t Technical Journal of The National Board of Boiler and Pressure Vessel Inspectors WINTER 2011 AUTHOR JAMES R. CHILES UNEARTHING 200 YEARS OF TECHNOLOGICAL DISASTERS BULLETIN WINTER 2011 • VOLUME 66 • NUMBER 1 David A. Douin Executive Director Richard L. Allison Assistant Executive Director – Administrative Charles Withers Assistant Executive Director – Technical Paul D. Brennan, APR Director of Public Affairs On the Cover: James R. Chiles, author of the book Wendy Witherow Inviting Disaster: Lessons from the Edge of Technology Publications Editor See story on Page 18. BULLETIN photograph by Greg Sailor. Brandon Sofsky Manager of Publications BOARD OF TRUSTEES Cover Story Jack M. Given, Jr. 18 James R. Chiles: On the Machine Frontier Chairman Joel T. Amato First Vice Chair Donald J. Jenkins Features Second Vice Chairman David A. Douin 3 National Board Synopsis Update Secretary-Treasurer John Burpee 4 National Board of Boiler and Pressure Vessel Inspectors Member at Large Organizes Brian Krasiun Member at Large 10 80th General Meeting In Las Vegas Gary Scribner Member at Large Milton Washington 14 A Case for the Code: Non-ASME Pressure Vessels at Risk Member at Large 26 National Board Pressure Relief Testing Laboratory: Celebrating 20 Years of Service and 30,000 Tests ADVISORY COMMITTEE Completed George W. Galanes, P.E. Representing the welding industry 28 New Benzene Extraction Unit Makes Gasoline Cleaner Lawrence J. McManamon, Jr. Representing organized labor Kathy Moore Representing National Board stamp holders Brian R. Morelock, P.E. Departments Representing boiler and pressure vessel users Charles E. Perry Representing boiler manufacturers 2 Executive Director’s Message: SAFETY: Consider the Alternative Michael J. Pischke Representing pressure vessel manufacturers 6 Inspector’s Insight: Liquid Penetrant Examination Robert V. Wielgoszinski Representing authorized inspection agencies 16 Pressure Relief Report: Welding Consideration for Pressure Relief (insurance companies) Valves 32 Profile in Safety: Michael Klosterman, Chief Boiler Inspector, State of Iowa The National Board of Boiler and Pressure Vessel Inspectors was organized for the purpose of promoting greater safety by securing concerted action and maintain- 34 Training Matters: 2011: Another Busy Year ing uniformity in the construction, installation, inspection, and repair of boilers and other pressure vessels and their appurtenances, thereby ensuring acceptance and interchangeability among jurisdictional authorities empowered to ensure adherence 35 Training Wrap-up to code construction and repair of boilers and pressure vessels. The National Board BULLETIN is published three times a year by The National Board 36 2011 Training Courses and Seminars of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229- 1183, 614.888.8320, www.nationalboard.org. Postage paid at Columbus, Ohio. nd Points of view, ideas, products, or services featured in the National Board BULLETIN 37 Update: Miami Hyatt Chosen Host Hotel for 82 National Board/ASME do not constitute endorsement by the National Board, which disclaims responsibility for General Meeting; Reminder: Technical Scholarship Deadline authenticity or accuracy of information contained herein. Address all correspondence to the Public Affairs Department, The National Board of Boiler and Pressure Vessel Inspectors, at the above address. 38 Transition: Ponce, Sheeron, Whitman Become National Board Members; © 2011 by The National Board of Boiler and Pressure Vessel Inspectors. All rights Given Elected Chairman, Washington Elected Member-at-Large; Japanese reserved. Printed in the USA. ISSN 0894-9611. CPN 4004-5415. Delegation Meets with National Board; Member Retirements: Jack Davenport, Daniel C. Price, James Harlan. 40 The Way We Were: Blast at McBain School SAFETY: Consider the Alternative BY DAVID A. DOUIN, EXECUTIVE DIRECTOR EXECUTIVE DIRECTOR’S MESSAGE EXECUTIVE DIRECTOR’S A number of years ago, I read a book revealing some pro- spanning 15 years, Mr. Montana led his teams to 31 fourth-quarter found insight on how accidents occur. come-from-behind victories. Rated by Sports Illustrated as the Specifically, the author observed: “machine disasters nearly number one clutch quarterback of all time, he has been designated always require multiple failures and mistakes to reach fruition. third on The Sporting News’ list of Football’s 100 Greatest Players A disaster occurs through a combination of poor maintenance, and the 25th greatest athlete of the 20th century by ESPN. bad communication, and shortcuts.” This year’s General Session will once again provide valu- He further explained: “. a failure begins when one weak able insight to current and recent industry issues, as well as a point begins linking up with others. Even at this stage the failure glimpse of future developments. In addition to hearing from will proceed no further if some force such as an alert employee Mr. Chiles and Mr. Montana, General Meeting attendees will intervenes to stop the chain of events . .” receive an update from Common Arc’s Jim Pillow on the weld- It is a well-known fact the main cause of boiler incidents in ing certification program, and PVMA’s take on mass-produced the US and Canada has always been and continues to be operator pressure vessel production. Chubb Group’s Michael Zdinak error. Hence the constant reminders of how human intervention will present his views on Jurisdictional Inspection Integrity and plays a crucial role in accident curtailment. Ethics. We’ll round out the program with additional perspec- Stopping to consider one’s actions is critical to the safety tive from our associates at ASME and the US Chemical Safety process. If those of us in the pressure equipment industry would Board. just take an extra second to evaluate every move of consequence While there is much to be accomplished by the National and the impact that decision might have on one’s own well be- Board during our week in Las Vegas, ASME – as always – will ing – as well as on the individuals in close proximity – we could be conducting a full complement of committee meetings. Your probably reduce accidents by 80 percent. attendance and participation are not only welcomed by ASME That is why we are designating SAFETY: Consider the Alter- but encouraged. Those who have previously attended the General native as the theme for our 80th General Meeting in Las Vegas. Meeting know these ASME sessions are an excellent opportunity Translation: thoughtful consideration to safety before an incident to witness our industry’s future direction. Additionally, they takes place is more effective than an accelerated decision-making permit those who participate an outstanding chance to share process during a crisis situation. critical code-making input. To amplify upon this General Meeting catchphrase, we have As mentioned last year at this time, the General Meeting invited to our General Session the person who wrote the above- is an ideal occasion to personally interact and exchange ideas mentioned book to provide us his keen insight. That book, Inviting with other pressure equipment professionals. There is no better Disaster: Lessons from the Edge of Technology, is the work of James way to keep up with new technology, the code development R. Chiles, a renowned technology and history author whose ar- process, and the most recent changes in jurisdictional rules and ticles have appeared in Smithsonian, Air & Space, Popular Science, regulations. More important, General Meeting participants will Harvard, Aviation Week, Mechanical Engineering, and Invention & leave Las Vegas with a renewed sense of duty and commitment, Technology. (See Cover Feature, page 18.) as well as the latest information on a wide selection of critical To launch our Opening Session, we have invited another industry issues (so much for the notion What happens in Vegas expert who knows something about decision making under stress: stays in Vegas. ). the iconic NFL Hall of Fame quarterback Joe Montana. Of course, you don’t have to attend this extraordinary inter- Few athletes over the years have amassed a comparable national event. It’s your choice. reputation for the ability to remain cool under pressure than But consider the alternative . this four-time Super Bowl champion. Over a professional career 2 NATIONAL BOARD BULLETIN/WINTER 2011 nationalboard.org FEATURE FEATURE FEATURE FEATURE NATIONAL BOARD SYNOPSIS UPDATE he National Board has completed its annual jurisdictional authorities survey for the purpose of updat- ing the 2010 SYNOPSIS OF BOILER AND PRESSURE VESSEL LAWS, RULES, AND REGULATIONS. Jurisdictions reporting amendments are individually listed below followed by the SYNOPSIS sections Tin which the adjustment(s) occurred. Please be reminded: • SYNOPSIS data is subject to change without notice. Consequently, users should directly consult appropriate jurisdiction officials regarding any actions having significant financial, legal, or safety ramifications. • All data on the National Board Web site is updated to reflect changes in the following categories: Utah – Minor changes to Date of Law Passage, Rules for Construc- STATES tion and Stamping, and Miscellaneous; Vermont – State Depart- ment, Date of Law Passage, Rules for Construction and Stamping, Alabama – Minor change to State Department; Alaska – Rules Inspections Required, Insurance Inspection Requirements, and minor for Construction and Stamping and State Fees; Arizona – Minor change to State Fees; Washington – Objects