Boiler Safety Bureau
Jack Given
Bureau Chief
1101 Mail Service Center
Raleigh, NC 27699- 1101
( 919) 807- 2760
1- 800- 625- 2267
www. nclabor. com
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This newsletter is a publication of the N. C. Department of Labor,
Boiler Safety Bureau. Our offices are in the fifth floor of the Old
Revenue Building, 111 Hillsborough St., Raleigh, NC 27603. Our
mailing address is 1101 Mail Service Center, Raleigh, NC 27699- 1101.
We may be reached at ( 919) 807- 2760, and our fax number is
( 919) 807- 2762. The Boiler Safety Bureau gives permission to make
photocopies of this newsletter for the distribution to employees
and business associates. Articles may be copied in part or in whole
provided credit is given to the Department of Labor.
                      	
                      	 
     
   
     	

     
            
    	   
   
          
                  	 
       
 
 
 
           
   
               
       
   
 	 
                               
           
 
           
    
February 2009 Volume 1, No. 2
The Boiler Safety Bureau lost a friend and
former leader on Tuesday, Nov. 25, 2008. Ben
Whitley, who had a massive stroke a couple of
weeks prior, was laid to rest on Nov. 29. Ben or
Bennie, as he was often referred to, came to the
Department of Labor in 1956 after serving in the
Merchant Marines and the U. S. Army. Then Chief
Inspector Sam Harrison hired Ben and a career
began. Ben served as an inspector until 1973, when
he became acting chief under Commissioner
Billy Creel. In early 1974, Commissioner Creel
promoted Ben and his service as chief inspector
really began. Ben served in honorable fashion
until 1986 when he retired.
During his tenure as chief inspector, Ben proudly served as a member of
the National Board of Boiler and Pressure Vessel Inspectors. Ben served as
a member of the board of trustees for that organization from 1978 until
1986. He was the chairman of that board for the last three years he was on
it. Ben was elected as an honorary member of the National Board after his
retirement and continued to be active at the meetings of the organization
through October 2008, when he attended his last meeting. I traveled with
him to that last meeting and somehow I knew it would be Ben’s last.
Ben was noted to have never met a stranger. At the Sheraton pier in
Atlantic Beach he was called “ four poles Ben.” He was a good friend to most
everyone who knew him. He loved to talk and he loved to make people
laugh. Ben was always ready with a good laugh. He was a mentor to many.
In March 1974, Ben took a chance and hired me. He helped me prepare
for the National Board commission examination. With his help, I passed it
the first time.
I was not the only new inspector that Ben was able to help. A number of
good inspectors received their start with the help of Ben.
Even after I became chief inspector, myself, Ben was always there to give
me sage advice on how to be good at the job. He helped me greatly and I
will truly miss him. Ben Whitley was a gentle man and a true gentleman.
Jack M. Given Jr.
Ben Whitley
Boiler Safety Bureau Chief
1973- 1986
INSIDE THIS ISSUE
--------------------------------------------------------------
A Word From Commissioner Berry............ page 2
Focus on Customer Service .......................... page 2
Public Awareness................................................ page 2
Pressure Vessel Safety Checklist.................. page 2
Air Tanks Do Explode ........................................ page 3
A Short Course in Computer Science ...... page 3
Kudos Corner ...................................................... page 3
Boiler and Pressure Vessel Inspectors .... page 4
A Helpful Hint ...................................................... page 4
Low- Water Cut Off Controls.......................... page 5
AWord From
Commissioner Berry
The New Year is a great time to
renew our commitment to safety by
setting new safety goals and making
new decisions that will ultimately
make our industry better.
I am so proud of the work that
our 14 inspectors with the NCDOL
Boiler Safety Bureau do each year,
but we cannot rest on the successes
of the past. The explosion that is
mentioned in “ Air Tanks Do Explode” on page 3 reminds us
that we can never take the condition of a tank for granted and
must follow the manufacturer’s recommendations on care and
replacement of components. Each inspector must make a
renewed commitment to treat each inspection as if they have
never been there before.
So let’s start 2009 with a renewed commitment to safety.
Focus on Customer Service
One definition of customer service is “ assistance that a
company provides to the people who buy or use its products
or services.” Even though we are a state agency, it is important
that we provide superior customer service. But who are our
customers?
Here in the office, the processing assistants have internal
customers and external customers. Our internal customers
include our state inspectors, management and co- workers. The
state inspectors rely on us to supply accurate information so
they can perform their safety inspections efficiently. We assist
management with day- to- day operations so they can focus on
their duties. We also serve our co- workers to keep the bureau
running smoothly and avoid problems that may arise.
Our external customers ( insurance inspectors, owners/ oper-ators,
and the public at large) are the reason for the bureau’s
mission. We encourage the insurance inspectors to call us
freely so that problems that come up can be dealt with up
front, which makes everyone’s job easier in the long run.
Owners/ operators of boilers and pressure vessels do not
always understand our mission. It is our responsibility to
answer their questions and explain the reason why we do what
we do, and to do so in a cheerful manner.
Sometimes I get the feeling that the public does not consider
us a typical state agency because of the level of customer service
the Boiler Safety Bureau provides. We are very proud of the
manner in which we treat our customers by being courteous,
knowledgeable and taking the extra step to provide excellent
service. I am glad that I am able to be a part of this process.
Terry Putek
Cherie Berry
Commissioner of Labor
Ensure that drains for air receivers work and the tank is
drained of any condensed moisture periodically.
Ensure that there is no trash accumulating around the pressure
vessel and make sure the vessel is clean of any dirt, grease, oil
or other materials.
Don’t tamper with controls, render them inoperative or bypass
them.
Don’t make or have made any unauthorized repairs to the
pressure vessel.
Do contact the N. C. Department of Labor Boiler Safety
Bureau at ( 919) 807- 2760 if you need help or have questions.
2
Public Awareness
One of our very high priorities is public awareness. With that
in mind we try to provide helps for owners and users of boilers
and pressure vessels. In the last issue we provided a boiler
safety checklist. The backside of that checklist is for pressure
vessels. We offer the pressure vessel criteria in this issue.
Pressure Vessel Safety Checklist  
Ensure that a current inspection certificate is available. If
there is no certificate, contact your insurer or the Boiler Safety
Bureau immediately before operations.
Ensure that there are no leaks from any part of the pressure
vessel or piping. Cracked surfaces must be repaired immedi-ately
by a qualified “ R” repair organization.
Ensure that there are no signs of corrosion or erosion.
Ensure that all gauges and meters are operational. Repair or
replace defective gauges and meters.
Ensure that the safety valves are installed properly and are
operating properly. Test safety valves periodically and replace
leaking or stuck safety valves.
Ensure that the safety valves, for air receivers and steam
accumulators, are installed directly on the vessel.
SAFETY REMINDER
Encourage your employees to maintain a clean
and tidy workspace. This will have the dual effect
of improving safety and productivity by removing
any potential hazards or distractions from your
working area.
Air Tanks Do Explode
I am not one to air dirty laundry; however, as the chief
inspector, I receive a lot of mail and phone calls. Recently I
received a letter. The names have been removed, but the facts
of the letter are correct. The letter writer is a customer of an
inspection agency. He said:
For two years in a row I have walked around with the
inspector to check on 10 compressors. All the inspector did
was look for his tags he put on the year before and sign and
date them. The inspector did not check any pop off valves or
condition of the tanks at all. I did not know until this year that
we are paying ( a fee) for his services which we did not receive.
Please address this issue because we are not getting what we
paid for.
We seldom get these type letters, but if we do, we deal with
them immediately. Failure to provide a proper inspection while
at the facility is just as bad as saying you went there and inspected
but did not. In addition to that, filing a report for an inspection
that was not conducted is not only unethical, it is downright
illegal. Charges could be filed against an inspector for filing a
false report. We have suspended commissions for just that.
That air tank is just as important to that automotive garage
as a boiler is to a dry cleaner or an electric utility. No, the
owner of that small business probably does not want you there
inspecting his or her equipment. However, that tank can put
them out of business if it fails catastrophically. Below are just
small examples of the force of an air tank. As we say on our
Web site, “ Air Tanks Do Explode.” Make it a point in 2009 to go
out of your way to give your very best to every customer you have.
A Short Course in Computer Science
After six years in the Boiler Safety Bureau, I’ve learned a
couple of things about computers they didn’t teach me in
school. For instance, Murphy’s Computer Laws, such as:
• There is always one more bug.
• If a program is useful, it will have to be changed.
• The 90/ 90 rule: the first 90 percent of the progress takes
90 percent of the effort; the last 10 percent of the
progress takes the other 90 percent of the effort.
But perhaps the biggest thing I’ve learned is about systems.
All computer systems are made up of three basic components.
Almost everyone thinks the most important part of a system is
the hardware, because that’s what you can see. But hardware
is not the most important.
I knew that the most important part of a computer system
was the software, because that’s what governs the behavior of
a system. But I discovered that this, too, is wrong.
Actually, the most important part of a system is the people who
use that system, or, as computer types like to say, the wetware.
Now, before you have to buy a new hat from all that cranial
swelling, realize that this is not because we are at the top of the
information food chain, as it were. No, that’s because of all the
components of the system, we are the most unreliable. This is
bitter news, but true.
And in that glorious human unpredictability lies the greatest
key to improving systems: changing how we interact with them.
As infuriating as computer systems can be, there are some
simple things that you can do to lower your blood pressure,
contribute to world peace and keep your boss at a tolerable
distance. Well, maybe two out of three.
1. Ask questions. If something doesn’t make sense, there is
probably a reason for that. Find out what it is, by using the
resources available to you, such as the staff in the Raleigh
office ( our processing assistants have many years of expe-rience
with our processes and are always glad to help). If
you subscribe to Jurisdiction Online, your company has a
tech support person assigned to you at Praeses. They aren’t
real people, because they are too cheerful. But they are an
excellent approximation— and an excellent resource.
2. However, before you reach for that phone, Mr. or Ms. User,
please read the instructions. We ( the Bureau) have written
and distributed detailed work instructions on the more
important processes we complete day after day; we have
them for companies both on and off of JO. Please read—
no, study— those instructions.
3. Then, provide feedback. We know that there are a lot more
processes that we need to document. Please weigh in with
the most important ones. Even better, let us know when
either our documentation or the process itself is broken.
We only see a part of the system— from the office view-point.
Tell us how it looks from the field.
continued on page 4 3
Kudos Corner
Congratulations to Mark Hutchens for completing all the require-ments
for a National Board ‘ A’endorsement. The ‘ A’endorsement is
required to conduct shop inspections of objects constructed to the
ASME Boiler and Pressure Vessel Code.
Getting that ‘ A’ endorsement on a National Board commission
card is not an easy thing to accomplish. An inspector must complete
a two- week course at the National Board in Columbus, Ohio. Subjects
included in the course are quality control, design, testing, fabrication
rules, welding requirements and so forth. Upon completion of the
course, the inspector must pass an eight- hour examination. After
that, there is a minimum of 80 hours of on- the- job training in ASME
shop fabrication inspection under the supervision of an authorized
inspector and authorized inspector supervisor. As they say, “ It ain’t
easy.” Congratulations, Mark.
Boiler and Pressure Vessel Inspectors— West
The N. C. Department of Labor’s Boiler Safety Bureau is
blessed to have an excellent inspection staff all across our
great state. These 14 inspectors have a combined total of 112
years of experience as inspectors for the Department of Labor.
Add to that another 50 years inspection experience with other
authorized inspection agencies and 194 years of related expe-rience
and you have a well- qualified staff. In this article we
will present the inspectors that serve us in the western region.
Bill Case came to us Feb. 16, 1998. Before coming to us,
Bill was an inspector for another inspection agency. He has
five counties and is headquartered in Cabarrus County.
Mark Hutchens began work with us Nov. 1, 2001. Mark is
headquartered in Wilkes County and has 12 counties.
Sam Kirkman arrived Nov. 1, 2001, also. Sam works six
counties and is headquartered in Forsyth County.
Scott Lane, our newest inspector, began work Jan. 2, 2007.
He has inspected for another state jurisdiction as well as an
insurance company. Scott works out of Buncombe County and
has the 12 far- western counties.
Andra Parnell began her work with us March 15, 2004.
Andra is headquartered in Lincoln County and has responsi-bility
for six counties.
Ray Payne, who inspected for another state jurisdiction
previously, came to us Sept. 18, 1995. Ray controls one county
but has several ASME shops that keep him busy. He is head-quartered
in Union County.
Jimmy Snuffer began his work with us Feb. 1, 2000. Jimmy
has only one county but it is the largest county in the state. As
well he covers an ASME shop. He is headquartered in Gaston
County.
These seven folks are a pleasure to work with says their
supervisor, Greg Davis. We here in the office agree 100
percent. The work ethic shared by these folks is notable and
we look forward to a long tour of duty with all of them.
4. Having said that, be advised that you need to be persistent,
as well as patient. We wear several hats here in the office,
and just because we don’t respond immediately doesn’t
mean we discounted your input. Check back with us if we
don’t respond in a timely manner. It helps to pull together.
5. Be nice, and share your discoveries— with each other as
well as with us. We get some of our best ideas from
inspectors. Insights, issues, ideas— they all help improve
our systems.
Reading this article counts as 0.0075 continuing education
units ( CEUs), redeemable for Green Stamps at your local
Winn Dixie. Wait, Winn Dixie is gone, aren’t they?
Chris Lehenbauer
4
A Short Course in Computer Science
continued from page 3
A Helpful Hint
A friend told me this story. “ The heating unit went out on
my dryer! The gentleman that fixes things around the house
for us told us that he wanted to show us something and he
went over to the dryer and pulled out the lint filter. It was
clean. ( I always clean the lint from the filter after every load
of clothes.) He said now watch this; he took the filter over to
the sink and ran hot water over it. The lint filter is made of a
mesh material. ... I'm sure you know what your dryer's lint filter
looks like. Well, the hot water just sat on top of the mesh! It
didn't go through it at all! He told us that dryer sheets cause a
film over that mesh, and that's what burns out the heating unit.
You can't see the film, but it's there. It's what is in the dryer
sheets to make your clothes soft and static free. ... that nice
fragrance too. You know how they can feel waxy when you
take them out of the box. Well, this stuff builds up on your
clothes and on your lint screen. This is also what causes dryer
units to potentially burn your house down with it! He said the
best way to keep your dryer working for a very long time ( and
to keep your electric bill lower) is to take that filter out and
wash it with hot soapy water and an old toothbrush ( or other
brush) at least every six months. He said that makes the life of
the dryer at least twice as long!”
( L- R): Dean Johnson ( Eastern Inspector), Greg Davis, Sam Kirkman,
Andra Parnell, Mark Hutchens, Bill Case and Ray Payne. Not pictured:
Scott Lane and Jimmy Snuffer.
SAFETY REMINDER
Try to care for your employees more than your
profits. If a machine is unsafe shut it down. If an
expensive repair job is required or a project is
delayed because of this, then so be it. Better that
than an injured employee.
Low- Water Cut Off Controls
There have been recent boiler low- water incidents that could
have been prevented. In the interest of safety and protecting a
sizable investment, it pays to be aware of manufacturers’
recommendations and to follow proper maintenance protocol.
Almost every boiler is required to have at least one low-water
cut off device ( LWCO) and some are required to have
two. Gas, oil or electrically fired boilers will have a LWCO or a
flow switch. Solid fuel boilers may not have either device. In
North Carolina, steam boilers require two LWCOs. One must have
a manual reset switch. This precludes the boiler automatically
starting back up if the water level re- establishes itself so the
reason for the low water condition might be identified.
LWCOs, whether snap switch or mercury switch models,
provide a reliable method of controlling a boiler feed pump
and/ or shutting down the boiler during a low- water condition.
Mounted at the boiler water line, it starts and stops the pump
as the boiler water dictates.
Consequently, it holds the
boiler water level at the limits
recommended by the boiler
manufacturer to maintain
maximum steaming effi-ciency
if used as a pump
control and can safely shut
off the burner if necessary.
The ASME Boiler and Pressure Vessel Code, Section VI
paragraph 7.07 G says:
Low- Water Fuel Cutoff and Water Feeder Maintenance
Low- water fuel cutoffs and water feeders should be dismantled
annually, by qualified personnel, to the extent necessary to insure
freedom from obstructions and proper functioning of the working
parts. Inspect connecting lines to the boiler for accumulation of mud,
scale, etc., and clean as required. Examine all visible wiring for brittle
or worn insulation and make sure electrical contacts are clean and
that they function properly. Give special attention to solder joints on
bellows and float when this type of control is used. Check float for
evidence of collapse and check mercury bulb ( where applicable) for
mercury separation or discoloration. Do not attempt to repair mech-anisms
in the field. Complete replacement mechanisms, including
necessary gaskets and installation instructions are available from
the manufacturer. After reassembly, test as per 7.05H.
While ASME Section VI and Section VII are not mandatory,
every owner/ maintenance organization should disassemble
and inspect all LWCOs annually and replace, repair or clean,
as needed. All chambered units are to be blown down, using
the drains provided, per manufacturer’s instructions and local
code requirements, if any. A local service company may
recommend a blow down schedule that will be based on water
quality and system operation variables. Refer to the installation
instructions provided with the product for specific assembly
and test procedures.
General troubleshooting for a float- type LWCO is as follows:
01. Plugged piping leading to the LWCO
02. Sediment holding the float in the “ up position”
03. Float collapse due to excessive pressure or water hammer
04. Chemical action on the components
05. Incorrect application of the control
06. Corrosion on the electrical components
07. Tampering with the control by operating personnel
08. Improper sizing of the control
09. Electrical shorts
10. Improper wiring
11. Blown fuses
12. Pump motor relays are stuck
13. Fuel valves stuck
14. Fused contacts
Most inspectors and repair companies know that a major
LWCO manufacturer, McDonnell- Miller, has stopped providing
mercury switches as of June 25, 2007, for their products. Snap
action switches are a suitable substitute and there are cross
reference charts to determine which switch is recommended
when replacing the mercury switches.
The manufacturer recom-mends
replacement of all parts
in the control head every five
years. Replacement of the
entire LWCO every 10 to 15
years, depending on the model,
is suggested. These same rec-ommendations
likely apply to
all brands of these controls.
Probe- type LWCOs rely on
water to provide conductivity
on the probe tip and ground
line and are suitable for many
applications. However, the probe tip can become fouled with
scale and fail to function properly. Probes should be removed
annually and inspected for fouling, tip damage and electrical
function.
Remember, the LWCO is just one of the lines of defense
against boiler failure. Take care of it, and it will take care of you.
Greg Lundberg
5
Float- type LWCO
Probe- type low- water cut off
SAFETY REMINDER
Ensure your workplace is well lit, allowing your
workers to see what they are doing and reducing
eye strain, which can be damaging over time.
Take a look around your boiler room. If you have
combustibles stored there, get them out and store them someplace
else. Keeping combustibles in a boiler room might be the reason your
business burns down.