Relief valve |
Previous | 3 of 4 | Next |
|
small (250x250 max)
medium (500x500 max)
Large
Extra Large
large ( > 500x500)
Full Resolution
|
This page
All
|
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 Stay in touch with today’s workplace issues. Sign up to receive a free subscription to the NC Labor Ledger at www. nclabor. com/ news/ ledgersubs. htm 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.
Object Description
Description
Title | Relief valve |
Date | 2009 |
Release Date | 2009-02 |
Description | Vol. 1, no. 2 (Feb. 2009) |
Digital Characteristics-A | 981 KB |
Digital Format |
application/pdf |
Full Text | 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 Stay in touch with today’s workplace issues. Sign up to receive a free subscription to the NC Labor Ledger at www. nclabor. com/ news/ ledgersubs. htm 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. |
OCLC number | 694404903 |