BULLETIN WINTER 2005 • VOLUME 60 • NUMBER 1 The USS Bennington was Donald E. Tanner destroyed by a boiler explosion off Executive Director the coast of San Diego. The story of Richard L. Allison its 100th anniversary can be found Assistant Executive Director – Administrative on page 12. Robert P. Sullivan Assistant Executive Director – Technical Paul D. Brennan, APR Director of Public Affairs Jami Brunk Young Publications Editor Kimberly A. Miller Publications Coordinator

BOARD OF TRUSTEES

David A. Douin Cover Story Chairman Robert Reetz 12 July 21, 1905 — USS Bennington’s Tragedy Remembered First Vice Chairman 100 Years Later Mark Mooney Second Vice Chairman Donald E. Tanner Secretary-Treasurer E. Dennis Eastman Member at Large Donald J. Jenkins Features Member at Large Yash Nagpaul 3 Some “Truths” About Practice and Education in Member at Large Welding and Joining — By Robert W. Messler Jr.

ADVISORY COMMITTEE 9 Fuel Efficiency and the Economic Case for a Jurisdictional Stephen Rudnickas Boiler Inspection Program — By Geoffrey M. Halley, P.E. Representing authorized inspection agencies (insurance companies) 20 Orlando: Experience the Magic Dr. W. D’Orville Doty Representing the welding industry Dr. Maan H. Jawad Representing boiler manufacturers Greg McRae Representing pressure vessel manufacturers Charles A. Neumann Departments Representing boiler and pressure vessel users William Carey Representing organized labor 2 Executive Director’s Message: Safety: Protection Through Inspection Edward J. Hoveke Representing National Board certificate holders 6 Inspector’s Insight: Transport Tank Code Section Focuses on Different Needs

8 Inspector Notices

32 have You Met . . .? Donald Jenkins, Chief Boiler Inspector, State of Kansas The National Board of Boiler and Pressure Vessel Inspectors was organized for the purpose of promoting greater safety by securing concerted action and maintain- ing uniformity in the construction, installation, inspection, and repair of boilers and 34 People: Board of Trustees Reelects Advisory Committee Members; Chicago’s other pressure vessels and their appurtenances, thereby assuring acceptance and Michael J. Ryan Joins National Board; Ron Scott Remembered for National Board interchangeability among jurisdictional authorities empowered to assure adherence to code construction and repair of boilers and pressure vessels. Service; National Board Mourns Death of Retired Arkansas Chief Inspector The National Board BULLETIN is published three times a year by The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229- 37 Do You Know . . .? Fred Harrison, Director, National Board Testing Lab 1183, 614.888.8320, nationalboard.org. Postage paid at Columbus, Ohio. Points of view, ideas, products, or services featured in the National Board BULLETIN do not necessarily constitute endorsement by the National Board, which disclaims 38 Training Matters: The Future of National Board Web-Based Training responsibility for authenticity or accuracy of information contained herein. Address all correspondence to the Public Affairs Department, The National Board of Boiler and 39 Training Calendar Pressure Vessel Inspectors, at the above address. © 2005 by The National Board of Boiler and Pressure Vessel Inspectors. All rights reserved. Printed in the U.S.A. ISSN 0894-9611. CPN 4004-5415. 40 The Way We Were EXECUTIVE DIRECTOR’S MESSAGE Safety: Protection Through Inspection

BY DONALD E. TANNER, EXECUTIVE DIRECTOR

There are three words that describe the very essence of what “Florida Trail,” participants will take a short eco-walk into the the National Board is all about: Protection Through Inspection. “Central Florida Everglades” and enjoy an exciting airboat tour of the area’s breathtaking natural preserves. TWe liked this phrase so much in 1999 that we used it as a title for a National Board video encouraging audiences to examine the Of course we saved the best for last: the all-day Wednesday out- trust placed in those responsible for public safety. ing to the Kennedy Space Center. All General Meeting attendees are invited to tour these extraordinary space facilities as well as In 2005, the continued relevance of this slogan has not been lost enjoy lunch with an astronaut. And we’ll be back in time to enjoy on those of us who are in the forefront of communicating the an evening of music, mirth, and magic during a performance by potential dangers of boilers and pressure vessels. That is why renowned master magician Giovanni. we are dusting it off and designating SAFETY: Protection Through Inspection as the theme of the 74th General Meeting, May 9-13, I would like to remind those contemplating bringing children that in Orlando. the General Meeting is not a function young people would enjoy. However, understanding the natural attraction of Orlando, we To articulate this important message, we thought it appropriate respectfully request no children under the age of 16 accompany to invite an Opening Session speaker who can enlighten our audi- General Meeting participants to National Board receptions. ence with words of inspiration and wisdom that are a product of his own personal experiences. In that spirit, we found an excep- Because this year’s General Meeting is conducted at a resort ho- tional motivator of men in legendary National Football League tel, we encourage participants and guests to dress in a business- Hall of Fame Coach Don Shula (see page 27). casual style for all hotel events except the Wednesday banquet (where ties and jackets will be the evening attire). In addition to Coach Shula, the General Session will again comprise an outstanding slate of noted industry professionals If you have not yet made plans to attend this year’s General — including American Welding Society Executive Director Ray Meeting, please review the descriptive information found on Shook — who will address a variety of timely technical issues. pages 20-31 of this BULLETIN issue. Or go to the National Board Web site at nationalboard.org where you can both electronically This year, we are pleased to present another excellent guest pro- register for the General Meeting and secure your hotel room. gram that will appeal to just about everyone who participates. And it all begins Monday afternoon with a short motorcoach trip The 74th General Meeting is going to be a great gathering spot to SeaWorld, where guests will have an opportunity to tour the for exchanging ideas, absorbing new concepts, and renewing popular 200-acre marine life adventure park and attend numer- old acquaintances. While it is my hope you will be part of this ous sea-themed shows and exhibits. outstanding international event, it is my particular wish that you will also take home a more profound appreciation for the The following day, guests will take another short trip to visit SAFETY: Protection Through Inspection message. one of Central Florida’s most exclusive retail venues: the shops of Winter Park. Following a specially prepared gourmet box See you in Orlando! ❖ lunch, it’s off to an adventure of another era. At the Tosohatchee 2 NATIONAL BOARD BULLETIN/WINTER 2005 FEATURE Some “Truths” About Practice and Education in Welding and Joining

by Robert W. Messler Jr.

There are few areas of manufacturing fabrication and assembly in which high quality is more essential than in the production of boilers and pressure vessels. Governed by the ASMET Code, every aspect of design and manufacture must follow methodical and meticulous procedures, meet stringent requirements, be supported by rigorous analysis and/or test- ing, with the end-product being right the fi rst time, every time, whether for one-of-a-kind or multiple units. And, behind every task there must be a properly educated and trained person, whether design engineer, process engineer, test engineer, machinist, welder, assembler, mechanic, technician, or inspector. State-of-the-art knowledge, from formal education and training to on-the-job experience, is critical. To be meaningful, such knowledge must be based on truth. Therefore, to be effective, all education — whether formal or informal — must be ever-aware of the truth, or truths, that underlies a discipline or craft. Truth, not lore, leads to strength in knowledge.

It could be reasonably argued that joining, in general, and welding, in particular, are the most critical processes in the manu- facture of boilers and pressure vessels. After all, one of the greatest advancements in boiler safety — as well as in capability — occurred when welding replaced riveting, with every aspect of welding defi ned by the “Code.” Yet it can also be shown that more failures of boilers and pressure vessels (including submarines) occur as the result of faulty welds or improper weld- ing than by any other fabrication-related process. Why do failures, no less catastrophic failures, continue to occur even as knowledge and technology continue to advance? The answer is that underlying knowledge is not always built on real truths.

At least as it pertains to welding and joining, we have either lost track of, never fully understood, or failed to heed some un- derlying truths, both in the practice of and in the education for welding and joining.

3 NATIONAL BOARD BULLETIN/WINTER 2005 - - - - is automated processing, over-control For processing will increasingly Automated processes need to employ what in welding power supplies welding power in what processes need to employ are as “synergic control”: all essential parameters is known for the desired outcome of pre-set (or otherwise interlocked) to switch a person switches scenarios. Give operating known and turn! and knobs to turn, and they will switch plant, manual processing. The good news is that human be The plant, manual processing. and for their creativity ings will then — hopefully — be used Education must focus on teach not their utility. adaptability, complex systems how on processes work, individual ing how and on the optimization of of processes can be integrated, become the not manipulating, will Trouble-shooting, both. key skill. #4 Truth as problematic as under-control. disturbing how It is sometimes surprising, pleasing, and virtually nothing know a car and yet people can drive many need not be best driver world’s The cars work. about how dominated In a world engineer. best automotive the world’s automated processing, process control needs to be robust by to a new para need to move We and simple to the operator. digm of “minimal essential control”: just enough to get the it needs to get done. During the education job done the way we need to and development, process, including research not to do what understand processes well enough to know More to do to control them satisfactorily. as what as much Truth #3 Truth manual processing. the replacement of force demands for Increasing sophistication of products, greater and a better product performance, global competitiveness, in societies that place shrinking pool of skilled tradespeople education will continue to emphasis on higher so much sup virtually to replace, and eventually automation force - - - - because results in practice quality Poor of application, not lack of knowledge Lack NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL quantity of output. What teacher considers thicker term considers thicker What teacher quantity of output. papers better than thoughtful ones? care about quality. Education must instill in new practitioners practitioners new in instill must Education quality. about care with which is a measure of the efficiency that productivity output of acceptable quality is created, not simply the sheer quantity is the driver, then either you or the worker is lucky. is lucky. or the worker then either you quantity is the driver, as their truly want we for what must be rewarded Workers we we say we are serious when they know way That output. Pay a worker for the quantity of his or her output, and that’s for the quantity of his or her output, and that’s a worker Pay If high quality results when will get: quantity. you what Truth #2 Truth high quality is not the basis for reward. future practitioners to apply what they are taught, and never they are taught, and never to apply what future practitioners the consequences could be devastating. compromise when fatigue, or weld-aggravated corrosion — all of which are eas corrosion — all of which fatigue, or weld-aggravated know, we already apply what ily understandable. If we don’t should teach We more? any of knowing is the value what percent of failures are attributable to solidification hot crack percent residual stress, cracking, embrittlement/cold ing, hydrogen ingly reveals the root-cause was avoidable if existing knowl avoidable the root-cause was ingly reveals Rarely do failures arise from edge had only been employed. In welding, probably 98 mechanisms. previously unknown knowledge, leads to most problems. knowledge, analysis of failures of a product or a process overwhelm The Truth #1 Truth recognized and accepted in industry, and articulated and recognized and accepted in industry, practitioners used as the basis for the education of future destined for industry. in driving not just boiler and pressure vessel design and design and not just boiler and pressure vessel in driving design and manufacture of fabricated manufacture, but all these “truths” should be As such, products and structures. There are seven “truths” that prevail or will inevitably prevail prevail or will inevitably “truths” that prevail are seven There

FEATURE 4 FEATURE 5 - - - ❖ to become will have practitioners Joining NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL About the Author About the is professor of materials science & Messler Jr. W. Robert Dr. engineering and director of materials joining at Rensselaer ASM Inter of He is a Fellow NY. Troy, Institute, Polytechnic Society. Welding American of the national and Fellow oversee it, as well as those who accomplish it, need to be accomplish it, as well as those who oversee scientists, engineers, come more sophisticated. In the future, replace hard-hatted riveters will increasingly and physicians creation of microelectronics and The and helmeted welders. of microsurgical limb nanodevices, and the practice will depend on joining and tissue engineering, reattachment a new breed. and execution by oversight Materials changing. are materials because changing is Joining — to meet greater demands because they must are changing they can, as the of designers and consumers, and because and engineer result of more sophisticated materials science as they led the ing. Educators must lead the change starting point is recognizing, accepting, The Renaissance. appears to be underlying truths: and building upon what are to all processes, and 2 of which are universal 5 of which specific to joining alone. A great future, as in the past, must be built on truth! Truth #7 Truth as joining processes become more more sophisticated sophisticated. learned solely on-the- engineer who of the welding era The #1. Truth no other reason than because of if for job is over, and technology As joining increasingly becomes an enabling process for manufacturing, those who not simply a pragmatic - will increasingly become an Joining a mindset, and quality Quality begins as evolve at least as fast as new materials evolve. Otherwise, of evolve. at least as fast as new materials evolve new materials be? will such value what ing will have to also be “engineered” not simply executed. ing will have engineers of all disciplines must be formally educated Young joining focus on having must about joining, and research But, such materials will have to be joined to create products materials will have But, such and join or efficiency, or structures of great size, complexity, for their functionally specific properties, the products and greater structures they can be used to create will display cost. performance, greater robustness, longer life, and lower enabling technology, not just a pragmatic process. not just a pragmatic enabling technology, As materials increasingly become more highly “engineered” a mantra, not just a metric! a mantra, #6 Truth but what is wanted is a sound weld. Why not monitor the Why is a sound weld. is wanted but what must instill quality as outcome and not the inputs? Education what is monitored must be what matters, not what is just matters, not what is monitored must be what what In welds, for example, it is easy to monitor easy to monitor. welding process, speed for an arc current, and travel voltage, hopefully in the formulation of the product to be designed!) hopefully in the formulation of the product better or for worse. and carries through manufacturing, for and ability to monitor quality needs to be embedded, The to find quality elsewhere, with no brand loyalty. If we’ve If we’ve loyalty. no brand with to find quality elsewhere, it is that it is not quality that about quality, learned anything Quality begins in design (or of quality. but lack costs money, leaving it to the customer to check, is unacceptable. is unacceptable. it to the customer to check, leaving and all too willing Consumers are simply too sophisticated, assurance cannot be meaningful as an afterthought. cannot be meaningful assurance worse, of processing or, for quality at the end Checking Truth #5 Truth INSPECTOR Transport Tank Code Section Focuses on Different Needs ’ S INSIGHT

BY CHUCK WALTERS, TECHNICAL PROJECTS ADMINISTRATOR

Throughout the history of the ASME Boiler and Pressure for the construction requirements of transport tanks with the Vessel Code, ASME’s intended goal has been to develop a uniform specific rules, based on Title 49, for new construction and set of construction rules that can be adopted by the jurisdictions continued service, repairs, and alterations of this equipment. Tand promote public safety — thereby reducing the potential for The committee fulfilled its responsibility with the adoption and accidents and explosions. publication of Section XII, effective April 1, 2005.

Today, the scope of the Code is expanding to include rules for In the development of Section XII, some very important concepts continued service, repairs, and alterations. had to be considered. These included establishing rules for pressures, temperatures, and design more stringent than The latest Code to reflect this new direction is ASME Code Section VIII, Div. 1. Section XII, Rules for Construction and Continual Service of Transport Tanks. Section XII, like other codes, concentrates on a The scope of Section VIII, Div. 1 includes pressures from 15 psi particular class of pressure-retaining items. Section VIII focuses to 3000 psi, whereas Section XII includes pressure requirements its requirements on pressure vessels, while Section XII addresses from a full vacuum to 3000 psi. Section XII limits both the thick- requirements on transport tanks. Included in the definition of ness of these units to 38 mm (1 ½ in.) and the minimum metal transport tanks are cargo tanks, portable tanks, rail tanks, and design temperature to a range of -269°C to 343°C (-452°F to ton tanks transporting dangerous goods over the highways, and 650°F). Design requirements are implemented by a system of by rail, sea, and air. Each of these tanks is controlled under the appendices (called modal appendices) for different classifica- Code of Federal Regulations, Title 49, Parts 100 through 185, tions of transport tanks. For the purpose of Section XII, “modal” Transportation. The jurisdictional authority for transport tanks is is defined as the transport of bulk packaging for dangerous goods. the federal government under the Department of Transportation (DOT). Section XII is formatted more in line with Section VIII, Divs. 2 and 3, with respect to each part being specific to an activity. As Section XII was developed under the concept that transported an example, Section XII Part TG, General Requirements, estab- units have different needs than pressure vessels designed, fabri- lishes duties and responsibilities of the manufacturer, owner, cated, and operated in a fixed location. user, and inspector, and scope of activities. Section XII Part TD only addresses design requirements. In other words, each part is Consequently, Section XII was written to recognize different self-contained and not repeated in any other part of Section XII. types of design rules and material requirements that would both withstand severe operating conditions and pass the proof of time Section XII recognizes three classifications of transport tanks: needed to provide reasonable safety to the general public. Proof Class 1, Class 2, and Class 3. of time is based on developing rules for the continued service, re- pair, and alteration for this pressure-retaining item classification. Class 1 transport tanks, operating with pressures in excess of 35 psi, must be inspected by an authorized inspector — and In developing Section XII, the committee was charged with the depending upon the medium — in a manner similar to pressure responsibility of blending applicable requirements of Section VIII vessels constructed to ASME Code Section VIII, Div. 1.

6 NATIONAL BOARD BULLETIN/WINTER 2005 INSPECTOR’S INSIGHT 7 - - - - ASME Boiler and Pres . ❖ NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Title 49, Parts 100 through 185 and the United Recom 49, Parts 100 through 185 and the United Title of Dangerous Goods-Modal mendations of the Transport shall be used in Regulations. This appendix, where possible, of the NBIC and conjunction with Parts RA, RB, RC, and RD of the Tanks” Section XII “Transport Code sure Vessel The appendix will establish the appropriate methods to be The appendix will establish the appropriate inspection used for continued service, repairs, and alterations establish the criteria requirements of transport tanks. It will also and inspector for inspection, reports, document maintenance, of this appendix, the duties and responsibilities. For the purpose on the class designation of the transport depending inspector, individual. tank, must be a National Board-recognized first part is formatted The appendix is divided into two parts. The The second part is for inspections such as Part RB of the NBIC. the methods used such formatted for repairs and alterations and as Parts RC and RD. the impending need to satisfy Section XII requirements, the With task group has established an aggressive schedule for the adop tion of the new appendix. The scope of Section XII covers manufacturing, examination, in and alteration, and will, like spection, continued service, repair, other safety standards, benefit the general public in transport tank safety. - , ------Na (NBIC). This requirement ensures a This appendix is to provide rules for continued service, and alteration of transport tanks (e.g., cargo tanks, repair, rail tanks, portable tanks, and ton tanks) that transport dan gerous goods as required in the Code of Federal Regulations, At the task group’s first meeting, it developed the following first meeting, it developed At the task group’s scope: rized inspection agencies, and jurisdictions. and alteration of transport tanks. The task group is made up of transport rail car manufacturers, representatives from DOT, tanks users, transport tank manufacturers, metallurgists, autho With the publication of ASME Code Section XII, the NBIC Com With mittee established a task group to develop a Nonmandatory Appendix to establish requirements for continued service, repair this system mandates a National Board commissioned inspector this system mandates a National Board commissioned will be involved in the inspections of repairs and alterations. tional Board Inspection Code Additionally uniform system for this activity will be maintained. A major strength of this code is that all repairs and alterations A major strength of this code is that all repairs with the to transport tanks are required to be in accordance requirements is performed by a Certified Individual. A Certified requirements is performed by a Certified holder who is certi Individual is an employee of the certificate fied by the certificate holder. Verification that Class 3 transport tanks comply with Section XII Verification The concept of the Qualified Inspector and the Qualified Inspec The concept of the Qualified Inspector and Section XII and is not tion Organization is unique to ASME Code found in other code sections. accredited by ASME (to QAI-1). The Qualified Inspector probably accredited by ASME (to QAI-1). The Qualified Board. will be qualified (certified) by the National Inspections of Class 2 transport tanks must be performed by a 2 transport tanks must be performed by Inspections of Class employed by a “Qualified Inspection Orga “Qualified Inspector” be nization.” A Qualified Inspection Organization most likely will - - - ❖ . Alternatively, a letter Alternatively, . www.nationalboard.org/NationalBoard/ The certificate holder is required to submit a revised The certificate holder is required to submit of a cover sheet The certificate holder must submit a copy The AIA must submit a letter to the National Board con A guideline for requesting a certificate of extension can If the AIA stays the same and there have been no signifi If the AIA stays the Programs/Pdf/R_Program/R_extend.pdf describing the details may be submitted. There is a fee for the extension; if granted, the National Board may extend the certifi cate up to 90 days on a case-by-case basis. Q. — When a company changes its postal code/address, Q. — When a company changes its is required? but the location is the same, what action A. — application NB-12. No fee is required. AIA, what action is Q. — When a company changes its required? A. — holder, certificate and AIA the both lists that agreement new the of new agreement. or a letter from the AIA acknowledging the has changed, Q. — When the ownership of a company the same, what but the name and location are still action is required? A. — firming an inspection agreement with the new owner. Q. — What is the procedure for requesting a certificate of extension? A. — from be downloaded Q. — When a company relocates its shop to a different relocates its shop to a different Q. — When a company certificate of what is required to get a revised city, authorization? A. — structure (extending from the cant changes in the management or in the quality program, the AIA QC manager to the president) inspection agreement. must acknowledge the continuation of the a change in the If the AIA has changed or there has been a review will management structure or in the quality program, be issued. be required before a revised certificate can - 2003 addendum has Frequently Asked Questions on Frequently Asked “R” and “NR” Accreditation when an Q. — What is required

National Board Inspection Code

The The organization must first revise the QC manual. Manual The organization must The AIA must acknowledge the inspection agreement with FIELD – A temporary location, under the control of the used for repairs and/or alterations to certificate holder, pressure-retaining items. The address is different from that authorization. of certificate holder’s certificate the on shown SHOP – A permanent location, the address of which is SHOP – A permanent location, the address from which a shown on the certificate of authorization, alteration of certificate holder controls the repair and/or pressure-retaining items. acceptance page with his or her signature. NB-163 for “NR”), or Inspector Notices Inspector the new name in writing to the National Board. everything else stays the same, what is required to get a revised certificate of authorization? A. — each permanent location to have its own certificate. Q. — When a company changes its business name but Webster’s Dictionary defines permanent as “intended to last Webster’s paragraph RA-2130(c) is for The intent of NBIC’s indefinitely.” field site? A. — are: defined both terms in Appendix 4. These Q. — What is the difference between a shop and a Q. — What is the difference between • Submitting a letter accepting the change, or • Signing the revised manual and submitting a copy of the verify acceptance of this change by: • Signing line 15 on the revised application (NB-12 for “R,” representative is confident the organization is capable of per representative is confident the organization scope, he or she may forming in accordance with the modified and program changes must then be accepted by an authorized must then be accepted by an authorized and program changes representative. The organization must inspection agency (AIA) Board. If the AIA submit a revised application to the National organization changes its scope from that listed on the its scope from that listed on the organization changes certificate of authorization? A. — NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

INSPECTOR NOTICES 8 FEATURE General view of the second and third pass flue tubes at the rear of a boiler with scale build-up.

Fuel Efficiency and the Economic Case for a Jurisdictional Boiler Inspection Program By Geoffrey M. Halley, P.E.

While the primary purpose of any jurisdictional boiler inspection program is to preserve public safety through the preven- tion of catastrophic boiler failures that can cause the loss of life, personal injury, or property damage, there are several other key reasons to implement a jurisdictional boiler inspection program.

Higher Boiler Operating Efficiency WDuring boiler inspection, the inspector checks both the fireside (surfaces exposed to flame and products of combustion) and the waterside (surfaces containing the boiler water). The fireside is inspected for soot formation due to improper combustion, furnace hot spots (which can lead to catastrophic failure), and water leakage at such points as tube joints. The waterside is inspected for scale formation, caused by impurities in the feedwater (primarily deposited salts of calcium and magnesium) and/or improper water treatment, as well as corrosive effects of dissolved oxygen in the feedwater.

Table 1 shows the effects of soot formation on the fireside of a boiler, while Table 2 shows the effects of scale formation on the waterside of a boiler, in terms of the extra fuel used to meet a given load or operating condition.

Table 1 — Effect of Increasing Soot Thickness in Firetubes on Table 2 — Effect of Increasing Scale Thickness on Boiler Fuel Boiler Fuel Usage Usage Soot Thickness Average Fuel Loss Scale Thickness Average Fuel Loss (inches) (%) (inches) (%) 1/32 2.9 1/64 1.5–4.0 1/16 7.8 1/32 6.0–8.5 3/32 10.7 1/16 11.0–13.5 1/8 13.6 1/8 16.0–20.0

9 NATIONAL BOARD BULLETIN/WINTER 2005 - - - - - Close-up view how scale showing has tubes to flaked off the flue due overheating. This was caused by the debris-filled water legs consid the effectiveness reducing of erably the primary heat surface transfer area (furnace). Reduced Costs Fuel ing a gas price of $5.25/Mcf and a high heating value of 1000 Btu/cu.ft.) will be same boiler $37,035. If this is operated with surfaces, of scale heat transfer 1/8 inch waterside on the there will be an increase 20 percent in fuel to usage of 16 percent depending upon type the of 18 per of scale. an average Using newcent, the of fuel cost will be Cleaning $43,701. heating the surfaces original their back to as-new will condition yield potential period. savings of $6,666 over a 30-day If a boiler is firing has oil and both sooting and scaling conditions, sav then ings be could even impressive. more of pollutants will atmosphere also the emitted to be reduced). Efficiency gains will result in reduced fuel meet usage to a giv emissions. pollutant total lowering therefore demand, load en If fuel usage is reduced, fuel of the willcost the be reduced in same proportion.the if a typical As boiler an example, 300 Bhp gas 80-percentoperates capacity with on natural at 30 days for a baseline efficiency fuel of 82 percent, (assum the cost then - - - - - Lower Pollutant EmissionsLower Pollutant

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL lutants emitted from a boiler installation is to directly related of fuel burned, amount of fuelthe burned amount the can be reduced in boiler by improvements efficiency amount (the that improper combustion is combustion occurring, improper that all probability and in is an increase there that in carbon and particulate monoxide pollutant of pol total quantity emissions the as Since well. of a properly controlled water treatment program is treatment usu water of a properly controlled reasonally the scale for Soot formation. indicates formation cleanliness of the heat transfer surfacescleanliness transfer heat of the (soot or scale forma Digressions in burner burner. of the adjustment tion) and the typically are adjustment cause soot the for and lack formation, faces, these performance can factors optimum the that define be expected pollutant emis in terms of operating efficiency, sions, and fuel cost.the The change time are variableswith that compatibility (from the viewpoint (from the compatibility of furnace heat release), and fuel selection set a boiler are once installation is operating. a properly adjusted burner sur and clean heat transfer With The amount of air of The amount pollutants emitted is dependent upon several factors. Of these factors, burner design, burner/furnace

FEATURE 10 FEATURE 11 - - - ❖ NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL ❖ However, some tradeoffs been have necessaryHowever, regarding the of carbon causedgeneration monoxide lower flame the by required reduce NOx to temperatures emissions. The present legal jurisdictions limit in many is 400 ppm of carbon monox of should it ide. This carbon amount be allowedto monoxide, in occupied areas, and concentrate leak into has potential the causeto over time. health problems industrial a number of larger are boilerWhile there facilities and inspectionwith well-run maintenance programs, there population larger of smaller facilitiesis a much operated by personnel or no knowledge with little of boilers and their and inspectionmaintenance requirements. all boiler Although facilities will benefit from a jurisdictional boiler inspection benefits groupprogram, that it is most. latter this A jurisdic reviewtional boiler annual inspector’s of a boiler installation will in identifying help potential areas and eliminating of con cern, will boiler can aid the be what owner a very in avoiding fuel and will savings. promote situation, expensive - - carrying load the building. of a school Geoffrey Halley, P.E., has worked in the aerospace, nuclear, and boiler industries. He spent 18 years 18 spent industries. He boiler and nuclear, aerospace, the in worked has P.E., GeoffreyHalley, Boiler was be to capable of no longer said cut away showing water leg water with filled showing scale cut away debris, inadequate maintenance. indicating Firebox boiler with rear half of outer wrapper wrapper outer of withhalf rearboiler Firebox Reduced Possibility of Carbon Issues Monoxide Reduction in Unscheduled Outages About the Author: the About working in the areas of boiler R&D and engineering and seven years in the contracting business performing design/build/ services consulting providing Inc.,Consultants, Sji operated has he years 12 past the For installations.boiler on service work to the boiler industry in the areas of design, operations, training, troubleshooting, and product liability. He is director of technical American affairs the for Boiler Association. Manufacturers In an ideal situation, a burnerIn an ideal be should situation, set burn up to in a produces least the of carbonmanner that amount monoxide. blocked air intakes, fans of added or exhaust interest in the boiler genera room the comfort, to can all of which contribute carbon monoxide. tion of excess On the combustion air delivery combustion On the side, it is not unusual to see sizedimproperly openings, air intake partially or totally to the corrosive effects the to also be of flue gas may a condensation factor. the result of improperly installed result of improperly the or modified flue gas venting systems (stacks and breechings) combustion and/or improper air supplies. system Deterioration over time due venting of the A major cause useA major the of fatalities of combustion to related equipment is carbon poisoning. monoxide times is this Many is that while the process may be completely dependent on the be process while the may completely is that boiler the does not actually product. produce boiler, environment in which a boiler in which supplying a processenvironment steam to dollarsis lower priority given much in terms of maintenance equipment process. involved other in the than reasoningThe of event can of schools as cause such shutdown problems the or factories, cases or in extreme prop loss or major of life industrial today’s instances in erty many are damage. There Unscheduled boiler outages typically are result of poor the procedures type this and/or neglect.maintenance Typically - - - Ben Benning exploded, exploded, crew of 197 men 197 men of crew Bennington to San Francisco. Francisco. San to Bennington’s Wyoming was first commissioned in 1891. She in 1891. She commissioned first was patrolled the Hawaiian Islands for nearly nearly for Islands the Hawaiian patrolled ’s Tragedy ’s Bennington Bennington Bennington in the Atlantic and European squadrons. In 1894, she 1894, she In squadrons. European and in the Atlantic (PG-4). Bennington

headed to the Philippines to assist in the suppression of the Filipino the Filipino of in the suppression assist to the headed Philippines to Bennington Bennington patrolled the waters off both coasts during her peacetime mission. Her original Her peacetime her mission. both during coasts off the waters patrolled

. The echo of two devastating explosions sounded through the harbor, halting everyone halting harbor, the through sounded explosions devastating of two . The echo Bennington was to depart from San Diego for Port Harford July 21, 1905. The 21, 1905. The July Harford Port for Diego San depart from to was injured in ways too horrible to mention. Plates ruptured on the starboard side of the ship. As a As the ship. of side the starboard on ruptured Plates mention. to too horrible in ways injured With steam up, the ship was ready to head out for this next assignment. Commander Lucien Young Young Lucien Commander assignment. this next for head out to ready was the ship up, steam With to rumored be to business-related, — reported errands on-shore his with the departure delayed absence his but the incident, prevented have not would presence his Obviously be saloon-related. the being court-martialed Secretary his to by the Navy. of contributed surely loose the on broke hell Young, Commander for in the bay waiting 10:38 a.m., the gunboat At nington also in turn boiler which exploded. another into it sending exploded, A boiler had earshot. within human its and the ship enveloped instantly the boilers from released steam moment, the same In the experience were those through who lived and the spot, on scorched were Men occupants. The The in 1891 placed the assignment the US in 1899. for Island Wake at the atoll claiming the Pacific, of the waters patrol to sent was the there, From Insurrection. service, of tour be the last her would what In the broken-down accompany to being asked before years two ton completed. just tour the tropical from in good spirits surely was In a frightening and tragic moment, the second of four boilers on the gunboat gunboat the on boilers four of second the moment, tragic and frightening a In every most sea instant, an In harbor. Diego in theSan day the peace a new summer’s of shattering the through rampaged that scalding steam by killed the boiler was injured of 200 feet or within man killed by were sailors 65 American final count, At deck. its from leap could a man than faster ship error. human by caused was determine a Court would Inquiry of that the boiler explosion the USS class, the Yorktown of a gunboat as Built a rifles and breech-loading 6-inch six of consisting battery a main with steel, of constructed was maximum- Her 30-caliber two guns. Colt and guns 10 rapid-firing secondary containing battery speed 17.5 knots. 3,392 with was of horsepower indicated to enemy became an the USS 21, 1905, steam of the crew July On be enemy. can an be steam can a friend, or Steam

S Bennington

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

USS USS Later Years 100 Remembered July 21, 1905 July

COVER STORY 12 COVER STORY 13

Bennington anniversary of the of anniversary th Courtesy of the San Diego Historical Society Historical Diego San the of Courtesy . Raised near San Diego, he essentially grew up grew up essentially he . Raised Diego, San near reflects on the circumstances surrounding July 21, July surrounding circumstances the on reflects NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Bennington BULLETIN Oder. Broeck Mr. of the help 1905, with interest special a has and California, Monterey, in resides Oder Mr. in the the for corpsman hospital a lifetime was father His the Navy. with Training the US Naval at worked Oder himself Mr. and Navy, Court of Inquiry ordered Ensign Charles Wade, in charge of the of in charge Wade, Charles Ensign Court ordered Inquiry of Secretary a court-martial, and to department, engineering ship’s Commander ordered subsequently Bonaparte Charles the Navy of court-martialed well. as Young 100 the commemorates year This the footnote, historical disastrous this of observance In tragedy. ’s boiler explosion were indeed were explosion boiler ’s Bennington those starting the boilers to notice this fact. Three men were held held were men this fact. Three notice those to the starting boilers them could against proceedings but the incident, for accountable The killed they since in the explosion. be were carriednot out followed. The cause of the explosion was directly attributed to an to attributed directly was of explosion the cause The followed. of the failure the boiler and second on gage steam unresponsive Events surrounding the surrounding Events killed were 65 sailors All told, history. in the Navy’s a tragic mark soon Inquiry of Court obligatory The injured. were 40 another and scalded bodies was stamped forever in the mind’s eye of onlookers onlookers of eye mind’s the in forever stamped was bodies scalded the shore. from result, water was allowed to enter, causing the gunboat to list. The The list. to the gunboat causing enter, to allowed was water result, a disabled men, screaming and steam hissing scene of graphic with littered a harbor and vapor, of in a cloud shrouded ship ’s Tragedy ’s

Bennington July 21, 1905 July USS Remembered 100 Years Later Years 100 Remembered - stood as disaster. disaster. Bennington Bennington . metrically with two above, one below. Each below. one metrically above, two with three under just the furnaces measured of in diameter. feet from resulting life of loss was a large There the during place took burns. What steam explosion? to it basically of B caused Boiler failure The prompting Boiler D, into backward shoot the of Part explode. to both boilers Center in San Diego in high school and in high school and Diego in San Center the from a history degree With college. Oder earned Mr. Diego, San of University the history in from degree master’s his his of completion with institution same the 1905 on thesis of chairman is he candidate, a PhD Now Catalina Santa at the history department School in Monterey. the board on Describe boilers the Bennington on boilers four The section B in the of forward Boilers A and D in Boilers C and and the boiler room, boilers four of the section. aft the Each then cylindrical— coal-fired, straight-way, — boilers gunboat locomotive as known Each in length. 9 inches 17 feet, measured sym furnaces three arranged contained

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

COVER STORY 14 COVER STORY 15 Courtesy of the San Diego Historical Society Historical Diego San the of Courtesy NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL - - - - - Ben published in published Concord and and Yorktown and her sisters sisters her and was built from 1889 to 1891, certain construction tech 1891, certain to 1889 construction from built was Bennington was only 230 feet long and 36 feet wide, with the boilers located about about located the boilers with wide, 36 feet and long 230 feet only was Bennington was far superior to punching them, and that counter-sinking was necessary. necessary. was counter-sinking that them, and punching to superior far was 1887 clearly stated that “the greatest care is to be taken in punching” the rivet the rivet be to is taken in punching” care greatest “the that stated 1887 clearly holes drillingknew rivet that everyone apparently time, that at Even holes. niques were used that should have seemed dubious even at the time, and and the time, at even seemed dubious have should used that were niques con forthe The specifications accident. the after glaring certainly appeared structionof the Navy Department to adequate long-term maintenance. long-term adequate to Department the Navy When In short, the incident, with all other factors being equal, could have been have could being equal, all factors with other the incident, short, In by attention subsequent and construction initial proper through prevented amidships. So for most of the ship to be filled with steam is easy to believe. be easy to to is filledsteam the with ship of most So for amidships. been prevented? have incident this could How ing water burns, judging from the descriptions of the corpses and the injured. the injured. the corpses and of the descriptions from judging burns, water ing die. in fact, not did more, that response heroic the crew’s to a credit is It nington Ruptured plates of the ship’s starboard side below the waterline allowed water water allowed the waterline below side starboard the ship’s of plates Ruptured the danger created the blasts initial and hazard, additional in, causing flow to scald and steam from came life of loss Most explosion. a magazine and fire of their directional bearings. their directional with clouds of scalding steam. The pervasive steam caused “blackout” condi “blackout” The caused pervasive scaldingsteam steam. of clouds with saved were see and escape they to testified not could later sailors Many tions. gain to men allowing thus shouting, decks below who came comrades by only of the explosion coming from Boiler B probably had a force of about 500,000 about of a force had Boiler B probably from coming the explosion of ofthe force feet.The as 50 much as crewmen threw explosion The foot-tons. ship filling virtually the entire connections, all the steam ruptured explosions explosive force went upward through the main deck, literally blasting the blasting literally deck, the main through upward went force explosive the surge initial expert An that testified officer. one off completely uniform -

- - - - Ben Yorktown and her sisters sisters her and lacked grease extractors! The Navy Navy The grease extractors! lacked Bennington Additionally, the collapse of the crown the crown of the collapse Additionally, a furnace removed the lower on sheet prevented it — a grease extractor — had — had — a grease extractor it prevented beennever the Navy installed, though even all on boilers on grease extractors required — via from reports known was It all ships. on the all boilers of — that the ship nington the problem. to attend not did simply significant longitudinal brace for Boiler B, Boiler B, for brace longitudinal significant , already obsolete and largely considered so at the so at considered largely and obsolete , already Concord taining small, old gunboats. gunboats. old small, taining and smallervessels because so new, few the Navy with remained time, of number a fair had We battleships. to relative being built, were ac kept similarly such, cruisers and of classes various ships, other other many the Navy, to in fairness However, when obsolete. tive placing great stress, even at a steam pressure of about 135 pounds, 135 pounds, about of pressure a steam at even stress, great placing one day from inferior holes, and rivet The rivets the boiler. on and tear and wear normal through substantially weakened and when they most way gave the years, over maintenance of lack so they had been done drilled have properly not would likely in the that note to important is It maintained. subsequently and ships Navy other three least at that out came courts-martial, it suffered not had but sheets furnace collapsed crown suffered had because all in those held! boilers rivets boiler explosions suf provide to ability lose boilers the 15-year-old would Why at speed ship’s the maintain to volume or pressure steam ficient 12 knots? of speed reduced reported the than rather 17 knots design/construction to addition in was reason that main The the proper received the boilers ensured never the Navy problems, was I suspect because this was money maintenance. long-term Theo particularlyPresident and Congress, the nation, and tight, main not battleships, building Roosevelt focused on mostly dore ------

had to sail for Honolulu Honolulu sail for to had ’s boilers, almost 15 years 15 years almost boilers, ’s Benning Bennington Bennington Bennington ’s presence! ’s Bennington went (at Ensign Wade’s recommendation and and recommendation Wade’s Ensign (at went , but I managed to get my hands on the on hands my get to I managed , but

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL ing to its complete collapse and the explosion of Boiler B. The The Boiler B. of the explosion and collapse complete its to ing have would because sheet the device that the crown onto got oil mony showed that as little as one-sixteenth of an inch of oil on on oil of inch an of one-sixteenth as little as that showed mony develop. to heat red of a condition cause could sheet the crown sheet,lead of crown the overheating oil the caused of sheen This It was speculated at the courts-martial that the cause of the of the cause the courts-martial that speculated was at It on settling oil of small amount a relatively involve to had disaster furnace Expert in Boiler B. the testi lower of sheet the crown necessitated necessitated boilers and machinery, the Navy Department refused to allow allow refused to Department the Navy machinery, and boilers saying be to done, the work in Hawaii on going nothing that be noted should 13. It May by Commander Young’s request!) into drydock at Mare Island in Island drydock Mare at into request!) Young’s Commander the explosion, before months three to two 1905, about April–May the on work major requested had Wade and Young although and old, never underwent renewal, thus contributing to the accident. the accident. to contributing thus renewal, underwent never old, Bennington properly. The boilers had a life expectancy of nine years before expectancy years before a life had nine of The boilers properly. renewal; complete needing cally, and the odds for an accident increased. Then, the other Then, the increased. accident an the odds for and cally, as defects such known remedy failed to in: the Navy kicked factor the boilers maintain failed to and valves, sentinel and the safety tions called for inferior construction. Add Add construction. inferior calledtions for install the to having as such this factors to verti of instead horizontally valves safety tion. One even hesitates to blame her build her blame to hesitates even One tion. specifica own when the government’s ers So, from the very from beginning, So, construc her virtue of by just fate tempted while that seems paltry today, that was a lot a lot was that seems paltrywhile that today, the federal and both the to Navy money of in the 1880s. government actual specifications and read it with my own own my with it read and actual specifications measure; a cost-related was it Perhaps eyes. and $522,000 each, about cost these ships was put into the specifications for for the specifications into put was ton I have never been able to discover why this why discover to been never able I have

COVER STORY 16 COVER STORY 17 - - - , and , and and the other the other and Concord , Bennington Yorktown ) and that the Navy had known known had the Navy that ) and those valves so they would not go off and and off go sothose not they valves would Everybody someone. injure accidentally in was known this That that.” knew/knows known widely and Department the Navy done the fleet, nothing with throughout became these valves, replace fix or to that this occurred on all three Yorktown this occurred all Yorktown three that on ( ships class Bennington these ships of years three to two this within defense The 1895). sea (about being at who officers engineering produced teams servedhad on whom all of in the mid-to-late-1890s, ships all the off those went “Oh, essentially, said ‘fixed’ sotime, basically always the crews admitted they never did anything with the sentinel the sentinel with they anything did never admitted NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Bennington of design flaws and the Navy’s failure to provide long-term main long-term provide to failure the Navy’s and flaws design of in the pressure proved, convincingly and argued, was It tenance. — with so exceeded pounds never 135 or probably the boilers Boiler B failed anyway. that 140–145 — but set at valves safety basically on factthe everybody that rested case prosecution’s The on the defense them! However, with bother even didn’t — just valves the that individuals countless of testimony through showed so installed poorly so designed and poorly were valves sentinel pressure practically allthey when even steam the time, activated established Testimony the valve. of the setting near nowhere was valves had been set. The safety valves were supposed to actuallyto supposed were been had valves set.valves The safety bleed until pressure lower thus the boiler and from steam release be could activated. ers faced Young and Wade reason why of the part is a large This the equipment, test and maintain to courts-martial: alleged failure in casesboth prosecution The regulations. Navy by mandated as in nonfunctional resulted had their negligence show to sought overpres to due the explosion caused in turn which equipment, officers two the argued that teams defense The in Boiler B. sure everything done had and conditions all reported thehad unsafe They argued the safety also the ship. maintain to in their power because rather but overpressure, of result a as not failed equipment - had a separate sentinel valve and a separate safety safety a separate and valve sentinel a separate had ’s boilers accounts for her inability to do much better better much do to inability her for accounts boilers ’s pressure, usually set at about 10–20 pounds pounds 10–20 about at set usually pressure, the which safety at the pressure below valve for each of the four boilers. The The boilers. the four of each for valve indication given have should valves sentinel of point a given reaching steam rising of safety valve on Boiler B. Boiler B. on valve safety Bennington to think the steam gage itself was faulty, per se, but simply simply per se, but faulty, was itself gage thinkto the steam the the function of affected have not this would secured, although that no one knew the exact pressure in Boiler B and thus the thus in Boiler B and knew the exact pressure one no that around theorized — some perhaps became excessive pressure reason no is there So, high 200 pounds. as as others 150 pounds, before the explosion, based on testimony that the pressure on that that on the pressure that based testimony on the explosion, before off moved never and zero, to pounds five from fell promptly gage suggested This the explosion. before just there still sitting zero, B had accidentally secured the valve to the steam gage when he when he gage the steam secured to the accidentally valve B had hours two secure cock. This to about theoccurred air meant quiry, which did a rather quick investigation within weeks of the of weeks within investigation quick a rather did which quiry, Inquiry; the Board of of criticism no they is that And explosion. on Boiler a fireman that concluded The board performed well. faulty steam gage. Why did this boiler not have at least one one least at have not boiler this did Why gage. steam faulty valve? safety operating In the Board of of the findings from came the confusion of Part than 12 knots. than a had boilers four of second ship’s the that was determined It did the same thing. Failure to perform major maintenance on on maintenance major perform to Failure thing. thedid same Bennington navies of the world, including the vaunted Royal Navy of Britain, Britain, of Navy Royal the vaunted including the world, of navies - - - - ’s crew crew ’s Bennington been “forced” or built faster than intended. But again, the fact the again, But intended. than faster built or been “forced” functioned, very have certain are would we which valves, safety in the boiler never the pressure strongly indicates activate not did substan been for the source have would which became excessive, attention the careful given Also, error. human tially contributory especially spaces, the engineering to paid had Wade and Young valves had indeed been serviced in March 1905 as Wade and and indeedhad been Wade 1905 as valves serviced in March certainly almost in were valves the safety that and testified, others the accident. the time of at condition functioning but valve, a sentinel have did boilers, the other like Boiler B, So, the of been had the commissioning since basicallyit useless the used test supposedly to the equipment Additionally, vessel. went thus and useless, almost use, to difficult proved valves safety Ameri With all gunboats. three on the crews by years for ignored different found all ships three of the though, crews ingenuity, can with valves, the safety check and test to ways courts- The of valves. the lifting the do required to a bar using the method they usedmartial be in found to board effective in the prescribed done if not even goal, the desired achieving knew well. the Navy something this was Again, manner. we attribute could causes or cause what to analysis, final the In explosion? the equipment some with failure, systemic Navy-wide was it Actually, hu for the potential although in. And thrown definitely failure limited is possibility that situation, in any exists always error man have in Boiler the B might fire suggested testimony Some here. could explode violently when under less than 55 pounds of pres of 55 pounds than less when under violently explode could 1905. before decades for known been had this that and sure, was valve safety whenBoiler be B’s noted: should factor last One not it was noted they experts explosion, the by after examined rust some — although sediment other rust or solid with packed the safety suggests strongly This present. surprisingly, not was, - - - ’s boilers underwent overhaul in March 1905, 1905, March in overhaul underwent boilers ’s Bennington

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL from testimony by several experts. engineering by Theseexperts testimony from boilers circumstances some under evidence that produced even explosion occurred. This, of course, discredited the prosecution prosecution the discredited of course, occurred. This, explosion theory the defense an of favored and overpressure of argument regard in this support clear received case defense The cause. other working condition, did not activate before the explosion, indicat the explosion, before activate not did condition, working most in the boilers the pressure that testimony, other did as ing, — when the pressure — a safe exceed 135 pounds not did likely The safety valves, set for about 140–145 pounds and clearly in clearly and 140–145 pounds about for set valves, The safety Thus, even though poorly designed and installed incorrectly, the installedand incorrectly, designed though poorly even Thus, in the equipment be reliable to the most appeared valves safety class. the Yorktown of rooms engine boiler and when filled with rust, with springs coated with cement, when cement, with coated when filled rust, springs with with needed to because the springs et cetera, sand, damp with packed function. to inch an of hundredth one-one only move to be able function reliably. Additionally, numerous tests done by the Navy the Navy by done tests numerous Additionally, function reliably. in these the defense specifically and for the accident before years function even would valves these safety types of cases showed just four months before the accident, and that Yorktown class class Yorktown that and the accident, before months four just still and overhauls annual with by get could valves safety gunboat However, it was revealed at the courts-martial that in fact the safety safety the fact in that courts-martial the at revealed was it However, on valves stop the Navy from trying to punish Young and Wade for the for Wade and trying Young from punish to the Navy stop they inspect alleging failed to that valves, the safety of condition et cetera. maintain, and while well-known in the Navy Department and throughout the throughout and Department in the Navy whilewell-known not did This it. about done got ever 1895, nothing about fleet by the defense testified that condensing steam left the internal spring spring left internal the steam condensing that testified the defense virtually all half-immersed in water least at valves the safety of Again, in the valves. the springs of rusting causing thus the time, ships’ design, the safety valves could not be installed not vertically could valves the design, safety ships’ be to installed had horizon instead — but manner — the correct for witnesses of array seemingly endless another a result, As tally. As for the safety valves, Yorktown class gunboats again had some some had again gunboats class Yorktown valves, the safety for As Because the of in the Navy. equipment notorious the most of and Wade essentially did nothing wrong by ignoring the sentinel the sentinel ignoring by wrong nothing did essentially Wade and valves. compelling evidence for the defense teams who argued Young Young who argued teams the defense evidence for compelling

COVER STORY 18 COVER STORY 19

- - - BULLETIN after the the after was decommis was ❖ The editors of the the of editors The thank-you a sincere extend this sharing Oder for Mr. to history. of piece incredible What became of the the of became What Bennington explosion? Bennington October 1905, 31, on sioned Island the Mare at sat and five about for facility naval use Sold in 1910 for years. she in Hawaii, a barge as the late until away toiled no was she 1920s. When even useful not and longer scrap, of particularly worthy aware owners, current her her afforded history, her of being sunk at of the dignity sea. NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL crewed those three ships that they operated as well as they did for they as for well did as they operated that those ships crewed three they as did! long as out, some people at the time thought the punishments should should the punishments the time thought at people some out, that periodicals Some outrage harsh. expressed been more have the ex the time of from almost but roll, head didn’t somebody’s — pointed the Navy of outside and — both inside many plosion, Stephen Admiral legendary The Rear system. the Navy’s at fingers publicly wrote even College, War the Naval of a founder Luce, B. gener needed not specialized officers, the Navy engineering that indeed was Young Commander duty. engineering standing alists as about is that but paperwork, his of some signing in not remiss just The evidence Wade. or Young in blaming go can you as far had gunboats class the Yorktown be that to overwhelming proved just were and the Navy, by maintained poorly been badly built, who men and the officers to a testament likely more is It old. plain - - ’s ’s Ben Bennington - - - Courtesy of Courtesy the Department of of Department the — seems closed. securely Cemetery Administration Cemetery Veterans Affairs, National Affairs, Veterans Young court-martialed as Young came the verdicts When well. Bonaparte became deter Bonaparte “example” an make to mined ordered and someone of ry had recommended only only ry recommended had the Ensign court-martial of Secretary the Navy of Wade; appropriate? Inqui the Board of Actually, received essentially a slap on on a slap essentially received was ac wristthe Wade and punishment the Was quitted. Commander Young and and Young Commander only the were Wade Ensign two Young court-martialed. nation and the physical evidence make it the most likely one. likely the most it evidence make the physical and nation actually, it wasn’t equipment failure so much as a failure by the by a failure as so much failure equipment wasn’t it actually, its caused that the ship maintain and equip properly to Navy elimi of process cause, a potential while And only this is demise. overheating of the crown sheet of the lower furnace. Thus, furnace. Thus, the lower of sheet the crown of overheating play, into come have quickly would conditions overtemperature So explode. the boiler to and collapse to sheet the crown causing What we are left with is the strong likelihood that likelihood that strong is the left with are we What be to present oil of a thin layer allowed grease extractors of lack the to the furnaces leading in Boiler of sheets B, the crown on nington the boilers, that avenue of human error — at least on board board on least at — error human of avenue that the boilers,

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Downtown Orlando T short hour’s drive to Atlantic Ocean beaches and only a two-hour drive to the beaches of short hour’s backdrop to the many outdoor activities that the Gulf. Its tropical clime offers a wonderful Orlando offers. City Beautiful.” This lush, colorful town has numer- The nickname of Orlando says it all: “The Leu Harry P. in the sunshine Florida is known for. ous public parks and gardens, all basking nd Orlando offers visitors and residents alike a broad and you will fi But take a look beyond the Magic Kingdom Disney. of Orlando, Florida, you think of Mickey Mouse and Walt There is a good chance that when you think see and do. range of entertaining and cultural things to between Jacksonville and Miami, and a Located in Central Florida, Orlando is midway NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

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Singing Tower offering of Orlando’s Golf enthusiasts will especially marvel at largest camellia collection and formal rose garden in the South. largest camellia collection and formal rose can walk amongst Visitors to the 157-acre Historic Bok Sanctuary lead to a 225-foot ecting pools and winding pathways that refl Gardens has more than 50 acres of green space and features the Gardens has more than 50 acres of green Experience the Magic the Experience Orlando The Mall at Millenia keeps the ball bouncing October through April at the TD Water- keeps the ball bouncing October through is coached by Johnny house Centre. Led by Grant Hill, the team Centre is also home to the Orlando Davis. The TD Waterhouse features high- Predators of the Arena Football League, which The league plays Febru- octane offense and fast-paced defense. enthusiast, Daytona ary through June. And for the motorsports with the mean rst-hand experience USA allows you to get fi speed of NASCAR. sures such as the Orlando Opera, the Bach Festival Society, and Opera, the Bach Festival Society, sures such as the Orlando Orchestra. the Orlando Philharmonic shopping bug while in Orlando, have If you get bitten by the to cure you is right around the corner. no fear: the medicine 52 million square feet of retail space Orlando has more than nd unique bargain hunt at outlet malls, fi and counting. One can boutiques, and power shop at one of gifts at one-of-a-kind largest mall, multi-leveled malls. Orlando’s eight the town’s Saks Fifth The Florida Mall, features anchor stores Nordstrom, and Burdines. Avenue, Orlando Magic NBA’s Sports fans, Orlando has you covered. The Morse Museum of American Art NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL in nearby St. Petersburg. Musically the city keeps time with trea- in nearby St. Petersburg. Musically the city tional Living Fine Art Gallery. And an impressive collection of tional Living Fine Art Gallery. work is maintained at the Salvador Dali Museum Salvador Dali’s world’s largest collection of Tiffany stained glass is housed at the collection of Tiffany largest world’s Art. A glimpse of Charles Hosmer Morse Museum of American a tour of the Inspira- an original Michelangelo can be had with The more than 44 million people who travel annually to Orlando The more than 44 million people who travel option to tour doz- uence have the looking for some artistic infl productions. The ens of art museums and attend various musical make up Orlando’s past and present. make up Orlando’s has sprung more than 4,500 restaurants and numerous cultural has sprung more than 4,500 restaurants and Center and Heritage centers. The Orange County Regional History the peoples who Square is a great place to start learning about now boasts a population of nearly 2 million residents of various of nearly 2 million residents of various now boasts a population Chinese, Japanese, Thai, German, Indian, nationalities, including of ethnicity Italian, Cuban, and Mexican. From this infusion sentinel duty in the area. sentinel duty in the area. an incorporated city in 1875, Orlando Eventually becoming 1857, Jernigan was renamed Orlando, it is said after US soldier Orlando, it is said after US soldier 1857, Jernigan was renamed arrow while on in 1835 by an Indian’s Orlando Reeves, killed referred to as Jernigan after Georgian settler Aaron Jernigan. By after Georgian settler Aaron Jernigan. By referred to as Jernigan

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74 22 74TH GENERAL MEETING 23 ❖ NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Florida Alligator your meal at the world’s largest Hard Rock Café, and sing along your meal at the world’s Margaritaville. If dancing is on the agenda, at Jimmy Buffett’s all guaranteed check out The Groove, CityJazz, or Pat O’Brien’s, are numerous and to get your toes tapping. The retail stores varied, ranging from the eclectic to the practical. Authority wants to The Central Florida Regional Transportation by providing a public make sure you get where you want to go the bus as “Lynx,” bus service throughout Orlando. Known in and around service makes 5,000 stops in the three counties locate a bus stop, simply look for signs with a lynx paw town. To print. Whether you come alone, are traveling with your spouse, or for everyone. Orlando has something bring your entire family, And no matter what it is you end up doing, be it hitting the beaches, riding the coasters, or checking out Epcot, the sunny vistas and warm Florida breezes are sure to delight. The Famous Florida Orange Tree

shopping, and entertainment – open 11 a.m. to 2 a.m. everyday. shopping, and entertainment – open 11 a.m. to 2 a.m. everyday. restaurant is cooking up, rock-and-roll through See what Emeril’s Looking for some late-night fun? Check out Universal CityWalk Looking for some late-night fun? Check out Universal CityWalk Orlando, a sprawling complex packed with restaurants, bars, to 75,000 square feet of entertainment. Best of all, the sailing is free! Suncruz Casino out of both Daytona and Port Canaveral combines free drinks with games, entertainment, and buffets. shore casinos. Sterling Casino boasts the world’s largest casino shore casinos. Sterling Casino boasts the world’s ship, with 1,000 slot machines and 50 table games, adding up be accessed and a real spacecraft can be viewed up close. and the ocean converge in Orlando in the form of off- Las Vegas center’s must-see activities is the IMAX theater, featuring large- featuring activities is the IMAX theater, must-see center’s lms. Everyone will enjoy a hands-on visit to the Kennedy format fi launch pad can where restricted areas of NASA’s Space Center, fers science buffs the opportunity to interact with exhibits such fers science buffs the opportunity to interact and Wired Science. Another of the KidsTown, as NatureWorks, Kids and adults will enjoy exploring the sciences, Orlando-style. Kids and adults will enjoy exploring the sciences, Science Center of- A hub of learning and teaching, the Orlando Pink Flamingo . be made through the be made 9:00 a.m.–2:00 p.m. a.m. 8:00 a.m.–11:00 8:00 a.m.–10:00 a.m...... must Registration Desk Hours:

received by April 7. received by Hotel Reservations: by calling 407.351.5555. in order to obtain refund. Renaissance Orlando Hotel Renaissance Orlando Pressure Vessel Inspectors Pressure Vessel National Board of Boiler and National Board of All room reservations must be All room reservations hotel reservations for attendees. 72 hours in advance of arrival date Room cancellations must be received Room cancellations must be received RATES INCREASE BEGINNING APRIL 8. APRIL INCREASE BEGINNING RATES When calling please mention Group Name: When calling please Hotel reservations Hotel reservations The National Board will not be responsible for The National Board will not be responsible National Board May 8 Sunday, May 9 Monday, May 10 Tuesday,

$ $ $ $ DATE DATE April 7. April Exp. Date ...... Email Fax Mail ...... April 7. April Fax ...... on or before after FEES ENCLOSED AMOUNT To preregister by telephone or fax using your preregister by telephone To and one guest (guest program participant). at 614.888.8320, Ext. 237, or fax 614.888.0750. PREREGISTRATION FORM PREREGISTRATION Additional tickets at $35.00 each Additional guests at $120.00 each Additional Only one registration fee will be charged for each attendee Only one registration fee will be charged for VISA, MasterCard, or American Express, contact the National Board American Express, contact VISA, MasterCard, or Accounting Department Only: AMOUNT $ AMOUNT Accounting Department Only: All checks and money orders must be payable in U.S. dollars to: Inspectors The National Board of Boiler and Pressure Vessel Preference for registration confirmation: Signature VISA Card # MasterCard American Express

(Each includes ONE banquet ticket) Ticket(s) Additional Banquet Additional Guest Fee(s) (includes ONE banquet ticket) Registration fee is $265.00 if received Registration fee is $295.00 if received General Meeting Preregistration Fee Affairs Department at 614.888.8320. Affairs *Additional guests (16 years of age or older) may register for a fee of $120.00. *Additional guests (16 years of age or older) may register asked to contact the Public Those requesting special or handicapped facilities are Additional Guest Address Additional Guest Guest Address Guest Additional Guest* Name Email Guest Name Address Company/Affiliation Company/Affiliation Telephone Name on Badge Name on Badge Title Name NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

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74 24 74TH GENERAL MEETING 25 - - - NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL ing the breathtaking atrium or the Orlando skyline. The Renaissance Orlando Resort is also among the largest full- service conference facilities in the area with 185,000 square fragrant flowers, and a spectacular gilded Venetian aviary alive Venetian fragrant flowers, and a spectacular gilded lobby is home to hun with brilliantly colored tropical birds, the dreds of rare fish holding forth in a massive freshwater Koi pond fed by a dramatic, cascading waterfall. Among first-class resorts and convention facilities, this outstand ing award-winning resort offers gleaming amenities, superior comfort, and deluxe accommodations. Among the largest guest rooms in Central Florida, each offers nearly 500 square feet of elegantly appointed living space, many with balconies overlook -

— among the world’s largest resort atrium lobbies — soaring — among the world’s foliage, plentiful 10 stories high. Adorned with towering tropical the luxurious Renaissance Orlando Resort. sunlit atrium Upon arrival, guests are greeted by a dazzling paradises, and a myriad of fantasy attrac sunshine, lush tropical it: Orlando is the place to be for There is no doubt about central to it all than tions. And there is perhaps no hotel more RENAISSANCE ORLANDO RESORT RENAISSANCE at SeaWorld ❖ unwind at one of the resort’s distinctive lobby or poolside unwind at one of the resort’s lounges. the Renaissance Award, In addition to the AAA Four-Diamond Orlando Resort has been honored with the prestigious Pinnacle and the Award the Aster Award, the Gold Key Award, Award, of Excellence. Come enjoy all Orlando has to offer — virtually at your doorstep — at the award-winning Renaissance Orlando Resort! - - During the day, guests can choose from a variety of indoor During the day, all food tastes — or or outdoor dining options — catering to lighted tennis courts, a volleyball/basketball court, and an Olym lighted tennis courts, a volleyball/basketball pic-size swimming pool. Space Center — are all within an easy 90-minute drive. Space Center — are all within an easy 90-minute Resort include three Other amenities at the Renaissance Orlando only 10 minutes of the resort and more than 18 additional sights only 10 minutes of the resort and more than and Kennedy — including Busch Gardens, Cypress Gardens, in 15 minutes (via round-trip shuttle service) of Universal Studios in 15 minutes (via round-trip shuttle service) and Magic Kingdom, Epcot Center, Disney World Florida, Walt attractions are within MGM Studios. In all, at least 17 prominent And it’s all close to where guests want to be. Located directly all close And it’s of Florida and across the street from the renowned SeaWorld Orlando Resort is with adjacent to Discovery Cove, Renaissance feet of meeting space including a dynamic 56,000-square-foot including a dynamic 56,000-square-foot feet of meeting space convention center. NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

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74 26 74

Featured Opening Session Speaker TH Legendary Coach MEETING GENERAL Don Shula

You Can Inspire Anyone To Be A Winner

When it comes to inspiration, few surpass the words and Coach Shula’s teams reached the playoffs a remarkable 20 times wisdom of legendary Pro Football Hall of Fame coach and busi- in 33 seasons. In that span, he suffered only two losing seasons. nessman Don Shula. In 1995, he concluded his 33rd season as an NFL head coach W and his 26th season as head coach of the Dolphins. Coach Shula is perhaps best remembered for taking the Miami Dolphins in 1972 to the only undefeated season (17-0) in Coach Shula has been the recipient of numerous awards, includ- National Football League (NFL) history. As head coach of the ing the prestigious 1993 Sports Illustrated Sportsman of the Year Dolphins (1970-95) and the Baltimore Colts (1963-69), he holds Award, 1994 Horatio Alger Award, the Bert Bell Award, and the the NFL record for the most career victories (347), surpassing the Pete Rozelle Award. His unanimous election to the Hall of Fame immortal George Halas in 1993. At age 33, the youngest head in 1997 was the ultimate honor in a career full of record-setting coach in the history of the NFL, Coach Shula went on to appear accomplishments. in more Super Bowls (6) than any other coach. He is only one of two coaches to reach the Super Bowl three straight seasons In addition to his considerable charity work, Coach Shula is (1971-73), and is only one of five coaches in NFL history to win equity partner in Don Shula’s Hotel & Golf Club and Don Shula’s consecutive Super Bowls (1972-73). Steak Houses, Inc. ❖ 27 NATIONAL BOARD BULLETIN/WINTER 2005 ❖

This outdoor tour requires a modest amount of walking.

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Registrants are not permitted to attendintended the Monday for designated or Tuesday guests. tours This policy will be strictly enforced. camera! NOTE: Wear comfortable walking shoes. And don’t forget to bring your Wear — their sights, sounds, tastes, and people. Or take in the Wild Arctic Exhibit where you’ll be plunged into the frozen north and the icy habitat of beluga whales and polar bears. — at 25 feet in length and fi ve tons — literally the biggest star ve tons — literally — at 25 feet in length and fi and share the romance east of Hollywood! Visit The Waterfront cities built around the sea and excitement of all the world’s in the wild antics of manatees, sea lions, penguins, dolphins, in the wild antics of manatees, sea lions, Show and meet and much more. Enjoy the Shamu Adventure attractions. And it’s conveniently located across from the attractions. And it’s bus trip, guests can Renaissance Orlando Resort. After a quick killer whales, and take get up close and personal with sharks and SeaWorld is the world’s most popular marine life adventure park most popular marine life adventure park the world’s is SeaWorld shows, and animal featuring 200 acres of sea-themed rides, General Meeting! most delightful tours ever offered at the one of the It’s

Program Guest All tours depart from Convention Center parking lot. All tours depart from Convention Center parking 1:30 p.m. – 4:30 p.m. SeaWorld Adventure SeaWorld Monday, May 9 May Monday,

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74 28 74TH GENERAL MEETING 29 day, May 10 day, Guest 9:30 a.m. – 5:00 p.m. Winter Park Shopping Tues All tours depart from Convention Center parking lot. All tours depart from Convention Center parking Luncheon & Air Boat Tour Luncheon & Air Boat NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Program ❖

Afternoon refreshments strictly enforced. Registrants are not permitted to attendthe Monday or Tuesday tours intendedfor designated guests. This policy will be NOTE: provided. This outdoor tour requires a modest amount of walking. are recommended. people. Again, comfortable walking shoes tures, including alligators and Ameri- no better can bald eagles. There’s rst fi way to relive the life of Florida’s natural landscape. Learn about the fresh water eco-system of the St. River and its wonderful crea- John’s certifi ed eco-guides lead a short 30-minute walk into Central Florida’s pristine wilderness before boarding guests on 15-passenger pristine wilderness before walk into Central Florida’s ed eco-guides lead a short 30-minute certifi airboats to explore the picturesque clothiers, bookshops, specialty merchants, and fi ne jewelry stores. and fi clothiers, bookshops, specialty merchants, Here, “Florida Trail.” General Meeting guests will be transported to the Tosohatchee Following a scrumptious gourmet box lunch, streets. Stroll down Park Avenue to visit an abundance of trees overhanging brick-lined streets. Stroll down Park Avenue Winter Park is a quaint neighborhood with nd over 100 will fi the ultimate shopping experience. Within walking distance, guests small boutiques and galleries that make this Everglades. of the Central Florida won’t forget: shopping at the elegant shops of Winter Park and a rustic ecotour a day guests It’s ❖ General Meeting, this is a day you won’t want to miss! th day, May 11 day,

Government-issued photo identifi cation required to enter the Kennedy Space Center. Government-issued photo identifi

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL NOTE: Sure to be a highlight of the 74 After lunch, guests will view two awe-inspiring fi lms on fi ve-story IMAX theater screens, and have an opportunity to visit Kennedy ve-story IMAX theater lms on fi After lunch, guests will view two awe-inspiring fi Space Center shops. delicious three-course lunch. Everyone will have an opportunity to ask questions and have photos taken with the astronaut. souvenir. each will receive an autographed Additionally, the Apollo missions is brought into full perspective. the Apollo missions is brought into full perspective. Guests will also enjoy the experience of dining with an astronaut and hearing fantastic space exploration stories while enjoying a view of America’s space history and visitors will even get a good look at the Vehicle Assembly Building where space shuttles are space history and visitors will even get a good look at the Vehicle view of America’s V Center where the spirit of nal destination is the Apollo/Saturn fi launch platform. Your assembled, tested, and placed on a mobile to three other exciting areas of the center. Guests will overlook the “clean room” where NASA technicians get ready to launch actual Guests will overlook the “clean room” where to three other exciting areas of the center. of this tremendous Full-sized module mock-ups give guests a true understanding components of the International Space Station. Gantry will provide a panoramic next leap into space exploration. The LC-39 Observation space construction project – the world’s The adventure begins at the visitor complex where guests walk The adventure begins at the visitor complex traveling by motorcoach through a life-sized rocket garden before internal workings. the Kennedy Space Center’s exceptional view of Get ready for a full-day tour providing an

Program Guest All tours depart from Convention Center parking lot. All tours depart from Convention Center parking 9:00 a.m. – 4:30 p.m. Kennedy Space Center Tour Kennedy Space Center Wednes

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74 30 74 TH Preliminary Program MEETING GENERAL for the 74th General Meeting of The National Board of Boiler and Pressure Vessel Inspectors

Monday, May 9

Opening Session 10:15 a.m. You Can Inspire Anyone To Be A Winner Don Shula, Former Head Coach* National Football League Hall of Fame

General Session 1:00 p.m. Boiler and Combustion Safety: What You Don't Know Can Kill You! John R. Pushkar, P.E., Owner Reminder: General Meeting details Combustion Safety, Inc. can also be found on InfoLink! located on the National Board Web site at 1:30 p.m. Welding Inspection: You Win With People nationalboard.org.

Ray W. Shook, Executive Director To obtain a discount of $30, all American Welding Society preregistration forms and fees must be received by April 8. 2:00 p.m. Break Preregister beginning January 14 via 2:15 p.m. Recycling Energy: Identifying and Eliminating email with your credit card through Losses in Pressurized Steam Systems to InfoLink! on the National Board Web site Generate Free Electricity at nationalboard.org. Sean Casten, President Turbosteam Corporation Or mail the preregistration form with your check or money order to: The 2:45 p.m. Understanding the Importance of National Board, 1055 Crupper Avenue, Insulation and Lagging Columbus, Ohio 43229.

Gary Bases, President Distribution of any and all literature, BRIL, Inc. other than informational materials published by the National Board and 3:15 p.m. ASME: 125 Years of Achievement ASME, is strictly prohibited at the Domenic Canonico, Vice President General Meeting. ASME Pressure Technology Codes and Standards All photos taken by the General 3:45 p.m. Inspection Considerations for Pipe Hangers, Meeting photographer will be available Restraints, and Snubbers for purchase at deanwilliams.net at the meeting’s conclusion. ❖ George T. Mulvaney, Partner Ocean State Technical Services

* Autograph session with Mr. Shula to follow Opening Session. 31 NATIONAL BOARD BULLETIN/WINTER 2005 HAVE YOU MET . .? Donald Jenkins Chief Boiler Inspector, State of Kansas

To those who meet him, Kansas Chief Boiler Inspector Don Jenkins is quiet. Soft-spoken. Reflective.

TBut very few know that beneath this reserved exterior is the heart and soul of . . . a big-game hunter?!

When it comes to putting food on the table, Don can do it. Many times with a single, well-placed round. And chances are that round was made in his basement — not too far from where he processes the meat he and his wife will often enjoy during evening dinner.

Born in Aitkin, located in north-central Minnesota, it was hard for young Don Jenkins not to grow up an outdoorsman. “Having lived in the woods, it was natural to hunt and fish all the time,” he volunteers with a nod. The son of a dairy farmer dad and store clerk mom was one of four Jenkins children brought up in the small Midwest resort community 125 miles north of Minneapolis.

Helping his dad work the farm, Don spent considerable time fixing KANSAS MUSEUM OF HISTORY tractors, plows, and a myriad of other agricultural implements.

“Probably the most distinctive recollections I have growing up a career in mechanical engineering. “Not surprising for a farm involve the bone-chilling Minnesota mornings,” he offers while boy,” Don quips with a smile. shaking his head. And then repeating himself for emphasis: “Bone-chilling.” Entering machinist mate school in 1962, Don focused on propul- sion in preparation to become an engine crew member. During The Minnesota cold, he surmises, was partially responsible for this time, he was exposed to a variety of different propulsion his decision to leave Aitkin and join the U.S. Navy. Eschewing components including those with which Don would become inti- farming in favor of finding a trade in a warmer climate, he signed mately familiar: boilers. with a local recruiter only after the recruiter promised to delay Don’s formal enlistment “until after deer season.” Assigned to the USS Wiltsie as a fireman, he joined the ship in Pearl Harbor before heading to ports of call in San Diego (home On a cloudy Minnesota morning, it was -20 degrees the day Don port), Japan, Hong Kong, Philippines, and Formosa. In 1965, left to join the service. Putting the future Kansas official through Don completed a tour of duty in Vietnam before returning to San a battery of tests, the Navy determined he was best suited for Diego and tending to a very important priority: getting married.

32 NATIONAL BOARD BULLETIN/WINTER 2005 HAVE YOU MET . . .? 33 s - - - ) BULLETIN ❖ NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL associates and friends to visit him and Ruth in Topeka for some associates and friends to visit him and Ruth in Topeka “great Kansas beef.” Just don’t come between September and January. hunting season. That’s Following the death of Kansas Chief Boiler Inspector Bill Brown Following the death of Kansas Chief Boiler position despite in September 1995, he applied for the chief’s “Interest having some trepidation about his own qualifications. wanted someone who could write regulations,” Don Kansas ingly, in that area.” explains, “and I had plenty of experience became Kansas’ In January 1996, the “farm boy” from Minnesota Picking up where he left off at the Bureau chief boiler inspector. program forward by of Indian Affairs, Don has moved the Kansas and inspectors. increasing both the number of state inspections still gets out to person Not unlike his days with the bureau, Don ally perform some of the inspections involving state and federal installations to keep himself “directly involved in the process.” having served on a variety of He is also involved in the industry, ASME subcommittees and National Board committees. Recently, Don was elected to the National Board Board of Trustees. Don doesn’t miss Minnesota, and even though he must still indulge an occasional “bone-chilling” morning or two, Kansas suits him just fine. And he extends a personal invitation to all his later, having “a better understanding of the questions.” having “a better understanding later, the position of chief boiler inspector for In 1982, Don assumed Affairs in Albuquerque, New Mexico. In ad the Bureau of Indian to efforts to bring the organization up dition to his considerable with helping to secure federal funding code, Don is also credited training school (see Fall 1993 for and pioneering a boiler operators. for Native American no boiler explosions When bureau officials decided in 1995 that school was abolished. meant no need for a training program, the of Indian Affairs, Don’ After 29 years of service with the Bureau job was also eliminated. But not his spirit. - - wedding th In 1978, Don traveled 220 miles to Phoenix to take the exam. And failed. But he was successful on his second attempt a year and pressure vessels and enlisted the help of my assistant fire and pressure vessels and enlisted the help of my assistant fire chief — a teacher — to tutor me in algebra,” he explains. started to see his career in a different light. Deciding to obtain a National Board Commission, he prepared himself for the exami on boilers nation. “I gathered just about every book I could find area fire school. native Minnesota the enough, not were responsibilities these if As for the plant’s 24/7 operation and maintenance. Additionally, he Additionally, 24/7 operation and maintenance. for the plant’s Navajo fire chief and taught at the bureau’s City’s served as Tuba Three and a half years later, the future National Board member Three and a half years later, City, in Tuba central heating plant transferred to the bureau’s Arizona. Although not having a specific title, Don was responsible position, Don and Ruth relocated to a remote bureau boarding position, Don and Ruth relocated to a remote from Flagstaff. school on the Navajo reservation 130 miles Arizona community of Kaibeto. “It was with the Bureau of Indian Arizona community of Kaibeto. “It was with road.” Accepting the Affairs at a location 25 miles from a paved Visiting the local post office to search for federal job vacancies, the local post office Visiting in the northern Don learned of an opening for a boiler operator machine operator in a paper mill.” Within four months, however, four months, however, machine operator in a paper mill.” Within for work. But not the mill closed and Don found himself looking for long. “I had a brother in Phoenix,” he notes with an ever-present an ever-present “I had a brother in Phoenix,” he notes with our new life in Minnesota accent, “and he sold us on starting was offered a job as a Arizona. Almost as soon as we arrived, I second class Don Jenkins and his new bride headed to Arizona. second class Don Jenkins and his new bride Thinking he had fulfilled his military obligation in January of Thinking he had fulfilled extended an additional four months. service was 1966, Don’s hesitation, newly discharged machinist mate without That May, two grown sons, Ruth and Don will celebrate their 40 two grown sons, Ruth anniversary this fall.) brance. “We wrote each other after I left for the service and our wrote each other after brance. “We long distance.” (The parents of relationship sort of developed “Ruth and I met in high school,” he explains with fond remem “Ruth and I met in high William Carey William Edward J. Hoveke Edward Charles A. Neumann - - -

NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL ❖ Pressure Vessel Rules, and as a trustee of the National Boilermaker Industrial Health and Welfare Trust. Welfare and Health Industrial Boilermaker National the of trustee a as and Rules, Vessel Pressure Hoveke was first elected in 2002. His new term will expire in August 2007. A resident of Chicago, Mr. he has served as president of the Industrial Council of Northwest Chicago and as president of the he has served as president of the Industrial Council of Northwest Chicago and as He also served on the Illinois Board of Boiler & Contractors Association of Illinois. Boiler & Tank senting National Board certificate holders. Company in Chicago since 1979. In that time, Hoveke has been president of Hudson Boiler & Tank Mr. Mr. Neumann was first elected in 2000. His new term will expire in August 2007. Neumann Mr. J. Hoveke to the Advisory Committee repre has reelected Edward the Board of Trustees Additionally, A resident of Penfield, New York, Mr. Neumann holds professional engineer licenses in the states of Neumann holds professional Mr. A resident of Penfield, New York, and Colorado. New York With the company since 1970, he has held positions as structural/project engineer and project manager. project and engineer structural/project as positions held has he 1970, since company the With boiler and pressure vessel users. is pressure vessel specialist/quality assurance manager for Eastman Kodak Company. Neumann Mr. Mr. Carey was first elected in 2002. His new term will expire in August 2007. Carey was Mr. representing Committee Advisory the to Neumann A. Charles reelected also has Trustees of Board The A certified welder and veteran of the US Air Force, Mr. Carey resides in Northborough, Massachusetts. Northborough, in resides Carey Mr. Force, Air US the of veteran and welder certified A ermakers, Iron Ship Builders, Blacksmiths, Forgers and Helpers, with more than 36 years’ experi Builders, Blacksmiths, Forgers and Helpers, ermakers, Iron Ship with the IBB for more than 25 years. He has been ence in the industry. representing organized labor. labor. representing organized T Brotherhood of Boil the international president of the International Carey serves as assistant for Mr. Carey to the Advisory Committee has reelected William of Trustees Board The National Board’s Board of Trustees Reelects Reelects of Trustees Board Advisory Members Committee

PEOPLE 34 PEOPLE 35 Ron Scott Michael J. Ryan - essel Unit. anner, National anner, ❖ NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL

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Joins National Board Joins National Chicago’s Michael J. Ryan Michael Chicago’s T Mr. Ryan resides in Chicago with his wife Christine and two daughters. He holds National Board resides in Chicago with his wife Christine and two daughters. He holds National Ryan Mr. Commission No. 12812. cial served in the US Marine Corps from 1971 to 1973. The Chicago official served in the US Marine Corps from 1976 to 1980, and became a journeyman boilermaker in 1980. He is a member of Local One Chicago a journeyman boilermaker in 1980. 1976 to 1980, and became a City of Chicago Stationary Engineer License. Boilermakers and has boiler inspector for the City of Chicago. boiler inspector for the an apprentice boilermaker from for the City of Chicago in 1985. He was began working Ryan Mr. is chief Board representing Chicago, Illinois. He has been elected to the National Michael J. Ryan M Mr. Scott is survived by his daughter Robin Hillemann and companion Ellie Grainger. Grainger. Ellie companion and Hillemann Robin daughter his by survived is Scott Mr. “Ron was a true asset to the National Board. His dedication to government affairs, training, and the “Ron was a true asset to the National Board. His dedication to government affairs, T field staff was exceptional. Our hearts are saddened by his loss,” expressed Donald Board Executive Director. Mr. Scott held National Board endorsements “A,” “B,” “N,” “S,” “I,” “IS,” “C,” and “CS.” Mr. From 1994 to 1999, Mr. Scott was a National Board Governmental Affairs and International Repre From 1994 to 1999, Mr. field staff. sentative. In 2002, he retired from the National Board’s also worked for the State of California for 10 years as a safety engineer in the Pressure V also worked for the State of California for 10 years as a safety engineer in the Pressure the National Board for nearly 20 years, he served as both training instructor and consultant. With Mr. Scott had more than 40 years’ experience in the boiler and pressure vessel industry. He was a more than 40 years’ experience in the boiler and pressure vessel industry. Scott had Mr. and US with Kemper Insurance Company, nuclear inservice inspection supervisor for the Western Scott Mr. Company. Insurance Royal for supervisor inspection nuclear a as Europe in years four spent California. employee Ron Scott. He resided in Hemet, National Board The National Board regrets to announce the October 15, 2004, passing of former Ron Scott Remembered for Ron Scott Remembered Service National Board Sam E. Lyons - . Lyons held numerous held numerous . Lyons , assistant chief inspector, staff , assistant chief inspector,

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NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL Lyons. Lyons. tended to Mrs. Lyons and family.” and tended to Mrs. Lyons Wilmer and brother, Lyons; and Todd is survived by his wife, Karen; two sons, Chris Lyons Lyons Mr. “Sammie Lyons will certainly be missed. His contributions to the boiler and pressure vessel industry will certainly “Sammie Lyons “Our sympathies are ex noted National Board Executive Director Donald E. Tanner. were many,” He was a member of the Masonic Lodge, US Submarine Vets, VFW, Vets Inc., and BPO Elks. Inc., Vets VFW, US Submarine Vets, He was a member of the Masonic Lodge, Board Commission No. 8025 with “A” and “B” endorsements. Board Commission No. 8025 with “A” and served as a member of the National Board from 1998 to 2003. Lyons Mr. In 1992, Mr. Lyons went to work for the Arkansas Department of Labor, Boiler Division, as deputy went to work for the Arkansas Department of Labor, Lyons In 1992, Mr. National He became chief boiler inspector in 1994, and retired in July 2003. He held boiler inspector. positions, including supervisor boiler and pressure vessel inspector positions, including supervisor boiler and regional supervisor inspector for engineering services. He retired in 1990. and engineer, Navy and served 22 years, retiring in 1975. Navy and served 22 years, retiring in 1975. and Insurance Co. in 1975, Mr Joining Hartford Steam Boiler Inspection boiler inspector Samuel “Sammie” E. Lyons. He resided in Ash Flat, Arkansas, and was 71 years old. He resided in Ash Flat, Arkansas, and was “Sammie” E. Lyons. boiler inspector Samuel T graduation, he joined the was graduated from Riverton (Kansas) High School in 1951. After Lyons Mr. death of former Arkansas chief regrets to announce the October 5, 2004, The National Board Retired Arkansas Chief Inspector Arkansas Retired National Board Mourns Death of Mourns Death National Board

PEOPLE 36 DO YOU KNOW . .?

Fred Harrison Director National Board Testing Lab

Fred Harrison had a milestone birthday in July of ’04. Look- ing back on his first 50 years of life has offered him quite a view.

F“Turning 50 makes you reflect on life and your purpose in it. I have learned to not be so absorbed in the day-to-day. Appreciate what you have,” he says philosophically.

And so goes a conversation of much length with the National Board Test Lab’s director. Fred is upbeat and positive, wise and It was during his time at OSU that he met Michele, and shortly perceptive. It is apparent he embraces life. thereafter that they were married. Now residents of the Colum- bus suburb of Westerville, they are the proud parents of two As test lab director, Fred oversees the pressure relief depart- grown daughters. And extra-proud grandparents of six-year-old ment, which includes nine employees who conduct nearly 1,800 grandson Gabriel. tests on safety valves a year. “Being a grandparent is the most amazing thing! The parenting If the name Harrison rings a bell, it is likely because of Executive rules completely change. A little one reminds you of what it was Director Sam Harrison, who led the National Board from 1968 to like to discover things for the first time. I am in awe of him,” 1985. Sam was Fred’s father. In fact, Fred’s birth announcement Fred reveals with a smile. ran in the BULLETIN when the elder Harrison was chief inspec- tor for North Carolina. With his naval background, it makes sense that Fred enjoys spending time on the water. More specifically, on Eagle’s Wings, With a start like that, it is easy to see why this safety official was the sailing vessel he and his wife utilize nearly every weekend of interested in working with the National Board. nice weather.

As a mechanical engineering student at The Ohio State University, Between family, his boat, his church, and work, this history buff Fred worked part-time as a technician at the test lab when it seems to be able to put it all into perspective. “Love for my fam- was located at the Picway Generating Station. After graduation, ily and faith in God are the most important things in life to me. he joined the Navy in 1977, did a five-year tour of duty aboard Everything else is secondary.” nuclear-powered subs, and rejoined the National Board as Test Lab director in April 1982. Might this be the wisdom of 50 years of life experiences?

“I had been involved with designing test equipment and proce- “I am just getting started,” Fred says with a laugh. ❖ dures for the lab before I left for the Navy. I did not intend to come back to the National Board; I wanted to pursue a career “Do You Know . . .?” is a BULLETIN feature introducing in nuclear energy. But the timing of the job offer was uncanny. I readers to the dedicated men and women who comprise the couldn’t say no,” Fred explains. National Board staff. 37 NATIONAL BOARD BULLETIN/WINTER 2005 TRAINING MATTERSTRAINING The Future of National Board Web-Based Training

BY RICHARD MCGUIRE, MANAGER OF TRAINING

The National Board considers training a vital part of what CIs) will find these courses particularly beneficial by employing makes a complete boiler inspector. That is why it was incor- them to satisfy the new three-year training requirement. porated in the Rules for Commissioned Inspectors (NB-263), requiringT inspectors to receive training every three years in Each applicable section is summarized and explained on the pass- order to renew their commission. One great way to satisfy this word-protected National Board Web site, where students may requirement is to attend a National Board training course held at review the material to fit their schedules. This program helps our Training and Conference Center in Columbus, Ohio, or select prepare students for the examination and to ultimately achieve upcoming courses in Houston and Minneapolis. certification by their employer. Currently, the National Board’s online program is the only online training for CI certification. Another option for students is Web-based training programs now online and under development by the National Board. Since Later this year, the National Board will introduce a training the online CSD-1 course was launched in March 2004, more program addressing the National Board Inspection Code (NBIC). than 120 individuals have taken advantage of the opportunity to Five courses focusing on the NBIC will be offered, starting with update their knowledge of CSD-1 requirements. Because several Part RB. As with other National Board online courses, the Web National Board staff members served on the CSD-1 committee, site will easily navigate the student through the requirements of this new course uses firsthand knowledge, ensuring the student Part RB, explaining and applying the various paragraphs of the Code. receives timely and insightful instruction. Those who have never been exposed to an online format will find the experience to be a Part RB will be followed with courses on RC, RD, RA, and the new remarkably easy and convenient exercise. appendix for installation recommendations. These interactive courses will use quizzes and examinations extensively to help the The latest online offering is a training program for Certified student gauge his or her comprehension level. Individuals (CIs). Manufacturers call upon a CI (employed by the manufacturer) when the Code does not require an authorized Other programs on the drawing board include ASME Section VIII, inspector. The CI’s responsibility is to ensure the manufacturer Div. 3, accident investigation, and repairs to heat recovery steam meets all ASME Boiler and Pressure Vessel Code requirements generators. before the Code Symbol stamp is applied to the vessel. Web-based training is an easy way to stay current with today’s Five different areas of study are offered as part of the CI program: changing world. It’s convenient and available whenever the electric boilers, cast-iron heating boilers, miniature unfired pres- student is. And every National Board student can be assured of sure vessels, reinforced thermoset plastic pressure vessels, and top quality training materials — supported by an experienced, pressure relief valves. The courses contain valuable knowledge eminently qualified staff — all reasonably priced. To find out on each of these subjects, even for those who do not wish to more about the National Board’s Web-based training programs, become a CI. Commissioned inspectors (not to be confused with visit nationalboard.org. ❖

38 NATIONAL BOARD BULLETIN/WINTER 2005 TRAINING CALENDAR 39 . nationalboard.org cancellation. For additional information regarding seminars Training and courses, contact the National Board Columbus, Avenue, Department at 1055 Crupper 614.888.8320, ext. 300, or visit the Ohio 43229-1183, site at National Board Web All seminars and courses are held at the National Center in Columbus, and Conference Training Board Ohio, unless otherwise noted, and are subject to Check/Money Order Enclosed # P.O. Transfer Payment by Wire VISA MasterCard American Express NATIONAL BOARD BULLETIN/WINTER 2005 NATIONAL City State/Zip Telephone Fax Email NB Commission No. (check one): Information Payment Cardholder REGISTRATION FORM REGISTRATION to and date(s) you wish the seminar/course(s) Please circle print. attend. Please Mr. Name Ms. Mrs. Title Company Address Card # Expiration Date Hotel Reservations list of hotels will be sent to you with your National Board A registration confirmation. — — TUITION: $335 — — TUITION: $1,250 — — TUITION: $2,200 TUITION: — — — TUITION: $1,250 TUITION: — June 6–17 June 29–July 1 — TUITION: $670 — — TUITION: $2,500 TUITION: — ENDORSEMENT COURSES ENDORSEMENT CONTINUING EDUCATIONAL OPPORTUNITIES CONTINUING EDUCATIONAL (N) Nuclear Inspection Course Basic April 4–8 (A) Course Authorized Inspector in 2005! Only time offered 7–18 March March 8–10 (WPS) April 4–8 Procedure Workshop Welding (VR) Seminar Pressure Relief Valves Repair of (R) Repair Seminar Boiler and Pressure Vessel MN) March 30–31 (Minneapolis/St. Paul, June 27–28 May 16–27 2 of course $1,190 Week (PEC) Pre-Commission Examination Course course TUITION: $2,500 Full two-week $660 Self-Study (week 1) portion* * self-study materials sent upon payment. (IBI) Introduction to Boiler Inspection Course April 11–22 April 30) April 25–29 (CWI Exam (VIW) ONLY Inspection Workshop $335 Visual Code) API-1104 (complete seminar with $1,110 (D1.1) Code Clinic ONLY $375 Structural Welding Clinic ONLY API-1104 $335 (WIT) ONLY Technology Inspection $440 Welding (CWI) Inspector Review Seminar Certified Welding seminar with D1.1 Code) TUITION: $1,150 (complete THE WAY WE WERE Greetings from Greenleaf, Wisconsin

The quiet countryside of Greenleaf, Wisconsin, was disrupted at 3:30 in the afternoon Friday, November 24, 1905, when a boiler exploded at Wilharms’ fl ouring mill. Sadly, the life of one of the mill’s proprietors, William Wilharms Jr., was taken in the disaster. He shared the duties of running the mill Twith his three brothers, and on that unfortunate day was acting as engineer for one brother (A.J.) in his absence.

According to the Brown County Democrat of December 1, 1905, “The real cause of the explosion of the boiler is unknown as the proprietor had been in the boiler room 5 minutes before the explosion and every- thing seemed in O.K. working order.”

It is interesting to note that in a September 17, 1896, article in the Democrat, it was reported that, “Wilharms . . . is of the opinion that water power is cheaper than steam, and is now expending from fi ve to seven hundred dollars in repairing old dams, new fl ume, new bulk head, new trunk and wheels curbing, etc., hoping to be able to run his mill day and night . . .”

Reports from the scene paint a sad image of wrecked machinery and a destroyed boiler room, with heavy irons scattered about the mill yard for hundreds of feet. The body of the 17-year-old Wilharms was located some 100 feet from where he was last seen fi ring the boiler, “partly covered in timbers and stone.” The verdict of the coroner’s jury was accidental death.

A curious point aside, the postmark of the canceled postcard was January 1910, more than four years after the accident had taken place. The newsworthiness of the event had passed. Can it be safely assumed that the grim scene chronicled on the front of the card was less important to the sender than the message of good wishes on the other side?

Have any information about this picture? We would like to know more! Email [email protected]. Thanks to the Brown County (WI) Library for its contribution to this column. 40 NATIONAL BOARD BULLETIN/WINTER 2005