air test line was added and a new maintenance area built. Air

24 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 25 BULLETIN COVER STORY

main area of the National Board Testing Laboratory contains three test systems using steam, nitrogen, and water. Each system features the following:

Steam Air Water Ambient Temp. Media Dry Saturated Steam Compressed Nitrogen Water Maximum 625 psi 850 psig (58 bar) 3,500 psig (238 bar) Source Pressure (43 bar) Sharp-Edged Flow Measurement Weighed Condensate Sonic Flow Nozzle & Orifice Plates& Prime Meters Sharp-Edged Orifice Plate Method Timed Weight Method Low Medium High Maximum Stamped 500 psi (34 bar) 500 psi (34 bar) 580 psi (39 bar) 1,100 psi (75 bar) 2,025 psi (138 bar) Set Pressure 4" (DN 100) 4" (DN 100) 6" (DN 150) 4" (DN 100) ¾" (DN 20)

Maximum Stamped 16,000 pph 13,000 scfm 25,000 scfm 5,000 scfm 550 gpm Flow Capacity (7,257 kg/h) (22,087 m3/h) (42,475 m3/h) (8,495 m3/h) (2,082 l/min)

DATA Acquisition A computer-based acquisition system is available to electronically capture the best data for flow computation and analysis.

The new line is equipped with full air valve testing output with the nitrogen system, which now makes the capabilities and includes a 4” line and a new test vessel with air. And by adding another test line, we’ve doubled our air permanently installed rupture disk rigs. A blast diffuser was testing capabilities.” And since the new line was installed with mounted on the far wall and the discharge end of the rupture permanent rupture disk rigs, set-up time is greatly reduced for disk rigs point at it to safely dissipate the released energy rupture disk testing. during testing. “This is going to be our everyday workhorse,” says The Pressure for Air Ashbrook as he motions toward the new test line. “We have the option of running three different jobs on one system: a 2,500-psi As mentioned, running out of air was becoming a problem line, a 1,350-psi line, and rupture disk tests.” as testing increased, so air supply capacity was one area the With the addition of the air test line, the lab can theoretically team wanted to improve. run all four test lines independently, essentially doubling the The lab was using three air compressors to make high- number of air tests the lab can accommodate at one time. pressure air supply for running tests. Two compressors produced “The set-up of the original lab was such that one crew would 65 standard cubic feet per minute (scfm) each, and the other spend all day with a customer testing one valve at a time and produced 75 scfm. With all three running, they supplied 205 moving from one test location to another to another. To make scfm of compressed air (volume). matters worse, we had a problem of running out of air,” says “One of our challenges was that we needed to refill the Ashbrook, noting it could turn into a long process for visiting stored air supply quicker. There were times we would wait an clients because of waiting on air storage bottles to refill to flow hour or longer for the storage bottles to top off so we could flow test valves. test a large capacity valve,” says Ashbrook. “Now we’ve fixed those problems in multiple ways,” Original plans called for adding two new 100-horsepower Ashbrook says. “We have more air storage. We have more (hp) air compressors. “We already knew we needed more supply,

26 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org which is why we planned on adding double the storage bottles,” Here’s what they came up with he explains. “We felt good about our plans to double the storage bottles and double our ability to make air. But what happened Running both new and older air compressors would next was not so great.” yield 370 scfm. So what would it take in gallons of liquid Steam Air Water When exploring what was needed to supply the extra nitrogen to equal this? One gallon of liquid nitrogen equals electric load of the new compressors, it was determined the 93.11 scfm of nitrogen gas. building would need more switch gear at the transformer to They divided 370 by 93.11 which equals 3.97 gallons. supply more power. They would also need to install an oil Knowing the conversion rate and target number, they interceptor into the floor for the condensate run off (oily water sized a pump with a nozzle of 4.2 gallons per minute to from running the compressors). Also, the dryer and cooler give them an output of 391 scfm. This met and slightly would need to be replaced with units that could bear the load exceeded their target range. “So if one pump would equal of the increased air capacity. four air compressors, two pumps would be better yet. Considering the cost of upgrading the air compressors, We realized that if we had a failure, we could run the the team turned their attention to liquid nitrogen air supply other pump and continue testing valves with no halt in systems. They calculated how much nitrogen they would testing and no lag time for customers,” Ashbrook says. need compared to the air compressors, and started running With both pumps running they make almost four times pros and cons. They found that the initial equipment purchase their original value. for an equivalent capacity nitrogen system was considerably Tom Beirne, senior staff engineer in the Pressure less than upgrading and adding more air compressors. And Relief Department, elaborates. “The air compressors and unlike compressed air, the nitrogen system was free of oil and completely dry, eliminating the need for oil separation, cooling, BELOW: From left to right: Lab staff David Hennon, Zach Burwell, and drying. The pros were outweighing the cons. and Brandan Ashbrook set up a rupture disk test on the new line.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 27 BULLETIN COVER STORY

By adding six new 4,000-psi storage vessels, the lab more than doubled its original storage capacity, expanded its testing range, and eliminated the delay between tests of larger capacity air valves, which also means less wait time for customers. Here are some details on the system:

The nitrogen system consists of a 6,000-gallon liquid nitrogen storage tank; two, 20-hp/4,000-psi pumps; and two vaporizers used to convert nitro- gen from liquid to gas.

The two, 20-hp pumps are set up to run inde- pendently or at the same time as needed to meet demand.

The nitrogen pumps each have a 20-hp motor and a 4.2-gallon-per-minute nozzle.

The cost of running one 20-hp nitrogen pump “We’ve nailed our ABOVE: Solar-powered cell phone objective,” Ashbrook is significantly less than what it would have cost monitor mounted on nitrogen tank. concludes. “We’ve to run all of the compressors (which would have RIGHT: New fully-automated test equalled 290-hp) for the equivalent output. successfully increased station consoles. our air capacity and FAR RIGHT: New control valves (green) Electricity savings are expected to nearly offset quickened customer on the steam line. the cost of the liquid nitrogen. testing times.” The last air test before the switch to the nitrogen system was performed on April 3 for General Electric. It was test number nitrogen system both function the same as a supply source, but 32,512A for research and development. we began to see that making the switch to nitrogen would be more efficient for our testing operation. And since we’ve made Test Station Automation the switch there have been no air shortages. It’s reliable. We haven’t had to wait for refill.” Prior to the 2012 expansion, the process of capturing and Ashbrook reinforces this point: “We’re using the same source measuring test results (data acquisition, DAQ) was semi- – compressed nitrogen is equivalent to compressed air – but how automated and used for rupture disk testing. With the increased we’re making it is more efficient. It took us about 15 minutes volume of tests, the decision was made to fully automate DAQ to top off all 12 bottles with the nitrogen system. So with our capabilities and expand its usage to all test station consoles. day-to-day testing, we are never waiting on supply anymore.” The automated DAQ system provides immediate test Ashbrook explains that the tank, located outside the results in digital format for analysis and reporting. Visiting building, has its own cell phone mounted on a solar panel. clients and technicians can view results and determine on Twice a day it sends a signal to the nitrogen supplier to monitor the spot (while the test setup is still intact) if repeat tests are the storage vessel levels. When the nitrogen hits a low level, necessary. Customized, preliminary reports are printed and the system alerts the company’s dispatch, which sends a truck given to clients at the conclusion of testing, while electronic to refill the liquid storage vessel. And the pumps that supply documentation is automatically forwarded to a professional the liquid to the vaporizers (and ultimately nitrogen gas to the engineer for approval. high-pressure storage bottles) are always on standby. When the Technicians can perform calculations at each station rather pressure dips below a certain set point, the pump kicks on and than manually enter results into a separate computer, and they the bottles are filled. also have access to National Board forms and applications at

28 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org the consoles. Overall paper usage is reduced, and digitizing Ohio, facility. (Manufacturers testing adjustable blowdown valves test results and recordkeeping reduces the opportunity for must still achieve blowdown requirements and may have to make human error. adjustments. For this reason they are encouraged to be present The DAQ system also eliminates manual methods for saving during testing.) and tracking the calibration and configuration information of each test station. A record of daily calibration and lab sensors "Steamlining" (pressure, temperature, and flow) used in testing is available for reporting and archiving test data. This greatly improves When considering adjustments to the steam testing line, the traceability and provides quick access to historical records for team wanted to create better control by way of replacing one old analysis and tracking to determine if test methods and equipment are consistent and reliable. All test stations can run independently in parallel with one another, and any test station can be driven by a computer at another station – a useful feature if one station has a computer failure, as testing needn’t be delayed or rescheduled. Another advanced function is that the system is capable of having new sensors and measurements designed into it. Acoustic,

control valve with two new control valves to split the amount of pounds per hour (pph) passing through. It was also decided to elevate the test line about 3.5 feet (from lying on concrete) to allow the installation of a larger dirt trap and condensate area to tie into the new steam trap, thus decreasing condensate and improving steam quality. Improvements to the steam line – and to all of the major expansion projects previewed here – have taken place while the video, laser, and other sensors can be optionally configured lab has continued its day-to-day operations of running tests and to any test station for additional methods of testing. Highly servicing clients, a fact that has a little something to do with the modular test software can be enhanced to add measurements landmark year the lab is experiencing. beyond the standard core tests. And there is increased precision “This endeavor has been a great strain and challenge with in set point measurements for valves characterized by set points unique obstacles,” notes Ashbrook. “But it’s resulted in greater associated with parameters other than “pop.” The new system efficiency for us and for our customers, and it reflects the continued also captures and reports additional behavior of valves, which dedication by staff members to keep the National Board Testing will give valve designers a new tool to help diagnose problems Lab at the forefront of capacity testing.” or improve valve design. Finally, all test data can be recorded and played back as if “live.” Clients who do not attend live testing can witness the The term “air” is used loosely throughout this article. The results as if they were there. This automated reporting will prove NBTL currently reports its results in scfm air calculated from especially useful to international customers who may want to witness their valves being tested, but do not want to incur the mass flow rate of nitrogen as the test medium. the associated costs of travelling overseas to the Worthington,

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 29 DEPARTMENT UPDATES & Transitions

National Board Member Selected ASME President-Nominee

National Board member Madiha Kotb, P.E., has been named ASME president-nominee for 2013–2014, effective July 2013. Ms. Kotb has been a National Board member representing Québec since 1989 and served on the National Board’s Board of Trustees from 1991-1993. She has been a member of ASME for 30 years. Madiha Kotb

New NBIC Committee Chairman Elected

The National Board Inspection Code (NBIC) Committee members gathered July 16-19 at Na- tional Board headquarters in Columbus, Ohio, for their biannual meeting. Donald Cook, principal safety engineer for the state of California, was elected new chairman of the NBIC Committee. Mr. Cook has been an active NBIC Committee member for eight years. Minutes of the meeting are available for review on the National Board website. The next meeting is scheduled for January 2013, in Mobile, Alabama. Location information to be announced. Donald Cook

Colorado Springs Chosen Host for 84th General Meeting

The Broadmoor hotel in Colorado Springs, Colorado, has been selected as home base for the 84th National Board/ASME General Meeting April 27 – May 1, 2015. The Broadmoor’s prime location neighbors some of Colorado Springs' most celebrated destinations, such as “America’s Mountain” Pikes Peak, exotic Garden of the Gods, and the US Air Force Academy. The Broadmoor promises soaring views and plenty of indoor and outdoor activities as only "Colorful Colorado" and the famous resort can deliver.

30 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Member Retirements

Vermont Chief Retires Wesley E. Crider Jr. retired as chief inspector for the state of Vermont on June 29, 2012. He served the US Navy for 20 years during Korea and Vietnam (1952-1972) and retired as a chief machinist mate serving aboard aircraft carriers. From 1973-1988 he worked as a boiler and pressure vessel field inspector for

the Hartford Steam Boiler Inspection and Insurance Company and then the New Hampshire Insurance Wesley E. Crider Jr. Group. In 1988 he was employed as a National Board commissioned inspector for the state of Vermont. He assumed the role of chief and became a National Board member in 2006. Mr. Crider holds A and I endorsements. Additionally, he has been a member of ASME since 1999 and served as assistant state fire marshal for the state of Vermont.

Oregon Chief Retires Michael D. Graham retired from his post as chief inspector on July 31, 2012. Mr. Graham’s career began in 1968 when he joined the US Coast Guard and served a four-year term. In 1973 he became employed with Boise Cascade paper mill in Salem, Oregon. He went to work for Container Corporation of America in Tacoma, Washington, in 1979 and obtained a Washington State boiler operation license. In 1989 he Michael D. Graham joined the state of Oregon working with the Fairview Training Center as a high-pressure boiler operator. Mr. Graham received a National Board Commission in 1996 and was employed as a state inspector for 10 years. In 2006 he assumed the role of chief. He served 23 years with the state.

Georgia Director Retires Paul J. Welch retired as director for the state of Georgia on July 1, 2012. Mr. Welch served the US Navy as an electrician for 20 years, from 1970-1990. After retiring from the military, he went to work for Norfolk Southern Railroad in 1991 as an electrician. He joined the Georgia Department of Labor in 1993 and served as boiler/elevator/amusement inspector and safety inspector supervisor I and II until Paul J. Welch he assumed the role of acting director in 2010. Mr. Welch is a commissioned inspector and holds A and B endorsements.

Detroit Supervisor Retires John Bell retired as supervising boiler inspector for the city of Detroit, Michigan, on July 12, 2012. Mr. Bell attended the Detroit Institute of Technology and Sienna Heights College. He holds a bachelor’s of applied science degree in plumbing and heating. He was employed as a commercial foreman for plumbing, HVAC, pipe fitting, and boiler installation, and later taught these subjects at high school and community college. Mr. Bell then joined the city of Detroit and worked as a mechanical inspector before assuming the role of supervising boiler inspector. He became a National Board member in 2008. John Bell

New Hampshire Chief Retires Wayne Brigham retired as chief inspector of New Hampshire on September 1, 2012. His ca- reer began in 1963 at the Hampshire Chemical Company as a boiler operator. Between 1970 and 1978 he gained experience working as a utility operator, combination and boiler safety inspector, authorized inspector (AI), and boiler engineer. Mr. Brigham worked for Home Insurance Com- pany as an AI from 1978-1992. From 1992-2000 he was an AI for Hartford Steam Boiler and then with Commercial Union Insurance Companies. In 2000 he returned to Hartford before joining the

state of New Hampshire in January of 2001. Wayne Brigham

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 31 DEPARTMENT Profile In Safety

Gary Scribner Deputy Chief, State of Missouri

f there were ever a poster boy for the US Navy, it would be Missouri Deputy Chief Gary Scribner. I One needn’t look far to locate him in a crowd. From the way he comports himself, to the Pegasus tattoo on his right arm, to the closely cropped pate of gray hair, there is no mistaking this Navy veteran of 22½ years. Born in the inner city of Baltimore in the shadows of old Memorial Stadium, Gary spent most of his formative years studying the mechanical dexterity of his welder father. And so it came as no surprise when the younger Scribner developed an affinity for working with his hands. “I started assembling model airplanes at a very young age,” he acknowledges with a grin. As with many of his teenage contemporaries, Gary took on a number of jobs to purchase his first car. The most memorable was working as a stock boy at an industrial equipment warehouse. photograph by Full Spectrum Photo “I was 14 at the time,” Gary recalls. “Not only was I responsible for stocking Bulletin parts – including boilers – I was allowed to assemble some of those parts.” being able to work as a mechanic while still that meant leaving high school before his With unique mechanical skills pursuing a creative outlet,” he emphasizes. senior year and being a year shy of the learned from model making and his blue- As the Missouri official began Navy’s age requirement. collar father, the young Baltimore native thinking seriously about a career, he Promising his mother he would found great satisfaction in being able to became increasingly aware of his changing obtain his GED within a year of his work on automobiles. neighborhood. “Gang activity was getting enlistment if she would sign an age waiver By age 15, he owned two cars: one worse by the day and I quickly came to the (a pact he would fulfill), Gary reported with a blown engine and another with a conclusion that finishing high school was to boot camp in 1975 to take a battery of wrecked front end. “With parts from both, a dangerous option,” he laments. tests to determine his naval career path. I was able to assemble one entire car that The Missouri National Board member “I really wanted to become an engine actually ran,” he laughs. reasoned that joining the Navy would mechanic but the Navy directed me In high school, Gary’s love of motor allow him to leave the neighborhood toward boilers. And I had no issues with vehicles prompted him to consider a career behind while at the same time permit working on boilers. The more I learned painting motorcycles. “It was my way of him more vocational opportunities. But the more I welcomed the opportunity.”

32 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Gary not only welcomed the where he could utilize his leadership Joining National Board membership opportunity, he took full advantage. skills as well as expansive military in 2007, the state official has been one of As a Navy seaman recruit, he was sent experience with pressure equipment. the organization’s more active members to a variety of schools before being sent “My first job was in Washington, as an outspoken advocate of CO2 safety to more advanced classes – every one of Pennsylvania, in 1997 where I managed [see his article, “Potential Dangers of which he excelled. “By the time I had gone maintenance, security, and transportation Carbonated Beverage Systems,” in through all of the schooling, I achieved 3rd for a senior care campus,” Gary explains. the summer 2012 BULLETIN] and as Class Petty Officer.” While residing in the Keystone state, the a member of the NBIC committee. A And so began an odyssey that would Scribners made a decision to work their member of the Board of Trustees since span over two decades. First stop: Boston. way back to Cathy’s central Missouri 2009, he was recently elected the Board’s “There I was sent to even more birthplace. And to seal the deal, they second vice chair. advanced boiler classes,” he explains. “I made a deposit on a 4½-acre piece of His leadership overseeing pressure was fortunate to increase in rank each time land in Russellville, about 25 miles south equipment safety notwithstanding, I was up for promotion.” With each climb of Jefferson City. But their westbound the Missouri National Board member up the ladder, Gary gained something else destination would endure a few detours. remains humble, unassuming, and yes, that would boost his career: confidence. “I left the care center in 1999 to take a firm believer in military discipline “The Navy was a great life,” he a job in Milwaukee as a maintenance and training. New Missouri inspectors emphasizes. “It gave me perspective, manager for a corrugation plant. In are required to complete three weeks established a lot of new friendships, and 2001, I took a similar position at a paper of “bookwork” and three months of allowed me to see places I could never see company in Arkansas,” Gary recalls. in-office training before stepping foot on my own.” “When that plant was bought out and into the field. As he progressed through the ranks, closed in 2003, Cathy and I packed our Today, Gary reports the double-wide Gary became an engineering repair belongings and moved to Russellville. has since been replaced by a home he and specialist who didn’t see a lot of land on his With no job prospects, we decided to his brother-in-law constructed between travels. That’s because a lot of the missions make the best of a modest severance his sojourns to and from Kansas City. he participated in involved surveillance. “I package and purchased a double-wide He is still an avid builder of models, but was assigned the US destroyer Blandy in trailer home for our undeveloped land.” now builds large-scale radio-controlled 1979. We were off the coast of Iran when Having boiler inspection experience naval ships, mainly from scratch. And the Iran hostage crisis was taking place. In from the Navy, Gary embarked on a Cathy, an animal lover who works for the the 1980s, while assigned to the US carrier mission to get a similar job with the state Missouri Department of Transportation, America, we also conducted surveillance and of Missouri. Applying for a position as is still rescuing whatever critters show air strikes during that era’s Libyan conflict.” field inspector in 2003, he was asked if up at – or under – the Scribner home. Leaving the America in 1987, Gary was moving to Kansas City was an option for Between them, the Scribners have sent to training command during the first the Scribners. It was not. Commuting, four grown daughters: three from Gulf War before assuming the position well, that was something different. Gary’s previous marriage, and one from of Navy Processing Center Director in “For three years, I drove back and Cathy’s. Pictures of no less than eight Wilkes Barre, Pennsylvania. A year later forth from Russellville to Kansas City grandchildren adorn the walls of the he was deployed to the US carrier Saratoga, just about every weekday,” the Baltimore Russellville homestead. home-ported in Mayport, Florida, before transplant laughs. “At nearly 200 miles to Thirty-seven years removed from punctuating his naval career aboard the and nearly 200 miles from Kansas City, I the mean streets of Baltimore, Gary nuclear carrier George Washington out of was logging six to eight hours of driving concedes life in the country is a lot Norfolk, Virginia. time per day!” more desirable. Once you’ve seen the While in Norfolk, the future National When the Missouri deputy director’s heartland, he emphatically notes, there’s Board member met Cathy Willis, a native of position became vacant in 2006, Gary was no going back to the big city. central Missouri, whom he would marry in made interim deputy chief, a position he “I’ve seen ‘em both, and there’s no 1991. Upon leaving the Navy in November held until becoming permanent chief of comparison!” 1997 as Chief Warrant Officer 3, Gary began the boiler and pressure vessel safety unit And that is why Missouri is the looking for work in the civilian world in November of that same year. “show-me” state.

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 33 BULLETIN TRAINING MATTERS

Student Evaluations Provide Constructive Feedback by Kimberly Miller, Manager Of Training

eedback from our students is important. After all, our students are essentially our clients. Tuition is Fpaid. Class begins. Expectations are set by students as well as instructors. Now, did we meet those expectations? Are students leaving National Board training more knowledgeable than when they arrived? Have we sent them off in the right direction? Will they be better inspectors because they received National Board training? These are just a few of the questions we ask ourselves every time we conduct a class. And this is why student evaluations are so important. At the beginning of this year we decided to take a new, two- pronged approach to student evaluations. On the first day of training, students are provided with a card listing all instructors for the class. Included is a photograph of each instructor along with two key words: Knowledge and Presentation. There are also four stars under each instructor’s photo. Students are asked to keep this “Rate the Instructor” card available throughout the derived from topics discussed during our course review class, making notes about each instructor’s presentation skills meetings, or even from conversations an instructor has with and knowledge level. At the end, students are asked to provide students during a break. If one student expressed an interest an overall rating for each instructor using the four-star scale. in wanting more information on a certain topic, would other This first step in the evaluation process can provide valuable students also share that interest? Let me provide a recent example. feedback to the instructors. For example, an instructor might We conduct a course which features several item recognition pace back and forth in front of the classroom or jingle change in sessions. We wanted to know if students found this time to be his pocket, but is unaware of it – most people have such habits. well spent; was there value added with those sessions? Students But if this is pointed out on an evaluation, the instructor can enrolling in this course have varied backgrounds and experience improve his presentation skills and work to eliminate those levels and we wanted their feedback. So we asked. Turns out habits. The same goes for positive feedback. If an instructor the majority of the students liked the material but felt we were receives an evaluation stating a student really appreciated a spending a little too much time covering it. So we reviewed and question and answer session, or that a personal experience modified the beginning of the course to better meet the needs shared by an instructor helped relate a topic to the class, the of our students. instructor is alerted to his strengths and may want to include Constructive feedback is vital for the strength of any more of those interactions into a session. educational program, and as such, has a role in the National The second part of our new approach occurs after the Board training program. Our students are the current and future training. Once a training class has ended and students have boiler and pressure vessel inspectors of the world and it is our returned home, they are sent an email survey to evaluate the job to provide them the best foundation possible to do their course material and content. This electronic survey is very jobs well. To do that, we want our students to be involved in brief – about five questions – and addresses specific sessions, the evolution of training whenever possible. learning styles, material, etc. Many of the survey questions are After all, they are the clients.

34 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org Training Courses and Seminars BULLETIN

2012 Classroom Training Courses and Seminars

The remaining 2012 training calendar is currently released through December. Additional class dates are released monthly and posted on the Training section of the National Board website. Class size is limited and availability subject to change. 2013 dates will be released this fall. Check the National Board website for up-to-date availability.

COMMISSION/endorsement courses continuing education Seminars

(B/O) Authorized Inspector Supervisor Course (VR) Pressure Relief Valve Repair Seminar TUITION: $1,495 TUITION: $1,495 October 29-November 2, 2012 TBA

(A) New Construction Commission and (RO) Boiler and Pressure Vessel Repair Authorized Inspector Course Seminar TUITION: $2,995 TUITION: $725 (complete seminar) December 3-14, 2012 $250.00 (day 1 only) TBA (NS) Authorized Nuclear Inspector Supervisor Course All training is held at the National Board Training TUITION: $1,495 Centers in Columbus, Ohio, unless otherwise noted. November 12-16, 2012

(C) Authorized Nuclear Inspector (Concrete) Course TUITION: $1,495 Tentative spring 2013

nationalboard.org FALL 2012 NATIONAL BOARD BULLETIN 35 DEPARTMENT The Way We Were

n the morning of St. Patrick’s Day 1909, a group of people the safety buffer at track’s end. Traveling at about 25 mph, the Owaited for loved ones in the ladies’ waiting room at Montreal’s train continued into the ladies’ waiting room before coming Windsor Station. to rest in the station’s main concourse, the front of the engine Like a half-million Boston arrivals and departures earlier, breaching the depot’s southernmost wall. the public mood in the waiting area was rife with anticipation. While there were no fatalities on the train, passenger WJ Constructed in 1889, the passenger terminal was not only a Nixon discovered his wife and two children perished when the Montreal landmark, but a proud symbol of the city’s heritage. engine slogged through the waiting area. Twelve-year-old Elsie As locomotive 2102 made the final approach to the station, Villiers was also killed instantly by building debris collapsing all an explosion rocked the engine car, causing a lurching effect around her from the horrendous impact. Engineer Cunningham that forced a driving wheel into the already damaged boiler. died from his injuries a few hours after the incident at a Montreal The escaping steam and hot water severely scalded engineer hospital. Eleven others were critically injured. Mark Cunningham and fireman Louis Craig, who both jumped The accident inspired songwriters Henri Miro and Raoul from the train in an act of self-preservation. Collet to write the musical piece La Catastrophe de la Gare Windsor Unbeknownst to the 200 passengers in cars behind the – translated, The Windsor Station Disaster. engine, the train lost no speed barreling without an operator to its final destination. When a conductor signaled the engineer a This account is an excerpt from National Board Public passenger was to be let off a station before Windsor, he became Affairs Director Paul Brennan’s forthcoming book, concerned when no response was received. B L O W B A C K. It is a noteworthy collection of stories Picking up speed estimated to be between 50 and 55 mph, detailing the dangers that exist when pressure equipment the runaway train crossed several Montreal blocks before a is misused, neglected, or defective. Anecdotal accounts span brakeman activated the emergency air brakes. But the brakes several centuries beginning with the first usages of steam failed to prevent the engine and its cars from smashing through to common pressure-retaining items employed everyday.

36 NATIONAL BOARD BULLETIN FaLL 2012 nationalboard.org

Headquarters, Training and Conference Center, and Inspection Training Center 1055 Crupper Avenue Columbus, Ohio 43229-1183 Phone 614.888.8320 Fax 614.888.0750

Testing Laboratory 7437 Pingue Drive Worthington, Ohio 43085-1715 Phone 614.888.8320 Fax 614.848.3474

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