––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURES BULLETIN

6 Making Your Way Through Combustion Systems — WINTER 2002 • VOLUME 57 • NUMBER 1 By Lee Richardson Donald E. Tanner 10 The California State Railroad Museum: On Track to Executive Director Preserve an American Legacy Richard L. Allison Assistant Executive Director – Administrative Robert P. Sullivan 20 Welcome to Colorado Springs and the 71st General Assistant Executive Director – Technical Meeting Paul D. Brennan, APR Director of Communications Joan M. Webster 34 Why Boilers Fail — By Rita M. DeHart, P.E. Staff Services Manager Valerie T. Sterling Publications Editor Kimberly A. Miller ––––––––––––––––––––––––––––––––––––––––––––––––––– DEPARTMENTS Publications Coordinator BOARD OF TRUSTEES 2 Executive Director’s Message: Safety by Design, Not by Default David A. Douin Chairman Robert Reetz 3 Regulatory Review: Membership Survey: Regulations of Antique/ First Vice Chairman Historical/Hobby Boilers Vary by Jurisdiction Mark Mooney Second Vice Chairman 8 Inspector’s Insight: Donald E. Tanner Venting of Combustion Equipment Secretary-Treasurer Yash Nagpaul 32 Have You Met . . . ? Yash Nagpaul, Manager/Chief Boiler Member at Large Inspector, State of Hawaii Richard D. Mile Member at Large Malcolm J. Wheel 40 People: Withers Joins National Board Staff, New Members Elected in Member at Large New Hampshire and Oregon, Bynog to Chair NBIC Committee, Lee Doran Robert R. Cate Retires from the National Board, Mooney Elected to Board of Trustees; Past Chairman Calling All Honorary Members ADVISORY COMMITTEE

43 Training Matters: Safety by Association Stephen Rudnickas Representing authorized inspection agencies (insurance companies) 44 Training Calendar Russell I. Mullican Representing National Board stamp holders Dr. W. D’Orville Doty Representing the welding industry ON THE COVER: Dr. Maan H. Jawad California State Railroad Museum and Railtown Curator of Railroad Operations Representing boiler manufacturers Jerry Stoeckinger Kyle Wyatt poses beside theC.P. Huntington, icon of the museum and corporate Representing pressure vessel manufacturers symbol of the Southern Pacific Railroad. Below: Wyatt at the panel of the Charles A. Neumann museum’s legendary Virginia & Truckee No. 12Genoa , constructed in 1873. Representing boiler and pressure vessel users Story begins on page 10.

The National Board of Boiler and Pressure Vessel Inspectors was organized the purpose of promoting greater safety by securing concerted action and mainta ing uniformity in the construction, installation, inspection, and repair of boilers a other pressure vessels and their appurtenances, thereby assuring acceptance a interchangeability among jurisdictional authorities empowered to assure adh ence to code construction and repair of boilers and pressure vessels. The National Board BULLETIN is pu2blished quarterly by The National Boa of Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus, O 43229-1183, 614.888.8320, http://www.nationalboard.org . Postage paid Columbus, Ohio. Postmaster: Send address changes to The National Board of Boiler and Pressu Vessel Inspectors, 1055 Crupper Ave., Columbus, Ohio 43229-1183. Points of view, ideas, products, or services featured in the National Boa BULLETIN do not necessarily constitute endorsement by the National Board, wh disclaims responsibility for authenticity or accuracy of information contain herein. Address all correspondence to the Communications Department, T National Board of Boiler and Pressure Vessel Inspectors, at the above address © 2002 by The National Board of Boiler and Pressure Vessel Inspectors. rights reserved. Printed in the U.S.A. ISSN 0894-9611. Cover Photography by Don Satterlee ––––––––––––––––––––––––––––––– EXECUTIVE DIRECTOR’S MESSAGE

DONALD E. TANNER EXECUTIVE DIRECTOR SAFETY BY DESIGN, NOT BY DEFAULT

ll of us are familiar with the phrase “As luck Award presented by the U.S. Department of wouldA have it . . .” Health and Human Services. Personal and professional success notwithstanding, Ms. Somers Unfortunately, those five words have been has not yet hurdled all of life’s difficulties. recently employed with alarming regularity in the Recently it was revealed she was undergoing boiler and pressure vessel industry to justify controversial homeopathic treatment for breast something that did or did not occur. Having found cancer. its way into the mainstream of our professional vocabulary, this phrase — and the reasoning it In addition to enjoying an exceptional opening suggests — represents a most disappointing program filled with surprises, General Meeting portrait of our industry’s safety objective. attendees will notice a decidedly different tone to this year’s General Session. The Monday The fact is, ours is a profession of cause and afternoon and Tuesday morning sessions have effect. If we do our job through proper planning been redesigned to include more presentations on and design, luck has no place in the outcome. issues, ideas and insight [see Preliminary Program on page 31]. To drive home that point, we are designating the phrase “Safety by Design, Not by Default” as the And don’t forget our Annual Awards Banquet on theme for this year’s 71st General Meeting, May 1. The highlight of each General Meeting, April 29 - May 3, in Colorado Springs, Colorado. this very special evening is our way of recognizing those who have made significant To illustrate why controlling one’s fortune is contributions to the boiler and pressure vessel better than trusting destiny, we have invited an industry. We’ll conclude this year’s banquet with exceptional Opening Session speaker who was a night of music and fond reminiscences from two victimized by fate at an early age and who — of the most dynamic teen idols of the ’60s: Lesley through determination and design — overcame Gore and Fabian. her plight to become one of the most talented and respected entertainers in the world of show If you have been fortunate enough to visit The business. Broadmoor hotel in Colorado Springs, you know how very special the 71st General Meeting will be. Suzanne Somers was raised in a family headed by This facility is truly one of the most extraordinary an alcoholic, abusive father. Suffering from low hotels found anywhere in North America. Framed self-esteem as a young person, she battled a against the natural beauty of the rugged Rocky number of childhood demons including dyslexia. Mountains, The Broadmoor will provide a Through her courage and desire to rise above spectacular setting for a spectacular program. what she endured as a youth, Ms. Somers has become a renowned comedienne, actress, dancer, This is one General Meeting that should not be poet, businesswoman, bestselling author, devoted missed — but not simply because of its majestic wife, and mother. Perhaps best known for her role location. Your participation is needed to reinforce as Chrissy on the ’70s television situation comedy the essential message in any worthwhile Three’s Company, she has worked hard to put the endeavor: safety is the product of design, not difficult experiences of her younger years to good default. use for the benefit of others. In recognition of her tireless efforts, she has been the recipient of a See you in Colorado Springs! ❖ variety of national honors, including the Distinguished Achievement in Public Service

2 NATIONAL BOARD BULLETIN / WINTER 2002 REGULATORY REVIEW ––––––––––––––––––––––––––––––––––––––––––––––

JOHN HOH ASSISTANT DIRECTOR OF INSPECTIONS MEMBERSHIP SURVEY: Regulations of Antique/Historical/ Hobby Boilers Vary by Jurisdiction

A tragic incident in July 2001 involving an Pressure gage comparison antique steam tractor in Medina, Ohio, has led to (or other means to ensure accuracy) 21 many jurisdictions reviewing their own Test the safety valve under regulations concerning historical boilers. pressure by raising the test lever 29 Test the safety valve by allowing it At the request of Ohio Chief Boiler Inspector to lift solely by boiler pressure 10 Dean Jagger, the National Board conducted Witness operation of injectors a survey of its member jurisdictions, to determine (or feedwater pump) under pressure 12 if and how these boilers are regulated. Each chief inspector has the responsibility of enforcing his or 4. How often is a hydrostatic test her jurisdiction’s laws and rules concerning required? boiler and pressure vessel safety. Every year 19 Every 2 years 4 The following reflects information received from Every 3 years 3 56 of 59 jurisdictions polled (95% return). Every 4 years 2 Every 5 years 3 1. Does your jurisdiction regulate antique/ At the discretion of the inspector 4 historical/hobby boilers? As needed 3 Yes 40 No response 2 No 16

2. How frequently are they inspected? Survey Key Every 6 months 1 Every year 33 MAWP: maximum allowable working Every 2 years 5 pressure Every 3 years 1 PSI: pounds per square inch NBIC: National Board Inspection Code ASME: American Society of Mechanical 3. What methods of inspection are used? Internal inspection 40 Engineers’ Boiler and Pressure External inspection 39 Vessel Code Determination of remaining CSA B51: Canadian Standards Association thickness in specific areas 29 Boiler, Pressure Vessel, and Hydrostatic test 35 Pressure Piping Code

NATIONAL BOARD BULLETIN / WINTER 2002 3 –––––––––––––––––––––––––––––––––––––––––––––– REGULATORY REVIEW

5. What hydrostatic pressure is used? NBIC & ASME 12 MAWP 10 NBIC & CSA B51 1 1-1/4 MAWP 5 Jurisdictional rules 1 1-1/2 MAWP 17 NBIC, ASME & jurisdictional rules 1 100 PSI 1 All current codes 1 200 PSI 1 NBIC, ASME & CSA B51 1 100% 1 Operating pressure 1 11. How many antique/historical/hobby MAWP + 10% 1 boilers are currently authorized to MAWP up to 1-1/2 MAWP 1 operate in your jurisdiction? At the discretion of the inspector 1 < 10 11 No response 1 10 - 24 8 25 - 49 7 6. Is an operating certificate issued upon 50 - 75 5 successful inspection? 90 1 Yes 40 93 1 No 0 100 1 150 1 7. Will you accept a valid certificate from 230 1 another jurisdiction in lieu of 300 1 performing an inspection? No response 3 Yes 15 No 24 12. How many of these boilers fail Conditionally 1 inspection each year? 1 - 5% 12 8. Will you accept inspections performed 6 - 10% 7 by anyone other than your own deputy 11 - 15% 1 inspectors? 25% 1 Yes 20 None 11 No 19 No response 8 Only if boiler is insured 1 13. Do you require welded repairs to be 9. Do you provide specialized training for performed by an “R” stamp holder? inspectors to inspect hobby boilers? Yes 32 Yes 17 No 7 No 23 No welding permitted 1

10. Do you use a code or standard as the 14. Do you require a license or mandatory basis for inspections? training for the operators of these Yes 38 boilers? No 2 Yes 13 If yes, please list code or standard No 27 used: NBIC 16 ASME 5

4 NATIONAL BOARD BULLETIN / WINTER 2002 REGULATORY REVIEW ––––––––––––––––––––––––––––––––––––––––––––––

Some National Board members included 125 thickness checks per boiler. The initial comments with their surveys, as follow: inspection involves internal UT checks and hydrostatic tests, and the certificate is issued on ■ It is hard for the jurisdiction to regulate the external inspection. historical boilers due to the fact that most are brought in on weekends when no inspectors are on ■ Inspections are performed by capable persons of duty. It has been brought to our attention that an owners association. Any engine that comes in these boilers are operating at shows all of the time. from another jurisdiction has to be inspected before The numbers are greater, therefore, than what has it is allowed to operate. Any engine that does not been reported as those registered within the pass inspection will not be allowed to operate until jurisdiction. This is a large concern. repaired. Ultrasonic tests are performed every three years, or sooner if the condition of the boiler has ■ The Antique/Historical/Hobby Boilers are changed or there is evidence of deterioration, or exempt until they are placed in an exhibition mode. yearly if the engine is stored outside.

■ Currently, rules are under review for inclusion ■ An ASME “S” stamp holder must establish the of more requirements not specified or directed MAWP or ASME documents to prove ASME specifically at these vessels. There is a class with construction. Plugs and injectors are inspected for other special procedures and policies in place. condition. If the condition warrants, the inspector may require demonstration. ■ The jurisdiction does not spell out or otherwise single out Antique/Historical or Hobby Boilers. ■ If the owner has a valid certificate from another They are all dealt with in the same manner as a jurisdiction, all we will perform is an external boiler built three years ago. inspection prior to issuing a state certificate. Those that fail inspection normally require repairs, which ■ The jurisdiction only inspects high-pressure are completed. Sometimes units from other states boilers where an employer/employee relationship is come in with welded repairs, but no documentation. involved. Privately owned antique boilers are not inspected unless requested or insured. ■ The jurisdiction has always enforced annual inspection and valid operating certificates for the ■ Only those hobby boilers inspected by the objects. The licensing of an operator may be in jurisdiction are the ones made known to it. doubt, but generally enforced. ■ All of these boilers are inspected in the spring, ■ The antique tractor owners would favor a state before the “fair season.” Repairs must be law and rules so they could take their tractor to performed by licensed welders, by a procedure other states that would recognize our certificate of approved by the department. Operators must pass a inspection. written and practical test. ■ Our jurisdiction is currently stiffening its ■ The jurisdiction does not allow any hobby standards. boilers into the state that have not been inspected previously by the jurisdiction. The National Board recommends that owners, operators and inspectors review the new ■ Operators must attend the boilers at all times. Appendix C of the National Board Inspection The statute also covers model boilers. Code, entitled “Historical Boilers.” ❖

■ The jurisdiction does ultrasonic thickness measurements on initial inspection. We average

NATIONAL BOARD BULLETIN / WINTER 2002 5 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

By Lee Richardson MAKING YOUR WAY THROUGH COMBUSTION SYSTEMS NFPA 85 requirements contribute to overall safety in industrial facilities.

Reprinted with permission from NFPA 85, Boiler and Combustion Systems represented by the former standards. The NFPA Journal ®, Vol. 95, No. 5, Hazards Code, provides minimum requirements chapters include “Fundamentals of Boiler © 2001, National Fire Protection for the design, installation, operation, and Combustion Systems,” “Single-Burner Boilers,” Association, Quincy, MA 02269. maintenance of large commercial and industrial “Multiple-Burner Boilers,” “Atmospheric boilers, heat-recovery steam generators, and Fluidized-Bed Boilers,” “Heat-Recovery Steam related combustion systems. These requirements Generators,” “Pulverized Fuel Systems,” and help prevent fires, explosions, and implosions, “Stokers.” and contribute to overall safety. Are there capacity limits? What equipment does NFPA 85 address? NFPA 85 is limited to boilers, including It addresses single-burner boilers, multiple- stoker-fired boilers, with fuel input ratings of burner boilers, atmospheric fluidized-bed boilers, 12.5 M Btu/hr or more. The capacity for heat-recovery steam generators, pulverized fuel pulverized fuel systems and heat-recovery steam systems, and stokers. generators is unlimited.

What is the origin of NFPA 85? What are the end-use applications for boilers? NFPA 85 is a compilation of six earlier standards: The function of a boiler is to produce steam. NFPA 8501, Single-Burner Boiler Operation; Typical applications use the steam to generate NFPA 8502, Prevention of Furnace Explosions/ commercial electric power and for commercial Implosions in Multiple-Burner Boilers; NFPA and industrial heating applications. 8503, Pulverized Fuel Systems; NFPA 8504, Atmospheric Fluidized-Bed Boiler Operation; How are heat-recovery steam generators NFPA 8505, Stoker Operation; and NFPA 8506, used? Heat-Recovery Steam Generator Systems. Heat-recovery steam generators capture waste heat from combustion turbine exhaust. The development and use of these standards can Combustion turbines, generally used for power be traced back to 1924 with the first edition of generation, are covered in NFPA 37, Installation the pulverized fuel systems standard. NFPA and Use of Stationary Combustion Engines and 8506, which was introduced in 1995, was the Gas Turbines, and NFPA 850, Fire Protection for newest standard. Electric Generating Plants and High-Voltage Direct-Current Converter Stations. The generator How is NFPA 85 organized? uses the recovered heat, which is either unfired or There is a chapter on requirements common to all has supplemental firing, to produce steam, which applications, followed by a chapter on the unique can be used to generate power or for other heating requirements for the six equipment applications applications.

6 NATIONAL BOARD BULLETIN / WINTER 2002 FEATURE ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

What are pulverized fuel systems used for? systems, flame monitoring and tripping systems, Pulverized fuel systems typically are used to ignition subsystems, main burner subsystems, process coal for use as fuel in multiple-burner warm-up burner subsystems, and duct-burner boilers. systems.

What are stokers used for? The combustion control system is defined, in part, Stokers are used for boilers that burn solid fuels, as “the control system that regulates the furnace such as coal, wood, refuse-derived fuel, fuel and air inputs to maintain the air/fuel ratio municipal solid waste, and other solid fuels. within the limits required for continuous combustion and stable flame throughout the What subsystems and support functions operating range of the boiler in accordance with does the code address? demand.” NFPA 85 covers structural design, purging systems, and fuel-burning systems, including fuel Are there any significant technical changes supplies, the main burner, the reburn fuel supply, in NFPA 85? combustion control systems, burner management To accommodate different technologies used to systems, furnace pressure control systems, and reduce the levels of undesirable nitrogen oxide

other system and function requirements. compounds (NOx), furnace emission requirements Procedures for normal and emergency startup and have been changed, and the coverage has been shutdown, fuel transfer, and firing of more than expanded. These changes include provisions that one fuel are also covered. Some requirements are allow the introduction of overfire air and the use specific to certain equipment applications. of flue-gas recirculation and reburn technology.

Does NFPA 85 have any training Overfire air is the air supplied for combustion requirements? that is introduced into the furnace at a point NFPA 85 requires the system owner or the above the burners or fuel bed. Flue-gas owner’s representative to provide formal operator recirculation introduces flue gas into the and maintenance training. secondary or combustion air supplied to burners. And reburn technology introduces fuel What is the basic function of the burner downstream of the main burners, creating a fuel-

management system, and how does it relate rich zone where chemical reactions reduce NOx to to the combustion control system? molecular nitrogen. ❖ The two control systems are separate and distinct, and, except for a certain circumstance in single- burner boiler applications, must be maintained independently.

The burner management system is defined as “the control system dedicated to combustion safety and operator assistance in the starting and stopping of fuel preparation and burning equipment, and for preventing misuse of, and Lee Richardson is NFPA’s senior electrical damage to, fuel preparation and burning engineer, Signaling Systems, and former staff equipment.” Subsystems can include interlock liaison for NFPA 85. systems, fuel trip systems, master fuel trip

NATIONAL BOARD BULLETIN / WINTER 2002 7 ––––––––––––––––––––––––––––––––––––––––––––– INSPECTOR’S INSIGHT

LEE DORAN GOVERNMENTAL AFFAIRS AND INTERNATIONAL REPRESENTATIVE VENTING OF COMBUSTION EQUIPMENT

One of the hazards associated with the Carbon Monoxide (CO) Poisoning operation of combustion equipment (such as boilers, water heaters, furnaces, etc.) inside Carbon monoxide is often referred to as CO, which buildings is the operation of burners with is its chemical symbol. Red blood cells absorb CO insufficient air to completely burn all fuel, which over 200 times more readily than oxygen. As levels in turn produces soot and carbon monoxide – two of CO in the air rise, this gas replaces oxygen in kinds of unburned fuel. In fact, carbon monoxide the bloodstream. As a result, body tissues are is a normal product of combustion that can be damaged and may die due to a lack of oxygen. produced by any fuel-burning device.

Employers and workers should be aware of the Carbon monoxide is often called a “silent killer.” danger of carbon monoxide poisoning from fuel- It is an invisible gas without any taste or smell, burning equipment. They should know the warning and it does not cause any unusual feeling in the signs of carbon monoxide exposure – headache, nose, mouth or throat as it is breathed in. faintness, dizziness, confusion, nausea and irregular heartbeat – and should NEVER ignore The most common symptoms of carbon monoxide them when working where fuel-burning equipment poisoning are headache, dizziness, weakness, is being used. nausea, vomiting, chest pain and confusion. High levels of carbon monoxide can cause loss of ——Centers for Disease Control and Prevention, consciousness and death. Unless suspected, U.S. Department of Health and Human Safety carbon monoxide poisoning can be difficult to diagnose because the symptoms mimic other preventable, provided maintenance technicians illnesses. Moreover, carbon monoxide exposure take extra care when operating combustion can result in long-term psychiatric problems equipment. There may be many reasons why a (more likely to occur in older individuals), such burner does not receive sufficient air to combust as personality changes, dementia and psychosis. all fuel, such as improper burner adjustment, blocked combustion air openings, or cluttered According to the Journal of American Medicine, boiler rooms. However, the real danger occurs exposure to carbon monoxide is the leading cause when combustion gases escape into a building. of accidental poisoning deaths in the United States. Fifteen hundred people die annually from One of the ways combustion gas escapes into carbon monoxide poisoning, while another 10,000 buildings is when different types of draft systems seek medical treatment. It is believed that many are connected, in essence connecting a natural more are misdiagnosed or never seek medical draft system with a mechanical draft system. care. A natural draft system uses the heat of combustion to vent the combustion gases (heat Though carbon monoxide poisoning is a serious rises). A mechanical draft system uses the and increasingly common occurrence, it is also mechanical force of a blower to vent the products

8 NATIONAL BOARD BULLETIN / WINTER 2002 INSPECTOR’S INSIGHT –––––––––––––––––––––––––––––––––––––––––––––

of combustion. Mechanical draft systems are usually described as being:

Forced draft – in which the blower is located at the inlet of the venting system [See Figure 1], or

Induced draft – in which the blower is located near the outlet of the venting system (usually at the rear of the fuel-burning equipment) [See Figure 2].

A national standard related to mechanical draft systems is found in the National Fuel Gas Code, 1999 edition (NFPA-54). This standard provides the following:

Mechanical Draft Systems a. Gas utilization equipment requiring venting shall be permitted to be vented by Figure 1 means of mechanical draft systems of either forced or induced draft design. b. Forced draft systems and all portions of induced draft systems under positive pressure during operation shall be designed and installed so as to prevent leakage of flue or vent gases into a building. c. Vent connectors serving equipment vented by natural draft shall not be connected into any part of mechanical draft systems operating under positive pressure.

Subparagraph (b) above essentially requires that the venting system under positive pressure (mechanical draft) must be gas-tight to prevent leakage of the combustion gases into the building. A connection into a positive pressure system from a natural draft system breaks the gas-tight envelope by providing a place for the combustion gases from a mechanical draft system to escape into the building through the open natural (atmospheric) burner. Subparagraph (c) prohibits connecting an atmospheric system into a mechanical draft system for the reasons stated above.

Figure 2 This type of improper installation is not uncommon. Systems must be checked to ensure that mechanical draft and natural draft systems are not cross-connected. ❖

IMPORTANT NOTICE TO MANUFACTURERS AND AUTHORIZED INSPECTORS Effective immediately, manufacturers submitting data reports to complete the registration process need send only the original data report.

Since its inception in 1921, the National Board’s registration process has required the manufacturer to submit an original plus one legible copy of each data report. The original was used for permanent storage and the copy was used for administrative processing. After processing, the copy was sent on to the National Board member in whose jurisdiction the boiler or pressure vessel was to be installed.

Recently, the National Board completed testing and implementing a new scanning and digital storage process for data reports. With this new process, the original data report is scanned and then is sent to the appropriate National Board member.

Additional copies of the data report are no longer required. Please note that this change must also be reflected in the manufacturer’s written quality system. ❖

NATIONAL BOARD BULLETIN / WINTER 2002 9 More Than Bells and Whistles . . . The California State Railroad M On Track to Preserve an Americ

Photography by Don Satterlee

or over a century, they were symbols of America’s industrial might. Traversing the country like one-eyed behemoths, steam locomotives not only moved a country’s hopes and dreams, they transported the people who would make those hopes and dreams reality.

And they were powered by boilers. Massive boilers.

What steam locomotives so impeccably illustrated — in both symbol and substance — were the countless contributions of boilers to the evolution of a great industrialized nation.

Indeed, without steam locomotives, America’s growth would have been easily retarded. How else could a burgeoning country have relied upon limited proximity to navigable waterways or seacoasts? How could important industrial and agricultural markets develop to meet the needs of a newly expanding populace? How could massive quantities of goods and materials be moved economically and quickly? How could people — and yes, news and ideas — be transported conveniently and efficiently?

For recent generations, the contributions of the steam locomotive are but footnotes to be occasionally studied in the textbooks of U.S. history.

And, at times, conveniently forgotten.

ALL ABOARD

So why, then, are steam locomotives more popular in 2002 than at any time since their demise at the conclusion of World War II?

Kyle Williams Wyatt has heard that question hundreds of times.

He wasn’t around during the steam locomotive’s evolutionary zenith. But as curator of railroad operations for the most visited railroad museum in the world, the California State Railroad Museum in Old Sacramento and the Railtown 1897 State Historic Park in Jamestown (about 100 miles southeast), Wyatt has some pretty good theories.

“I think steam trains are a curiosity for younger people and a way for our older patrons to revisit an earlier part of their lives,” he explains with a smile of satisfaction. “For many of our senior visitors, these extraordinary machines represent stories — human stories — of times both good and bad. And that is what makes visiting a tourist railroad and museum such an interesting and valuable experience.”

By the very nature of their existence, trains are of profound interest, the animated curator observes. “To stand next to one is to feel a certain raw power that few have occasion to experience. More oftentimes than not, the closest many people get to a steam train is seeing one on TV or at the movies.”

0 10 NATIONAL BOARD BULLETIN / WINTER 2002 eum: Legacy

➣ Sierra Railroad 2-8-0 No. 28 passes by the famous Petticoat Junction water tower at Railtown. (The three- digit number following the railroad line is the Whyte Classification System for identifying the arrangement of each locomotive’s leading, driving and trailing wheels.) Photo credit: California State Railroad Museum. NATIONAL BOARD BULLETIN / WINTER 2002 11 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

Wyatt should know. It is his responsibility It is Wyatt’s job to not only arrange the to oversee maintenance operations at the preparation of the trains for film work at Railtown 1897 State Historic Park Railtown, but also to see that select pieces (operated by the museum), which is also of equipment are kept in good working known as “The Movie Railroad.” A order for visitor excursions at both popular Hollywood location site going Railtown (on the private Sierra Railroad back to 1919, the park and many of the line) and the California State Railroad historic locomotives and railroad cars Museum (on the Sacramento Southern preserved there have appeared in more Railroad). than 200 films, television productions, and commercials. “The most In Old Sacramento, restoration and photographed railroad in the world,” as it maintenance work takes place at a is called, has seen the TV series The Lone massive boiler shop (constructed in 1888) Ranger, Lassie, Gunsmoke, Rawhide, The just 300 yards north of the 25-year-old Big Valley, Bonanza, Petticoat Junction museum. Currently being converted to a and The Wild, Wild West filmed on its restoration shop, the boiler facility is one premises, as well as the movies My Little of only a half dozen or so buildings Chickadee, Go West, High Noon, Back to (including the nearby erecting shop, site the Future, Part III, and more recently, of the planned Railroad Technology Unforgiven. Museum) still standing at the historic 44-acre Southern Pacific Sacramento Shops complex.

TO PRESERVE AND PROTECT

With a total of 100 steam locomotives and cars (some of which have been restored) at the 100,000-square-foot Museum of Railroad History, and an additional 50 displayed at Railtown, Wyatt assumes a tremendous responsibility.

“It can be a bit overwhelming,” he modestly admits, “especially when you consider that we are preserving for future generations a lot of equipment that is 100 years old!”

And then some. “The steam locomotive had its beginnings in England starting in the early 19th century,” Wyatt explains. Records in 1820 reveal the use of several different types of locomotives in and around Great Britain’s mines and ironworks. In 1829, four coal mine engines were imported to America. ➣ At the erecting shop in Sacramento, Kyle Wyatt displays the mangled cab of a Consolidation 2-8-0 — destroyed by a boiler explosion around 1905. 2 12 NATIONAL BOARD BULLETIN / WINTER 2002 FEATURE ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

According to the museum, the first steam work with modern Federal Railroad locomotive to establish regularly Administration (FRA) boiler standards to scheduled passenger service in America ensure safe-running steam locomotives. began operation on Christmas Day, 1830, at Charleston, South Carolina. The Best In the 1820s and ’30s, both vertical boilers Friend of Charleston carried 141 (favored by few American manufacturers) passengers at speeds of 15 to 25 miles per and the more common horizontal firetube hour. It was destroyed six months later boilers were employed to power American when a fireman, irritated by the sound of steam locomotives. After 1841, only hissing steam, held the safety valve horizontal firetube boilers were used. closed, thereby blowing the boiler “into a Among those most favored in the 1830s fine assortment of pieces.” and ’40s were two designs of British origin: the Stephenson and the Bury. By 1857, America boasted half of the railroad trackage in the world. During The more popular Stephenson, designed that period of American history, trains by the Stephenson Works, was generally were the most significant and most widely identified by a slightly swelled region used means of land transportation. located around the firebox crown. Considerably easier to construct, it It was during the late 1930s that a safer, featured a large firebox grate. The Bury easier to maintain, and more economical boiler was designed by Edward Bury and alternative to steam — diesel-powered was characterized by its oversized locomotives — was perfected. World hemispherical dome. With a desired War II delayed the conversion from steam generous capacity for steam, it also to diesel but, according to Wyatt, “the possessed a comparably smaller firebox diesel gained ascendance by the late grate and was more expensive to build 1940s and early ’50s.” and maintain. For railroads having access only to poor water, the Bury boiler was Between 1945 and 1960, over 40,000 preferred for its additional steam capacity steam engines were scrapped and and ability to handle foaming. But as the replaced with nearly 26,000 diesel-electric trains grew larger, so too did the need to locomotives. Today in North America, enlarge the boilers. Efforts to expand the only about 1,800 steam locomotives Stephenson and Bury designs were survive, mostly in parks, museums and on unsuccessful. tourist railroads. Less than 200 are capable of operation. Constructed in 1850 by the Rogers Locomotive Works, a locomotive called the Madison revolutionized the steam process STOP . . . LOOK . . . with a new design that combined the best LISTEN features of the Stephenson and the Bury. Referred to as the Wagon Top, the new Without proper care and attention, a boiler design boasted a relatively large steam boiler can do serious damage. But grate area, generated ample steam, and even in the days of steam, locomotive was easy to construct. Supplanting the boiler explosions were fairly rare. Its Stephenson and Bury, the Wagon Top potential for danger notwithstanding, the went on to become the most successful steam locomotive boiler was modified very locomotive boiler type in America. But little over its more than 100 years of like its predecessors, this newer design deployment. Today, well-trained crews had its shortcomings: weak joints in the

NATIONAL BOARD BULLETIN / WINTER 2002 13 1 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

firebox and in the steam dome, and an college curriculum, to my knowledge, that excessive number of staybolts (to support leads to a degree.” the firebox sheets) and crown stays (to provide the necessary strength to hold the For Wyatt, the route was pure luck. firebox together). Originally from the coast of northern California, he obtained his degree in the Early boilers were constructed of cast-iron history of technology before going to work plates riveted together. Riveted steel for four years as an historical researcher boilers were introduced around the mid- for the museum’s restoration shop. “I left 1850s. But it would not be until 20 to 30 the shop to pursue my master’s degree years later that steel replaced iron as the and to do some additional graduate work primary boiler material. Even though cast before accepting the position of curator of iron was more brittle than steel, steel’s history for the Nevada State Railroad greater cost discouraged its use by boiler Museum in 1990.” In 1999, he left the manufacturers early on. Only when less Nevada position to assume his present expensive steel and more malleable alloys responsibilities. became available did steel finally overcome iron as the material of choice. For Kyle Wyatt, being curator for a museum that annually hosts 500,000 visitors (plus an additional 50,000 at I’VE BEEN WORKING ON Railtown) is his ideal job. That’s because a THE RAILROAD typical day is anything but typical.

Kyle Wyatt was On a warm fall morning last October, he first introduced to found himself in Jamestown to check on trains when he the rebuilding of one of Railtown’s most was two years old. famous steam engines. Having played a starring role in several TV series “My parents gave including as the “Hooterville Cannonball” me a wooden train on Petticoat Junction, the Sierra set,” he recalls Railroad 4-6-0 No. 3 sits partially with fondness. disassembled in the Jamestown “I still have it and roundhouse undergoing a comprehensive I’ve been in love overhaul to bring it into compliance with with trains ever the Federal Railroad Administration’s since.” new standards for steam locomotives.

So how does one “These standards have been extremely prepare for a important because they have caused us to career in railroad ‘reverse engineer’ the boiler to determine preservation and its structural strength and integrity,” restoration? comments Gerald T. Hanford, Railtown’s railroad restoration specialist. “This “One doesn’t,” the process is especially important for the museum official No. 3 which, even though it has been in acknowledges. operation on the Sierra Railroad line since “There is no 1897, lacks any original boiler drawings. ➣ Railtown Railroad Restoration Specialist Gerald Hanford checks for metal corrosion on the No. 3’s 110-year-old firebox.

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“Reverse engineering involves removing the boiler’s tubes and appliances, then inspecting, testing, and documenting all existing materials and conditions ‘as is’ at regular, closely spaced intervals,” Hanford explains. “With this data, we can determine the boiler’s safe working pressure, verify its performance to current standards, and make whatever repairs might be necessary.”

Acknowledging that the new federal directive represents the first comprehensive railroad code revision in more than 80 years, the Railtown staff member says the new standards go a long way in recognizing changes in technology — such as welding. “More importantly for ➣ Among Hollywood’s most famous trains, the Sierra Railroad Railtown,” Hanford points out, “these new 4-6-0 No. 3 sits partially disassembled at the Railtown roundhouse in Jamestown. Pictured is the No. 3 chassis with its boiler in the standards recognize the fact that a tourist above left background. railroad operates a lot differently than a conventional railroad.”

But the cost of compliance is expensive. Hanford estimates that Railtown invested four months and approximately $100,000 last year in time and materials to bring another of its steam engines — the Sierra Railroad No. 2 — up to the new federal requirements.

Back in Old Sacramento a day later at the museum’s boiler shop, work continues on schedule to restore a 1924 observation car. Railroad Restoration Specialist Al Di Paolo knows whatever parts are lacking to bring the car back to its grand, old splendor will either have to be located or replicated from scratch.

“We do make a lot of our own parts,” Di Paolo explains while at the same time acknowledging that he is perhaps among the more fortunate in the restoration discipline. “The California State Railroad Museum,” he notes with pride, “has one of ➣ Railroad Restoration Specialist Al Di Paolo examines the the largest inventories of parts and interior of a 1922 Baldwin boiler (from the Stockton Terminal & artifacts in the world.” Eastern 2-6-2 No. 3), part of the inventory at the Southern Pacific Sacramento Shops boiler facility. NATIONAL BOARD BULLETIN / WINTER 2002 15 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

This is thanks in large part to a lengthy Despite the availability of renowned tradition of conscientious collecting over archives, the museum curator cannot many years by museum staff. As a result avoid facing an occasional challenge or of their efforts and from generous two, the most frustrating of which is donations of railroad materials, the having to locate old drawings and museum has amassed several warehouses specifications for vintage equipment full of railroad Americana ranging from items. “The No. 3 at Railtown is a good locomotives, engine parts, boilers, rail example,” he laments. cars, furniture, and period railroad signs to valuable, specially designed railroad “Here’s a locomotive that was used in a china, crystal and silverware. number of famous movies such as High Noon and the 1929 classic, The “One of the great things about the Virginian,” Wyatt observes. “Built in railroad restoration community is that we 1891, it’s been in continuous operation for share a lot of information,” Wyatt over 100 years and retains its original emphasizes. “If our organization needs a boiler. Who knows when the boiler’s particular artifact or part, we can often drawings or specification sheets were last call around to other museums or tourist used or seen? Given the new FRA railroads to research availability. At the requirements, having those documents same time, we are always keeping our could save us considerable time and eyes and ears open for what might become resources today. Fortunately, through available on the open market. If a reverse engineering, we can compute new particular item fits into what we want to calculations and formulas, and completely communicate to our audiences through rewrite the specifications.” the museum, we’ll make a concerted effort to acquire it. Even though we share Although missing drawings and information, obtaining equipment and specifications are a headache for the artifacts can be a very competitive museum official, they are by no means exercise.” the most serious problem facing his organization. While collecting items for the museum is an important part of his responsibilities, “Actually,” he emphasizes with a pause, the curator admits it is not as personally “the problem of finding qualified steam satisfying for him as the research process. locomotive mechanics is both a current A member of the Tourist Railroad and future concern.” It is the one Association Board of Directors, Wyatt shortage, Wyatt says, that could both finds considerable gratification in jeopardize the steady growth of tourist researching and physically completing a railroads in the U.S. and create serious restoration project from start to finish. safety issues. His efforts are complemented by having direct access to the California State According to Railtown’s Hanford, “There Railroad Museum Library, the largest are really two problems: finding the older railroad-only research facility in the world mechanics to fix steam trains and locating featuring an extensive collection of the young people who want to learn what railroad-related books and publications, the older mechanics can teach them. Since with well over one million photographs, there are no formal schools for this type of maps, drawings and corporate records. thing, the industry could be headed for a very difficult time.”

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➣ Railroad restoration specialists Vance Dickenson (left) and Al Di Paolo prepare exterior surfaces for the restoration of a 1924 observation car at the boiler shop in Sacramento. This “extra fare” car catered to high- end travelers and included both a cocktail lounge and barbershop. NATIONAL BOARD BULLETIN / WINTER 2002 17 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

Despite the mechanic shortage, Wyatt is vast collection of historic locomotives and adamant: “The California State Railroad railroad cars, along with formal museum Museum will do whatever is necessary to exhibit galleries interpreting railroad preserve what we feel has been an engineering and technology. excellent record of safety. We will never compromise the well-being of our visitors, The museum’s expansion, the marketing employees, or volunteers.” director emphasizes, parallels national trends that indicate a growing popularity for industrial heritage preservation –— TICKETS, PLEASE and railroads in particular: “Thanks to restoration and preservation efforts, we One area where there is no lack of now have more steam trains in operation manpower is within the ranks of the in the U.S. than at any time in the last 800 men and women who make up the half century.” museum’s volunteer staff.

“Being operated by the California NEXT STOP Department of Parks and Recreation with assistance from the California State With more than 20 years’ experience Railroad Museum Foundation, and having under his belt, Kyle Wyatt continues a only 50 full-time employees between the relentless pursuit for his next project. two entities at both Sacramento and Scouring the Internet, perusing trade Railtown, necessitates the involvement of magazines, attending industry many volunteers,” the curator carefully conferences, keeping in touch with explains. “They are a dedicated group, railroad enthusiasts — it is his job to quite a few of whom are senior citizens.” broaden both the museum’s inventory and Doing everything from operating the its appeal. The result to date: a diverse museum’s excursion trains, to serving as collection of worldwide repute and docents, to providing expertise and significant investment. insight in many diverse subjects, the volunteers are — according to Wyatt — When asked the estimated value of the “an important part of the museum’s plans California State Railroad Museum to expand the public’s enjoyment and collection, Wyatt keenly observes: “Value appreciation of America’s railroad can only be determined by what someone heritage.” is willing to pay.”

Among the plans now headed to the As for the most valuable item he has drawing board is a conversion of the taken in, the curator doesn’t have to think Southern Pacific Sacramento Shops site twice. into a dynamic cultural attraction. According to Director of Marketing “It’s that wooden train set my parents Paul Hammond, the concept is designed to gave me,” he notes with a grin. “It’s not allow visitors the opportunity to view the for sale at any price!” ❖ actual renovation of rail equipment, ➣ For more information on the California “thereby creating a living industrial State Railroad Museum, access museum.” www.californiastaterailroadmuseum.org on the Internet, or visit the shared Railtown Hammond says the spacious railroad shop 1897 State Historic Park homepage at www.railtown1897.org. buildings will accommodate the museum’s

18 NATIONAL BOARD BULLETIN / WINTER 2002 ➣ An interior view of one museum display featuring the North Pacific Coast Railroad 4-4-0 No. 12 Sonoma, considered to be the finest restored example of an American Standard-type steam locomotive in the United States. Thousands of these American Standard engines were built by several dozen manufacturers and came to typify the era of steam. First operated in 1876, the No. 12 reflects the elegant design and beauty of steam engines at the end of the 19th century. Photo credit: California State Railroad Museum.

NATIONAL BOARD BULLETIN / WINTER 2002 19 WelcomeWelcome toto ColoradoColorado SpringsSprings andand theth Soaring to New Heights . . . t’s not a figment of the imagination. The sun is always shining in Colorado Springs — or at least it is 70 percent of the time. That’s because this outdoor landscape of snowcapped mountains, scenic nature trails and soaring white water boasts more Ithan 250 days of sunshine per year.

Unique among many General Meeting sites, Colorado Springs is an unaffected resort community offering something to visitors that larger cities cannot — world-class hospitality in one of the most breathtaking natural settings anywhere on earth. After all, it was Colorado Springs’ Pikes Peak that prompted Katherine Lee Bates to coin the

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1st1st GeneralGeneral Meeting!Meeting!

lyrics to “America the Beautiful” more than a century ago. Attracting more than six million visitors annually to a city of 500,000, Colorado Springs brings home the timeless splendor and awe that inspired Ms. Bates to write her famous anthem.

For visitors interested in soaring to new heights, Colorado Springs is truly the place to be. The city lays claim to the highest railroad in the United States — the Manitou and Pikes Peak Railway ; the world’s highest suspension bridge — at Royal Gorge ; and the only zoo in the U.S. built at 6,800 feet elevation — Cheyenne Mountain Zoo .

For those who prefer recreation of a less lofty variety, Colorado Springs also boasts beautiful rivers and lakes, as well as some of the best man-made attractions of a resort town, like world-class shopping, restaurants, cafés and more.

Today, Colorado Springs is a bustling yet cozy locality with a solid economic base of government centers and computer-driven industries. However, it was the mining and railroad industries of the late 1800s that first put Colorado Springs on the map. Founded in 1871 by General William Palmer, Colorado Springs was one of a few settlements built at the foothills of Pikes Peak — an area that experienced a huge population boom in response to rumors of gold found nearby. Growth in Colorado Springs was supported by the flourishing mining and rail industries. Despite this legacy, the city itself was never wholly dependent on mining. And it was a good thing, too. When those industries began to flag in the early 20th century, a burgeoning shift to tourism helped the city grow steadily and prosper. One of the world’s finest luxury hotels — The Broadmoor — was christened as a first-class resort in 1918, and today it

NATIONAL BOARD BULLETIN / WINTER 2002 21 still stands as a testament to the level of comfort and luxury Colorado Colorado Springs dedicates to its most valuable industry — tourism.

While tourism fueled the city’s growth in the early 20th century, Springs a solid tax base from industry and government centers has helped stimulate growth more recently. Colorado Springs is home to several government headquarters, such as the United States Air Force Academy , the United States Olympic Committee, the U.S. Forest Service and NORAD, the North American Aerospace Defense Command.

Serving as a contrast to these high-tech government centers is the breathtaking beauty of a resort community. With an incorporated area of 190 square miles, an amazing 8,200 acres of Colorado Springs is designated public parkland. One of the oldest of those public areas is Garden of the Gods — a The United States Air Force Academy registered national landmark located near the foot of Pikes Peak. This beautiful park was established by railroad magnate Charles Elliot Perkins, who in 1879 purchased 240 acres of land at the convergence of several towering red sandstone formations. Mr. Perkins initially intended to build a summer home on the property, but decided instead to leave the land in its natural state to be enjoyed by the public. He added considerably to his original land purchase, but died before he could officially donate the land to the public. However, his children, wishing to honor their father’s intentions, made the gift official in 1909, with 480 acres. Today, Garden of the Gods has expanded to The Garden of the Gods 1,300 acres, and includes picnic facilities, foot trails and horse trails. Also recently added to the park is a state-of-the-art Visitors Center , which functions as a welcome center and natural history museum.

Many visitors making the trip to Garden of the Gods find themselves continuing uphill to Pikes Peak, via the historic Manitou and Pikes Peak Railway , which celebrated its centennial in 1991. Known as the highest cog railway in the United States, the track climbs from a starting elevation of 6,500 feet to over 14,000 feet, offering passengers an The Manitou and Pikes Peak Railway unforgettable vertical ascent of 7,500 feet! 22 NATIONAL BOARD BULLETIN / WINTER 2002 71ST GENERAL MEETING –––––––––––––––––––––––––––––––––––––––––––

Traveling from the zenith of Pikes Peak to the lower elevations of such man- made attractions as golf courses and boutiques, visitors are advised to dress in layers and keep plenty of water on hand for the dry conditions. Climate and altitude can change dramatically in one day, especially if a busy and varied itinerary is planned. However, if caught without a winter parka for the snowcapped vistas, visitors to Colorado Springs will find plenty of shopping opportunities.

Old Colorado City — located just west of downtown Colorado Springs — offers visitors more than 100 galleries, shops, restaurants and boutiques. Stroll down old-fashioned cobblestone streets in a charming historic setting.

For those who want enrichment above and beyond the consumer variety, more than a dozen museums are located in Colorado Springs, with something for everyone’s taste. Museums found within the city limits include the Museum of the American Cowboy , the Colorado Springs Fine Arts Center , the World Figure Skating Museum , the Peterson Air and Space Museum , the Rodeo Hall of Fame and even the Rocky Mountain Motorcycle Museum .

Enjoy the beautiful outdoors at any one of Colorado Springs’ 8,200 acres of public parkland. Or brush up on educational pursuits at one of the city’s unique museums. No matter what the vacation itinerary is, Colorado Springs is sure to amaze and delight all visitors! ❖

Downtown Colorado Springs, Colorado NATIONAL BOARD BULLETIN / WINTER 2002 23 PREREGISTRATION FORM ROOM RESERVATION FORM Name Name for Badge The National Board of Boiler and Pressure Vessel Inspectors/ Title ASME International Company or Affiliation 71st General Meeting • April 29 – May 3, 2002 Telephone Number ( ) All room reservations must be received by MARCH 15, 2002. Company Address Mail this form to: The Broadmoor Home Address P.O. Box 1439, Colorado Springs, Colorado 80901 Or fax to 719.577.5738. Reservations can also be made by Guest Name telephone at 1.800.634.7711. Guest Address WHEN CALLING, PLEASE MENTION GROUP NAME: The National Board of Boiler and Pressure Vessel Inspectors Additional Guest* Name Please print or type. Additional Guest Address Name(s) Address * Additional guests (16 years of age or older) may register for a fee of $95.00. City Those requesting special or handicapped facilities are asked to State Zip contact the Communications Department at 614.888.8320. Telephone Number ( ) FEES Only one registration fee will be charged for each attendee and Indicate desired accommodations: one guest (guest program participant). Single $199.00 Double $199.00 General Meeting Preregistration Fee...... $ (includes ONE banquet ticket) Request: Registration fee is $210.00 if received on or before March 29, 2002. Nonsmoking Room Registration fee is $240.00 if received after March 29, 2002. 1 Bed (Q or K) 2 Beds (Double/Double) Additional Guest Fee (each includes ONE banquet ticket) ( additional guests at $95.00 each) ...... $ Room Tax and a daily service charge of $14.00 for single or double occupancy applies to all guest rooms, Additional Banquet Tickets plus $2.50 for each additional person. ( additional tickets at $25.00 each) ...... $ No charge for children under 18 rooming with an adult. AMOUNT ENCLOSED ...... $ Method of Guarantee To preregister by phone or facsimile using your Deposit for one night plus 8% room tax enclosed. VISA, MasterCard or American Express, contact Joan Webster Make check or money order payable to The Broadmoor. at 614.888.8320, ext. 226, or FAX 614.888.0750. Do not send currency. Credit Card for guarantee: VISA MasterCard American Express American Express VISA Diners Club MasterCard Discover Carte Blanche Card Number Exp. Date Card Number Exp. Date Signature Signature All checks and money orders must be Arrival Date Number of Nights payable in U.S. dollars to: Check-in after 4:00 p.m. Check-out by 12:00 p.m. The National Board of Boiler and Pressure Vessel Inspectors Sharing With: For Accounting Department Only: AMOUNT $ DATE 24 NATIONAL BOARD BULLETIN / WINTER 2002 71ST GENERAL MEETING –––––––––––––––––––––––––––––––––––––––––––

The Summit of Luxury

To call The Broadmoor a “picture perfect setting” is closer to the truth than most people realize. After all, artist Maxfield Parrish — one of the most well-known illustrators of the early 20th century — painted The Broadmoor in his trademark mystical style. The result is the stuff of fantasy. Deep purple-hued mountains rise skyward while a sapphire lake reflects the resort’s palatial image.

While Parrish may have used artistic license in creating a fantasy image of The Broadmoor, he didn’t have to stray far from reality in doing so. Located at the foot of the Rocky Mountains, The Broadmoor is surrounded by natural beauty. Cheyenne Lake, located opposite the Rockies, offers guests a beautiful vista in all directions.

The real treasure of The Broadmoor, though, is its unrivaled reputation for quality. Visitors to this castle-like resort are genuinely treated as royalty. The resort is one of the few in the United States to have earned the Mobil Five Star and AAA Five-Diamond ratings every year since the awards were established.

The Broadmoor’s emphasis on customer service traces its roots to the early 20th century. When entrepreneur Spencer Penrose purchased the site in 1916, he declared that his goal was to create the most beautiful resort in the world. Top architects and artisans were brought in from around the globe to create an atmosphere of world-class elegance, comparable to the day’s most fashionable resorts in Europe and the Orient. The result came two years later, in 1918, when The Broadmoor officially opened with four wings and an 18-hole golf

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course designed by master architect Donald Ross. Soon after its unveiling, the resort gained a reputation as one of the world’s finest. Many visitors thought the clean mountain air could relieve symptoms of tuberculosis and other bronchial ailments.

While The Broadmoor still enjoys its reputation as a world-class resort, it had unlikely beginnings prior to the Penrose renovations. Originally built in 1891 on a 2,400-acre site, The Broadmoor first experienced success as a gambling casino. Later that year, a small hotel was added to accommodate gold barons from nearby Cripple Creek. In 1897, the casino and hotel were sold and eventually leased for local events. At one point, the site was even converted into a boarding house and day school for girls.

The modern legacy of The Broadmoor calls to mind more of the craftsmanship of the world’s top designers and architects of 1918, rather than its past as a casino and boarding school. Today, the resort boasts numerous guest amenities. Among them are:

• The Broadmoor Spa, Golf and Tennis Club, a full-service, state-of-the-art spa and fitness center with indoor and outdoor pools • The Charles Court Restaurant, offering lakeside alfresco dining and access to an extensive wine selection of more than 3,000 bottles • The Cheyenne Gourmet, a gourmet shop offering daily cooking demonstrations by any one of the hotel’s distinguished chefs • More than a dozen retail shopping facilities on-site, from fine art galleries to clothing boutiques to decorative craft shops.

Guests visiting The Broadmoor for the first time will no doubt be awed by the natural beauty of one of the world’s finest resorts, no matter the time of year. Whether hiking at one of the property’s numerous foot trails, enjoying a vintage wine by the lake, shopping for fine art, or lounging by the pool, visitors are sure to find The Broadmoor elevates the word “resort” to a new level. ❖

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Suzanne Somers to Speak at 71st General Meeting

The National Board, in conjunction with the ASME International Boiler and Pressure Vessel Committee, is pleased to announce actress and author Suzanne Somers will address the 71st General Meeting Opening Session in Colorado Springs, Monday morning, April 29.

Ms. Somers, perhaps best known for her star turn as Chrissy on the ’70s sitcom Three’s Company, has accumulated countless credits in an impressive career. Now in her fifth decade in the public spotlight (beginning with television guest appearances in the ’60s), Ms. Somers has been no stranger to public battles. Her 1991 book Keeping Secrets chronicles the trials of growing up with an alcoholic and abusive father. Her 1992 follow-up book, Wednesday’s Children: Adult Survivors of Abuse Speak Out, details the emotional, physical and sexual abuse of 22 noted celebrities, in an effort to publicize the trauma that can result from an abusive upbringing. More recently, Ms. Somers has To obtain a discount of $30, all preregistration forms garnered headlines for her announcement that she suffers from and fees must be received by March 29, 2002. breast cancer, as well as for her controversial decision to undergo homeopathic treatment. Preregister TODAY via email with your credit card through InfoLink! on the National Board Web site at www.nationalboard.org. Ms. Somers has been the recipient of numerous awards, both for acting and for public service, including two People’s Choice Or mail the preregistration form with your check or Awards, Las Vegas Entertainer of the Year, the National Council money order to: The National Board, 1055 Crupper on Alcoholism Humanitarian Award and the National Avenue, Columbus, Ohio 43229. Association of American Drug Counselors President’s Award. Reminder: All details about the General Meeting can While noted for her commitment to public service, Ms. Somers be found in this BULLETIN issue or through InfoLink! on the National Board Web site at still maintains an active profile in the performing arts. Her www.nationalboard.org. No other brochures will be popular sitcom Step by Step, co-starring Patrick Duffy of Dallas, mailed. enjoyed a long run during the ’90s. She has also proven herself as a talented singer and composer, performing a one-woman Distribution of any and all literature, other than show in Las Vegas in the ’80s. Her breakout role came in the informational materials published by the National 1973 movie American Graffiti, with her portrayal of the Board and ASME International, is strictly prohibited at “mysterious blonde in the T-Bird.” ❖ the General Meeting. NATIONAL BOARD BULLETIN / WINTER 2002 27 colorado springs

Monday, April 29 Colorado Springs Tour

Take a peaceful drive through some of the most historic and scenic stops in the western United States! Departing from The Broadmoor, guests will tour by coach breathtaking surrounding mountainscapes, as well as several of the area’s most beautiful homes.

Historic “Millionaires’ Row” achieved fame during the Gold Rush of the 1890s. Over the next ten years, the city’s population increased by 300 percent, with more than 50 of these newcomers quickly becoming gold-mining millionaires. During a driving tour through this area located just north of downtown, guests will view the magnificent mansions of that era’s gold-mining tycoons. Noted residents included prospector Bob Womack, who first discovered gold in a cow pasture, a vein which eventually produced more than $125 million in its first decade alone. Other residents included former plumber James Burns, whose Portland Mine yielded $60 million, and Phillip B. Stewart, director of the Colorado Title and Trust Company and friend to Theodore Roosevelt, who was known to dine at Stewart’s lavish mansion. Once it had been established as an enclave of wealth, Millionaires’ Row also began to attract wealthy out-of-towners seeking the thin mountain air to cure them of tuberculosis.

After driving through Millionaires’ Row, guests will visit downtown Colorado Springs, which has recently experienced an economic boom. A number of successful renovations have been completed, including the addition of several new restaurants and shops. Thanks to corporate and charitable donations, the downtown landscape also features a unique series of attractions: 25 pieces of public sculpture — from the lighthearted “Uncle Wilbur” water jet fountain, to the formal likeness of Spencer Penrose, founder of The Broadmoor resort.

It is recommended that guests wear comfortable walking shoes, layered clothing and a light jacket. ❖ guest program

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Garden of the Gods and Old Colorado City Tour

Garden of the Gods , the 1,300-acre park located at the base of Pikes Peak, offers a striking view of two converging landscapes — the Great Plains and the Rocky Mountains. On this walking tour, participants will encounter natural features unique to this unusual crossroads, including towering red sandstone formations. A professional tour guide will escort the group, detailing the park’s history and unusual geological features.

After touring Garden of the Gods, visitors will travel to Old Colorado City for lunch tentatively planned at Cafe Latte, a quaint restaurant serving sandwiches, salads, teas and espressos. Old Colorado City is a national historic district Tuesday, featuring more than 100 shops, galleries and restaurants in April 30 just three city blocks! After lunch, the first stop is the Michael Garmens Gallery , featuring a miniature replica of an “Old West” town, followed by a walking tour of the area, as well as additional shopping opportunities. ❖ Pick Your Historic Colorado Springs Tour Pleasure On this tour of Colorado Springs by luxury coach, knowledgeable guides will present an Tours overview of the city, followed by a visit to two of the area’s eminent historical sites. The McAllister House is the restored home of Visitors may choose Army Major Henry McAllister, one of the city’s between one of founding fathers. Built in 1873, the home is a registered national historic landmark, and these tours: stands as one of the few surviving houses from that era. (During that time, many homes were actually ordered by mail and shipped from Chicago!) Major McAllister vowed that his home would symbolize the permanence of the new settlement at Colorado Springs.

Another national historic landmark, the Fine Arts Center offers visitors several forms of art (music, dance, theater, film, sculpture, painting and drawing) in one showcase. One of the center’s most popular features is its collection of 19th- and 20th-century western American art, including Native American and Hispanic works.

Lunch is tentatively set for the Hearthstone Inn, an historic renovated Victorian home. Like the Old Colorado City tour, this tour closes with shopping opportunities for visitors. ❖ guest program

NATIONAL BOARD BULLETIN / WINTER 2002 29 colorado springs

Wednesday, May 1 The Manitou and Pikes Peak Railway

This tour is not One of approximately 55 rack or “cog” railways in the world, the Manitou and Pikes Peak Railway suitable for those is the highest anywhere and features the greatest elevation gain — over 7,500 feet! On Wednesday morning, guests will depart from Manitou Springs (elevation 6,570 feet), traveling through the with breathing Pike National Forest and up Pikes Peak, until finally reaching the summit at 14,110 feet. difficulties and/or heart conditions. Only the remarkable cog rail system makes such an ascent possible. The modern railcars employ the Abt rack system and are diesel-hydraulic: powered by diesel engines which in turn power a Since reservations are traction motor for the ascent. They descend using a hydraulic retardation braking system. Some limited, guests are sections of the cog railway climb a 25 percent grade, with an average grade of 15 percent. asked to register early. The journey up Pikes Peak takes guests through five of Colorado’s eight distinct life zones, ranging Lunch will be served from a plains zone to an alpine zone. Animal life varies from small prairie dogs and rabbits, to at approximately bears and mountain lions, up to the alpine zone’s yellow-bellied marmots and bighorn sheep. 1:00 p.m. The historic Manitou and Pikes Peak Railway was completed in 1891, by mattress company magnate Zalmon Simmons. Originally powered by steam locomotives, tourist trains have been operating here ever since.

Lunch is tentatively set for the Briarhurst Manor, a Victorian Tudor estate built in 1876 and offering spectacular views of Pikes Peak.

Following lunch, tentative plans include a tour of the U.S. Olympic Committee headquarters, training site for many top Olympic athletes. ❖ guest program

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PRELIMINARY PROGRAM for the 71ST GENERAL MEETING of THE NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTORS and THE ASME INTERNATIONAL BOILER AND PRESSURE VESSEL COMMITTEE

MONDAY, APRIL 29 — TUESDAY, APRIL 30 —

Opening Session: General Session: 10:00 a.m. Remarks by Suzanne Somers 9:00 a.m. “FALCON FUTURE” INFRASTRUCTURE REINVESTMENT AT THE U.S. AIR FORCE 12:00 noon LUNCH BREAK ACADEMY COLONEL SCOTT BORGES, Commander of the General Session: 10th Civil Engineer Group 1:15 p.m. “JUNKYARD WARS”: United States Air Force Academy AN IMPROVISED STEAM CAR JEFF DEL PAPA, Team Leader 9:30 a.m. AN INSPECTOR’S GUIDE TO THE The New England Rubbish BREWING PROCESS Deconstruction Society (The N.E.R.D.S.) BILL KARLIN, Utilities Engineer Coors Brewing Company 2:30 p.m. BREAK 10:00 a.m. “WHICH END IS THE FRONT?”: REGULATIONS 2:45 p.m. AMERICAN INSURANCE ASSOCIATION: FOR HISTORIC LOCOMOTIVE BOILERS IN A PROMOTING SOUND SAFETY LEGISLATION NEW CENTURY IN THE BOILER AND PRESSURE VESSEL INDUSTRY BILL WITHUHN, Senior Curator of Transportation History JERRY STURCH, Chairman Smithsonian Institute AIA Boiler and Machinery Legislative Committee 10:30 a.m. BREAK

3:15 p.m. THE CYCLE OF PREPAREDNESS 10:45 a.m. STATE POLICY AND NEW ELECTRICITY GLEN NICKEL, Vice President, Operations GENERATION Center for Preparedness Training MATTHEW BROWN, Director of the Energy Project National Conference of State Legislatures

11:15 a.m. WHY BOILERS FAIL RITA DeHART, P.E., Owner Reliant Engineering

preliminary program

NATIONAL BOARD BULLETIN / WINTER 2002 31 –––––––––––––––––––––––––––––––––––––––––––––– HAVE YOU MET . . . ? Yash Nagpaul Manager/Chief Boiler Inspector, State of Hawaii

abandon his intention of making sure that each of his children secured a good education.

But Yash had some goals of his own. “Since the eighth grade, my heart was really into becoming an actor,” he reveals with a grin.

However, family members had other ideas. “My older brother was instrumental in convincing me that I should pursue a career in medicine by going to college,” he explains.

In order to continue his education, Yash found it necessary in 1963 to get a job following high school. Accepting a position more than a thousand miles from home at a steel company power plant in Rourkela, he devised a plan to get his bachelor’s degree in science by working the late 10 p.m. to 6 a.m. shift and attending college during the day.

If there is any doubt that safety is viewed with anything less than reverence in “That was essentially my routine for the four different parts of the world, one should speak with Yash Nagpaul. years I pursued my degree at Rourkela Science College,” he explains. It was also during this The India-born manager/chief boiler inspector for the state of Hawaii can offer a four-year period that he decided to become a multinational perspective. And the message is reassuring. boiler engineer instead.

“I think all of us want to feel safe,” he articulates in words that still reflect the “Following my 18-month training period at the cultural influence of his native country. “What separates safety issues among power plant, I was placed into a position of boiler different parts of the world is often the financial resources available to make that operator,” he continues. “I remained at the plant personal security a reality.” for three years after earning my degree.” And he might have worked there even longer if not for a For some Third World countries, Yash explains, that means having public and letter and photograph he received from his father corporate safety officials who assume their responsibilities with “uncompromising early in 1972. determination and commitment.” “The letter said, quite simply, that I was engaged It is that same dogged sense of dedication that Yash brought to Hawaii 21 years ago to the young lady in the photo,” Yash recalls with when he went to work for the jurisdiction as a boiler inspector. For him, it was the a gentle smile. “As is our tradition, my father had culmination of a career evolution that began as a youth growing up in the Indian arranged my marriage with a family he had known state of Rajasthan. for about 35 years, from our early days in Pakistan.” “My birthplace of Lyallpur, India [now Faislabad, Pakistan], was politically partitioned in 1947,” Yash relates with a tone of resignation. Although only two Returning home to formalize the engagement, years old at the time, his grain merchant father and mother emigrated with their four Yash realized it would be three months before he children to Rajasthan, “so my family could continue to earn a living.” Although it finally met his bride-to-be . . . on the day of their meant leaving behind just about everything the family owned, Yash’s father did not wedding. 32 NATIONAL BOARD BULLETIN / WINTER 2002 HAVE YOU MET . . . ? –––––––––––––––––––––––––––––––––––––––––––––––

It was shortly after Santosh and Yash Nagpaul inspector,” the Hawaiian official explains. “The wed in 1972 that Yash learned of a plastics only condition of my employment was to obtain company in Bombay [now Mumbai] looking for my National Board commission within six experienced engineers. Hired as an assistant months.” boiler engineer, the Hawaiian official spent two years in that position before old yearnings from It took Yash only two and one-half months to sit his youth began to resurface. for and pass the rigorous examination. After five years as a field inspector, he was promoted to “I still had the desire to get into television and supervising boiler inspector. He was named chief movies,” he explains. Deciding to audition for an boiler inspector in 1992. opening as a Hindi newscaster at a Bombay television station, he was among 25 finalists “In retrospect, the decision to come to America selected to take a field test from a field of 250. was good both for my family and myself,” Yash Although apparently having done well on the explains. His son Ashu owns a clothing import voice portion of his audition, it was — Yash business while daughter Ritu is finishing her believes — “the large mustache” he was sporting master’s degree in information technology. at the time that finally doomed his first bona fide flirtation with show business. “In terms of professional satisfaction,” Yash emphasizes, “I can’t think of anything I would In 1974, Yash applied for and secured a job as rather be doing than protecting the public.” To boiler controller at a coal-fired thermal plant in that end, he has been involved with numerous the city of Bhatinda in the state of Punjab. It was efforts to amend and fine-tune state standards. here six years later that he would reach a decision that would change his life as well as the lives of According to Yash, much of his operation’s his family members (which now included a small success is due to the outstanding cooperation son and daughter). received from Hawaii Occupational Safety & Health Administrator Jennifer Shishido. “Her During a trip back to India, Santosh’s brother — support of my involvement with the National who lived in Hawaii — encouraged the Nagpaul Board has been particularly important to the clan to join him in the 50th state. There, he people of Hawaii,” he acknowledges with a smile. emphasized, Yash and his young family would be Yash’s work in Hawaii and respect within the exposed to a much wider selection of National Board earned him election last year to opportunities than those available elsewhere. the National Board Board of Trustees as member Additionally, the brother-in-law reasoned, Yash at large. would be in a better position to advance his career. With only six years to go before retirement, Yash likes to spend his limited amount of free time Reminiscent of Yash’s father’s decision in August doing the things that provide the creative outlet of 1947 to bring his family from Pakistan to India, he so craves: photography and cooking, and of the future National Board member — without a course, singing and playing his harmonium. And job or any job prospects — took a remarkably then there are those occasional opportunities bold step in August of 1980 by effecting his own when he receives a request to sing before an family’s relocation from India to Hawaii. audience.

With an impressive menu of professional As for his more than fifty-year love affair with the experience under his belt, it was not long before stage, the Hawaiian chief inspector has not yet the Indian emigrate was once again gainfully given up on catching the proverbial “big break.” employed. “There is still time,” he confirms with a wink. “But Don Ho needn’t worry.” “In December of 1980, I joined the state boiler and elevator inspection branch as a boiler At least not yet . . . ❖ NATIONAL BOARD BULLETIN / WINTER 2002 33 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

Why Boilers Fail

By hy Boilers Fail” – a simple title with broad implications. The conditions described in this Rita M. DeHart, P.E. “Warticle are only a fraction of the causes of boiler incidents. Causes of boiler incidents can come from problems arising in operation, maintenance practices, and company policy. Here are just a few of them.

Poor Operation and Maintenance Practices

Low-Water Conditions Most pressure-part explosions are the result of low boiler water level conditions. Adding water to a boiler with a dangerously low water level is the leading cause of these explosions. When in doubt, kill the fire and allow the boiler to cool before restoring it to service. Downtime is expensive, but replacement is even costlier. Of course, no one can put a cost on injuries and lost lives.

Results of low-water conditions: For locomotive boilers, rupture of the crown is inevitable if water drops below the crown sheet. Exposed metal becomes red hot, greatly reducing the tensile strength of the metal. Rupture of a crown sheet is violent, and a dangerous explosion will often follow. Locomotive boilers are of particular interest because they are still widely used in antique machinery society traction engine steam shows and railroad museums. [Editor’s note: See page 10 for more information about maintenance and repair of steam locomotive boilers.]

For horizontal return tube (HRT) firetube boilers, low water causes successive leaking of tubes from top to bottom as the rolled-in seat is broken by the expansion of overheating tubes. Explosion is not as likely as with locomotive boilers; however, the tubes may melt.

A dangerously low level in a watertube boiler can cause the expanded seats to break. Low water may also cause tube rupture or tube melting. Tube ruptures are very dangerous and have resulted in fatalities.

Causes of low-water conditions: The following are either direct causes of low-water condition or can result in a low-water condition: ■ Failure to test low-water cut off (LWCO) devices. ■ Failure to blowdown LWCO and gage glass columns daily. ■ Failure to perform the LWCO slow-drain (actual low-level) test. ■ Faulty feedwater regulator (regulator stuck, scale build-up, leaks, actuator control-air problems). ■ Feedpump speed problems (drive turbine speed control malfunction, faulty hydraulic coupling scoop tube operation). ■ False high readings due to foaming in the boiler/drum. ■ False high readings due to sludge and scale in the gage glass and level control instrumentation.

34 NATIONAL BOARD BULLETIN / WINTER 2002 FEATURE ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Some CRT-based distributed control systems Prior to establishing ignition in a boiler, the (DCS) allow operators to DISABLE steam drum furnace must be purged with clean air to remove level trips. This ENABLE/DISABLE feature is a combustible substances. Basically, a purge simple electronic toggle that is normally activated consists of displacing a given number of furnace from the boiler feedwater flow control screen volumes with clean air for a defined time period. graphic. The use of this feature should be Purging is defined in the new National Fire restricted to persons who have “controls Protection Association (NFPA) Code No. 85, configurer” status, and only used when the boiler Boiler and Combustion Systems Hazard Code. is out of service. Even the best trained and most This document was authored in 2001, and is a knowledgeable operators can become distracted compilation of individual NFPA standards based during abnormal operation, thus forgetting a on firing type. [Editor’s note: See page 6 for more “DRUM LEVEL TRIP DISABLED” condition information about NFPA 85.] and causing possible catastrophic tube rupture in watertube boilers. Purge interlocks must NEVER be bypassed in order to save time or to circumvent CAUTION: Surprisingly, most low-water failures malfunctioning equipment. If ignition is lost, the occur in boilers with automatic controls. This is furnace MUST be purged before re-lighting. likely due to over-reliance on automatic boiler feedwater systems. A boiler operator must Flame safeguard systems (FSS) and burner NEVER completely rely on automatic feedwater management systems (BMS) must only be tuned controls. Visual inspection of water level and and maintained by qualified personnel. maintaining level gages and control equipment in A potentially dangerous practice involves good working order are crucial. configuring control systems when a boiler and its associated systems are in service. Online control Failure to Purge configuration has been made easier by the advent Failure to properly purge a boiler is a leading of the DCS. cause of fireside explosions, flarebacks and “puffs.” Furnace or fireside explosions occur CAUTION: There are other causes of furnace when unwanted combustibles build up in a boiler explosions. Sometimes these explosions can be furnace and are subsequently ignited. This occurs caused when liquid fuel pools on a furnace floor in two general ways: (1) introduction of unburned due to a leaking fuel valve or broken burner fuel in the furnace, and (2) presence of fuel-rich components. In this instance, a purge would be products of combustion. ineffective in removing combustibles. Nothing takes the place of a thorough visual inspection of The second cause of furnace explosions can be the furnace, firing components, and surrounding subdivided into (a) substoichiometric combustion1 area prior to light-off. and (b) momentary lapse of ignition. A fuel-rich combustion gas mixture can ignite as secondary “Puffs” can be caused by rapid load changes, combustion in the convection pass sections of malfunctioning or slow-responding induced draft utility and large industrial watertube boilers. (ID) fan control dampers, ID fan trip, sootblower operation, and tube ruptures. Operators and other persons in the vicinity of a boiler must wear 1 Utility boiler low NOx burners and cyclones deliberately proper protective gear, especially when opening burn in a fuel-rich environment. However, overfire air is added (staged combustion) to the fuel-rich mixture and observation doors. completes the combustion as the gases enter the main furnace and before the gases enter the convection pass area of the boiler. NATIONAL BOARD BULLETIN / WINTER 2002 35 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

Flame Impingement insulators, the steam pocket can cause tube metal Flame impingement can cause damage to boiler overheating and resulting tube failure. Watertube pressure parts and refractory. In HRT firetube boilers are susceptible to the scale formation and boilers, flame impingement on the boiler shell corrosion that also affect firetube boilers. will cause excessive evaporation of the water at the point of contact. The high temperatures can Improper Water Chemistry cause damage due to scale formation or corrosion Inadequate or incorrect water chemistry can lead that would otherwise be dormant. The temperature to (1) deposits, (2) scale, (3) erosion and may also be high enough to cause overheating of (4) corrosion. Any one of these can lead to boiler the plate, resulting in serious damage. failure.

In watertube boilers, direct flame impingement Deposits: Deposits are defined as materials that can cause steam pockets to form. This is caused originate in a location other than the deposition when the rate of evaporation is greater than the site. Deposits are typically related to localized rate at which cooler water can be replaced. heat input, water composition, or water Because steam blankets can act as thermal turbulence at the tube wall. Common deposits include calcium carbonate, silicates, phosphates and elemental copper.

Scale: Scale is especially dangerous to boiler tubes. Scale acts as a thermal insulator, preventing water and steam from removing heat and causing overheating of the affected tubes [see Figures 1a and 1b]. In addition, heat that is not transferred to the water in the scale-affected tube will be bypassed to clean tubes, causing an excessive heat input to the water and/or steam in those tubes as well. Figure 1a — Typical tube profile across tube wall. Reprinted with permission of ALSTOM Power Inc. Erosion: Erosion is rare in the water- and steam- sides of boiler tubes. Erosion can occur when flow is restricted by scale or lodged foreign objects. Erosion on the inside of water/steam tubes generally is not a primary cause of boiler failure; associated problems such as overheating will generally cause failure before erosion can cause severe damage. For example, forming defects in tubes can contain fissures that open up during service, causing steam-cutting (erosion) of adjacent tubes.

Corrosion: Corrosion can be caused by a number of conditions and substances. Of particular Figure 1b — Temperature profile across tube wall interest is stress-corrosion cracking. Stress- with internal deposit. corrosion cracking occurs when a vessel under Reprinted with permission of ALSTOM Power Inc. pressure, such as a steam drum, operates in a 36 NATIONAL BOARD BULLETIN / WINTER 2002 FEATURE ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

high pH environment. The caustic water corrodes pressure. For example, one pound of dry saturated the drum metal, causing intercrystalline cracks to steam at 150 psia occupies approximately 3 cubic form [see Figure 2]. The combination of operating feet, while one pound of dry saturated steam at 50 pressure (the stress) plus corrosion causes psia occupies approximately 8.5 cubic feet. The damage to occur. In riveted drums, this can be an densities are also quite different: at 150 psia, the extremely dangerous condition, leading to rupture density is 0.332 pounds per cubic foot, while at of the entire vessel. In welded drums, stress- 50 psia, the density is 0.117 pounds per cubic corrosion cracking can cause failure where the foot. Since boiler generating circuits are designed tubes are welded to the drum. for a given design pressure, operating substantially below this value changes the circulation and heat distribution in the boiler, which can lead to tube overheating and scaling. This is because at lower pressures the volume of steam becomes so large that it can choke the flow inside the tubes.

Secondly, the circulation ratio is altered. Circulation ratio is defined as the mass of steam generated vs. the mass of water in the generating circuits, and varies with the saturation pressure. Steam separating equipment is designed for a given circulation ratio corresponding to the design pressure. Changes in this value can cause problems in the separating equipment, such as Figure 2 — Stress corrosion appearance. priming. Reprinted with permission of ALSTOM Power Inc. Problems can also be encountered with Another phenomenon of interest is flow- superheaters in a lowered-pressure condition accelerated corrosion (FAC), often found in heat- because the steam might not divide equally recovery steam generators (HRSGs). FAC occurs between the elements. primarily in the two-phase (evaporator) circuits, and is caused by (1) the flow geometry, (2) the Improper Shutdown and flow velocity, and (3) excessive dissolved oxygen. Lay-Up Practices It is essential that sufficient oxygen-scavenging An improper shutdown of a boiler can cause chemicals are used and that deaerators are corrosion and subsequent deterioration of boiler functioning properly (on those HRSGs so equipment in much the same way as improper equipped). operation. Corrosion is caused by oxygen, water, and low pH; therefore it is all-important that Off-Pressure Operation either water or oxygen are kept out of the system Most people in the boiler industry are aware of during idle periods. the dangers of operating boilers at pressures above design. Fewer are aware of the problems Soot, if not cleaned, can form sulfuric acid on with consistently operating boilers at pressures boiler fireside surfaces, especially if the boiler is significantly below design. located in a damp environment. Filling a boiler with non-deaerated water introduces excessive First, the density and specific volume of saturated oxygen. steam change appreciably with changes in NATIONAL BOARD BULLETIN / WINTER 2002 37 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– FEATURE

The two ways to lay up a boiler are: (1) keep the tubes. HRSGs are particularly susceptible to interior dry and (2) fill the interior with water. damage caused by dissolved oxygen, and proper deaerator operation on these units is a must. Dry Method (Long-Term): Remove all soot and ash. Thoroughly wash out the interior of the boiler Deaeration is both a thermodynamic and and allow it to dry. Place unslaked lime mechanical process that operates on Dalton’s Law (or reusable dessicants such as silica gel or of partial pressures and on Henry’s Law. The activated alumina) in open containers inside the latter law basically states that the partial pressure drum. The lime or dessicant will absorb moisture of a non-condensable gas within a saturated from the air confined in the boiler. Inspect the environment must be zero. This means that the interior every few months and replace any lime noncondensable gases are already “primed and that has become slaked (reduced to fine powder ready” to come out of the feedwater inside the by the absorption of water). Dessicant can be deaerator, which when operated properly is at dried out by heating and then reused. saturation condition. The steam mechanically removes the gases. Wet Method (Short or Indefinite Term): Add caustic soda or sodium sulfite in concentrations In a typical tray-type deaerator, feedwater enters specified by the manufacturer. Fill the boiler to through a spray nozzle header where the water is the top of the drum with deaerated feedwater. broken up into small droplets. Water leaving the Analyze the water often, and if caustic alkalinity spray nozzles cascades over a series of staggered and sodium sulfite are below specified values, trays, causing further breakdown in water droplet lower the boiler water level and add chemicals to size. At the same time, steam is admitted to the increase the concentration to the original values. deaerator vessel and flows upward between the Heat the water to circulate the chemicals and rows of trays, thus scrubbing the dissolved gases completely fill the drum again with deaerated water. from the water. The steam carries the gases out through a vent valve. Another method of storing a boiler is to add chemicals as described above and place a Anything that causes the deaerator to operate nitrogen blanket above the water. This blanket improperly will cause the introduction of prevents air from leaking into the boiler and dissolved oxygen and carbon dioxide into boiler introducing oxygen. feedwater piping and boiler water circuits. A common malfunction in deaerators is broken Auxiliary Equipment: spray nozzles. This condition manifests itself as Faulty Deaerator loud intermittent “banging noises” coming from Even though the deaerator is located outside of the deaerator, along with rapid pressure the boiler envelope in most installations, proper excursions. Another malfunction is the “galloping operation of the deaerator plays a key role in tray syndrome” caused by broken tray and tray preventing damage to boiler feedwater piping and housing supports. boiler circuits. Operator-controllable deaerator malfunctions Deaeration is the removal of dissolved oxygen, include using insufficient steam flow, and off- carbon dioxide, and other non-condensable gases design steam pressures and temperatures. Of from boiler feedwater using steam as the course, bypassing the deaerator by filling a boiler “scrubbing” medium. Dissolved oxygen and or HRSG using non-deaerated water prior to carbon dioxide cause corrosion and subsequent startup introduces dissolved oxygen and carbon damage to boiler feedwater piping and boiler dioxide into the boiler/HRSG water circuits. 38 NATIONAL BOARD BULLETIN / WINTER 2002 FEATURE ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

PERILOUS POLICIES players in maintaining healthy boiler life. Some doctors still do make house calls! Failure to Train Personnel As stated previously, adding water to a boiler with “Duct Tape Maintenance” a dangerously low level is the leading cause of There are thousands, if not millions, of public pressure-part explosions, and failure to properly buildings that contain boilers, all of which must purge is one of the leading causes of furnace be operated and maintained properly. Quite often explosions. In many instances these incidents are these institutions are not industrial in nature, and caused by lack of knowledge on the part of the the boiler is thought of as “that round thing in the boiler operator. Even in 2001, too many operators basement with pipes coming out of it.” As a result, fail to avail themselves of proper training, and the management frequently gives little thought to misconceptions surrounding boiler operation are mechanical systems, and fail to appropriate widespread. Boilers are very safe when tended by sufficient monies for their institutions’ engineering operators who know the equipment and the budgets. operating limitations. Those who operate boilers without knowledge of the equipment are doing so The results can make quite an impression. Often on borrowed time. inexperienced maintenance personnel try to keep malfunctioning boilers operating by tinkering There are many excellent boiler operator training with the combustion controls while the boilers are materials and workbooks available at reasonable in service. There are numerous documented cases costs for facilities with conservative training of furnace explosions, including a violent furnace budgets. Budget constraints are NOT an excuse. explosion at a school that injured three workers.3 A training program that consists of (1) “go-follow- Budget constraints discourage the hiring of that-guy-and-see-what-he-does” and (2) “you- qualified mechanics and electricians as well as can-stick-this-piece-of-paper-in-the-float-switch- qualified (“R” stamp-holding) repair firms for to-stop-that-nagging-alarm” is virtually welded repairs. Rita M. DeHart, P.E., guaranteed to bring down the house. is the owner of Reliant Lack of consideration for the boiler and resulting Engineering [not affiliated Failure to Inspect the Boiler budget constraints can also lead to cutting with Reliant Energy] in Charlotte, North Carolina. A tragic example of a failure due to lack of corners when procuring new and replacement DeHart has been affiliated inspection occurred in 1982 when an 80-gallon parts. It is vital to purchase equipment that is with the electric power steel water heater exploded at the Star Elementary built to the ASME Boiler and Pressure Vessel generation industry since 1975 School in Spencer, Oklahoma, killing seven Code. Fittings and controls must be accepted by in operations, plant results, and training. DeHart, a native people and injuring 42. The water heater’s agencies such as Underwriters Laboratory (UL). of Tampa, Florida, is a temperature probe was missing, the safety valve Rebuilt controls must never be used. registered professional was in the wrong place, and the controls had been engineer in the state of North Carolina and earned an MBA altered. In addition, the water heater had been in Training and qualification are as important for from Queens College in a state of disrepair for three or four years. A maintenance personnel as they are for operators. Charlotte. trained boiler inspector would have easily noticed It is also a good idea to provide some basic boiler these problems, but at the time, Oklahoma’s orientation training for procurement personnel Ms. DeHart will elaborate on WHY BOILERS FAIL, with boiler laws pertained only to high-pressure and building occupants. ❖ particular emphasis on HRSGs, boilers, and there was no formal inspection at 11:15 a.m. on Tuesday, program for water heaters.2 Political jurisdictions April 30, during the 71st 2 In 1982 the law was modified to include water heaters as National Board/ASME General do well to adopt comprehensive boiler inspection a result of this tragedy.

Meeting in Colorado Springs. laws. It is also essential for boiler owners and 3 ❖ National Board BULLETIN, “School Boiler Maintenance operators to welcome boiler inspectors as key Programs: How Safe Are the Children?,” Fall 1997. NATIONAL BOARD BULLETIN / WINTER 2002 39 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– PEOPLE

NEW MEMBERS ELECTED IN NEW HAMPSHIRE AND OREGON

Wayne Brigham, state boiler inspector with Wisconsin, Ohio and Pennsylvania. He holds the New Hampshire Department of Labor, and National Board Commission No. 7502 with an F. Ray Andrus, acting chief inspector with the “A” endorsement. State of Oregon, have been elected to the National Board. Mr. Andrus replaces Curt Lundine, who resigned from National Board membership in September. Mr. Brigham joined the State of New Hampshire Now serving as acting chief boiler inspector, in January 2001. He had been employed Mr. Andrus has been employed with Oregon’s previously by Hartford Steam Boiler as a boiler Building Codes Division since 1996, first as machinery inspector. deputy chief boiler inspector and then as Wayne Brigham assistant chief boiler inspector. Mr. Brigham’s career began in 1963 at the Hampshire Chemical Company, where he was Prior to joining the State of Oregon, Mr. Andrus employed as a boiler operator for seven years. His had been employed for ten years as a stationary industry experience also includes serving as an engineer at Eastern Oregon University/State of authorized inspector for Home Insurance Oregon. In a career that spans more than three Company for 14 years and for Commercial Union decades, he also has experience as a power plant Insurance for five years. Mr. Brigham was operator, building maintenance supervisor and employed previously as a boiler safety specialist boiler mechanic. He served in the United States for the State of Wisconsin for three years, Air Force from 1965 to 1969. performing inservice and shop inspections. Mr. Andrus holds National Board Commission F. Ray Andrus Mr. Brigham is licensed to inspect boilers in all No. 11898, with “A” and “B” endorsements. ❖ New England states as well as in New York,

MOONEY ELECTED TO BOARD OF TRUSTEES

During the Chiefs Technical Meeting in October, Commonwealth of Massachusetts as a district National Board members confirmed Mark Mooney engineer inspector, he worked at the Bechtel as second vice chairman of the National Board Semass Waste-to-Energy Facility from 1988 to Board of Trustees. Mr. Mooney is completing the 1996 as an operating engineer, eventually term of former Oregon Member Curt Lundine, becoming the chief engineer. who resigned from National Board membership in September. His term will expire in 2003. Mr. Mooney was graduated from the Massachusetts Maritime Academy with a Mr. Mooney has been employed with the bachelor’s degree in marine engineering. He Massachusetts Department of Public Safety for resides in Mattapoisett, Massachusetts, with his Mark Mooney five years as assistant chief of inspections/chief wife, Judy, and two children, Zech and Mikayla. boiler inspector. Prior to joining the ❖

40 NATIONAL BOARD BULLETIN / WINTER 2002 PEOPLE –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

BYNOG TO CHAIR NBIC COMMITTEE

George Bynog, chief boiler inspector with the Mr. Howard had been chairman of the NBIC Texas Department of Licensing and Regulation, Committee since 1995. has been elected chairman of the National Board Inspection CodeCommittee. His election took Donald Tanner, executive director of the National place during the NBIC Committee meeting in Board, praised Mr. Howard’s many contributions August and was later confirmed by the chairman throughout his career in the boiler and pressure of the Board of Trustees. He replaces Ron vessel industry: “Ron Howard has been a true Howard, who retired from the position and from his friend of the National Board. We wish him a career in December. healthy and happy retirement.”

George Bynog Mr. Bynog has been a National Board member In other NBIC Committee news, Robert since 1989 and holds National Board Commission Wielgoszinski has been elected NBIC vice No. 9683. He has been a member of the NBIC chairman, and three National Board members Committee since 1990. have been appointed to serve on the NBIC Committee. They are Robert Cate of Louisiana, Mr. Howard was employed by the Hartford Steam Mark Peterson of Alaska, and John Engelking of Boiler Inspection and Insurance Company for the Maryland. ❖ past 27 years. He most recently held the position of assistant vice president of quality, engineering services.

Ron Howard

CALLING ALL HONORARY MEMBERS

If you are an elected honorary member of The National Board of Boiler and Pressure Vessel Inspectors, we want to hear from you!

The National Board is in the process of updating its list of honorary members, including current mailing addresses.

To receive a special gift and confirm/update your mailing information, please contact Office Manager Judy Longhenry by phone at 614.888.8320 or by email at [email protected] at your earliest convenience. ❖

NATIONAL BOARD BULLETIN / WINTER 2002 41 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– PEOPLE

WITHERS JOINS NATIONAL BOARD STAFF

In September, Chuck Withers joined the National Pressure Protection Committee and the Board of Board staff as a senior staff engineer, with Trustees Nominating Committee. responsibility as secretary of the National Board Inspection Code Committee. Mr. Withers was employed previously as an authorized inservice inspector with Kemper Mr. Withers left his post as chief boiler and National Insurance Companies (1985-96) and as pressure vessel inspector of Colorado, a position an authorized nuclear inspector with Hartford he had held for the last five years. In Colorado’s Steam Boiler. He served in the United States Department of Labor and Employment, Navy from 1976-82 as a nuclear machinist mate Mr. Withers managed a department of 15 and qualified engine room supervisor. Chuck Withers employees and provided technical support to more than 50 third-party insurance inspectors. Mr. Withers holds National Board Commission He has also served on the National Board’s Over- No. 10043 with “A” and “B” endorsements. ❖

LEE DORAN RETIRES FROM THE NATIONAL BOARD

Leroy (Lee) J. Doran, governmental affairs and international representative, has retired from the National Board, effective January 1. He had served in that position for three years.

Mr. Doran had been employed by the National Board since 1995, when he was hired as a field staff representative. He also was a consultant for the Bureau of Indian Affairs/Southwest Indian Polytechnical Institute. From 1991 to 1992, he served as chief inspector for the State of Florida and was elected a National Board member. Prior to that, he was quality control manager for Clark Boiler & Engineering in Lakeland, Florida. Mr. Doran also served as a private boiler repair contractor for more than ten years.

For almost 22 years, Mr. Doran served as a marine engineer in the U.S. Navy and is a veteran of the Vietnam conflict. He retired as lieutenant commander in 1975.

Throughout his career with the National Board, Mr. Doran has served on numerous committees. He has been recognized for his contributions by many governmental entities and industry organizations. Most recently, ABMA presented him with its 2001 Volunteer of the Year Award.

Donald Tanner, executive director of the National Board, praised Mr. Doran’s many contributions to both the National Board and to the boiler and pressure vessel industry as a whole: “Lee Doran has been a valuable member of our National Board family, and we will miss his expertise and knowledge. We wish him and his wife, Coletta, all the best.”

Mr. Doran holds National Board Commission No. 8028 with “A” and “B” endorsements.

The Dorans are retiring in Los Lunas, New Mexico. ❖

42 NATIONAL BOARD BULLETIN / WINTER 2002 TRAINING MATTERS –––––––––––––––––––––––––––––––––––––––––––––––––

RICHARD D. McGUIRE MANAGER OF TRAINING

SAFETY BY ASSOCIATION

It’s a fact: association helps jog the human memory. • Inspection, Repair and Alteration of Graphite Pressure Equipment (Appendix 8) For example, when much of North America resets • Historical Boilers (Appendix C) its clocks in accordance with Daylight Savings • Recommended Procedures for Repairing Time, the public-service message from the local Pressure Relief Valves (Appendix E) fire marshal encourages homeowners to change • Recommended Guide for the Inspection of the batteries in each home’s smoke alarms. That Pressure Vessels in LP Gas Service – way, every six months, we are reminded to install Nonmandatory (Appendix H). fresh batteries simply by virtue of association. Regardless of whether we gain or lose an hour of Three National Board courses are tailored to the sleep, our homes and families are safer in the needs of various industry segments, with special event of fire. sections devoted to NBIC revisions.

Similarly, the release of a new edition of the Those charged with overseeing a company’s NBIC is an ideal time to take a refresher course quality control must be especially vigilant in on it. Every three years the National Board keeping their employers’ safety regulations and releases a new edition of the National Board practices current with industry developments. Inspection Code (NBIC). The NBIC is a living Please consult our Web site at document – because the boiler and pressure www.nationalboard.org for a complete description vessel industry is changing and developing so of the Manufacturers and Repair Organizations rapidly, many updates are made to it during any Seminar (M), a five-day course. given three-year span. Those charged with inspecting inservice boilers Boiler and pressure vessel inspectors, quality and pressure vessels, or with performing or assurance managers, and anyone performing or overseeing repairs or alterations to them, must overseeing repairs or alterations, must stay also be vigilant in complying with inspection and current with the latest safety rules and regulations repair requirements. We recommend the Boiler concerning pressure equipment. and Pressure Vessel Repair Seminar (R), a two-day course, or the one-day seminar entitled How to For instance, since the release of the 1998 Complete a Data Report/Highlights of the edition, inspection requirements related to the National Board Inspection Code. following significant topics have been revised and/or added: Whichever course best fits your needs, an NBIC • Additional Requirements for Alterations (Part refresher course is designed to cover all Editor’s Note: The complete 2002 training RC-3000) information included since the last edition was schedule is now available on the • Steam Locomotive Firetube Boiler Inspection released, and to provide critical insight into National Board Web site. Access and Repair (Appendix 3) technological advances within the rapidly www.nationalboard.org and click ❖ on “TRAINING & • Examples of Repairs and Alterations changing boiler and pressure vessel industry. CONFERENCE CENTER.” (Appendix 6) NATIONAL BOARD BULLETIN / WINTER 2002 43 –––––––––––––––––––––––––––––––––––––––––––––– TRAINING CALENDAR

ENDORSEMENT COURSES CONTINUING EDUCATIONAL CONTINUING EDUCATIONAL (A) Boiler and Pressure Vessel Inspection OPPORTUNITIES OPPORTUNITIES Course (ASME Code Sections I, IV, V, VIII - Divisions 1 and 2, IX, X, and B31.1) — (CWI) Certified Welding Inspector Review (R) Boiler and Pressure Vessel Repair Seminar — TUITION: $2,200 Seminar — TUITION: $300 TUITION: March 11–22, 2002 February 11–12, 2002 June 10–21, 2002 Full Seminar (all three courses): $995 AWS Member April 8–9, 2002 $1,070 Non-AWS Member June 24–25, 2002 (B) Authorized Inspector Supervisor Course/ Structural Welding (D1.1) Code Clinic: (O) Owner-User Inspector Supervisor Course $320 AWS Member $395 Non-AWS Member (RTL) Review Team Leader Seminar — (Duties and attributes of a supervisor) — TUITION: $350 TUITION: $1,100 Welding Inspection Technology (WIT): $420 AWS Member April 3–4, 2002 February 18–22, 2002 $495 Non-AWS Member Visual Inspection Workshop (VIW): $320 AWS Member (VR) Repair of Pressure Relief Valves Seminar — (I) Authorized Nuclear Inservice Inspection $395 Non-AWS Member TUITION: $1,100 Course (Acceptance Standards, NDE Procedures, Health Physics, Quality Assurance, February 4–8, 2002 (CWI Exam February 9) January 28–February 1, 2002 Welding and Reporting Requirements, ASME May 13–17, 2002 (CWI Exam May 18) April 8–12, 2002 Code Sections V and XI) — TUITION: $1,250 (M) Manufacturers and Repair Organizations (WPS) Welding Procedure Workshop — April 22–26, 2002 Seminar — TUITION: $600 TUITION: $1,100 February 13–15, 2002 (N) Basic Nuclear Inspection Course on April 15–19, 2002 April 10–12, 2002 Fabrication, Nondestructive Examination and June 26–28, 2002 Inspection of Welded Pressure Vessels (ASME Code Sections III, V, IX, SNT-TC-1A, N626 and NQA-1) — TUITION: $1,250 April 15–19, 2002

All seminars and courses are held at the National Board Training and Conference Center in Columbus, Ohio, unless otherwise noted, and are subject to cancellation. For additional information regarding seminars and courses, contact the National Board Training Department at 1055 Crupper Avenue, Columbus, Ohio 43229-1183, 614.888.8320, ext. 300, or visit the National Board Web site at www.nationalboard.org.

REGISTRATION FORM HOTEL INFORMATION Please circle the program(s) and date you wish to attend. Please print. ❑ single arrival date: Name ______❑ double ______Company ______❑ smoking ______Address ______❑ nonsmoking ______departure date: Phone ______NB Commission No. ______Please enclose check; money order; VISA, MasterCard or American Express number; ______or company purchase order for the total amount of all programs you wish to attend. The National Board is in no way liable for credit card information sent electronically, via mail, or facsimile.

Amount enclosed $ ______

Cardholder ______No. ______Exp. ______/ ______

This form must be received at least 30 days prior to the beginning of the applicable program. For those requiring special assistance facilities, this form must be received at least 60 days in advance of the activity. The National Board will confirm arrangements one month prior to the program. Course fees subject to change without notice. 44 NATIONAL BOARD BULLETIN / WINTER 2002