Page 107 - Boiler_Operators_Handbook,_Second_Edition

92 Boiler Operator’s Handbook

move the jumper or reset the high pressure switch then be injured by the failure of another boiler that inspector
demonstrate that it opens at or near its setting and be- doesn’t properly inspect. Imagine that boiler is in the
low the set pressure of the safety valves. building where your children go to school! It’s a subject
The inspector should also expect you to demon- near and dear to my heart because there isn’t enough
strate a functional test of the low water cutoff, either by monitoring of inspectors. I have hard and unpleasant
an evaporation test or a “slow drain” test. The evapora- experience with such situations. I know of one little girl
tion test consists of boiler operation with the boiler feed that was severely burned and… That’s all I’ll say on a
pump off or feedwater control valve closed so no water subject I could rant on for another ten pages but I won’t.
is fed to the boiler. As the water evaporates the level I’ll just trust you to do the right thing.
drops until the low water cutoff shuts the burner off. A Testing of safety valves and inspection of the boil-
slow drain test is used when there is little or no steam ers by inspectors is essential in reducing our exposure to
demand. The blowdown valves are opened to drain the a boiler failure. We certainly don’t want to return to con-
boiler slowly until the low water cutoff functions. ditions that existed in the first decade of the last century
When performing these tests you should not take when millions were injured and thousands died from
your eye off the gage glass or have someone else watch boiler failures.
it. Fully one third of all boiler failures are due to low It’s the benefit of a third-party inspection with no
water condition according to National Board data. That responsibility to the owner of the boiler that makes the
means those low water cutoffs fail; that’s why you’re system as good as it is. Every boiler inspector is well
performing a functional test of each one. trained and tested before receiving a commission as a
The inspector can also require you demonstrate National Board Inspector. You should take advantage of
the function of other safety interlocks. Specific tests are their training and skills during every inspection, calling
required by code depending on the size of your boiler their attention to changes or conditions that you ques-
and State laws can include other requirements. ASME tion. Never treat them as someone you have to hide
CSD-1 has a checklist requirement. NFPA-85 contains things from. That’s exposing yourself. After all, who’s
a list of mandatory tests. The National Board promoted going to be closest to that boiler if it does explode?
adoption of those Standards in the mid 1990’s and most
jurisdictions have adopted them. You will find, how-
ever, that not all inspectors are up to speed on those OPERATING DURING
Standards. MAINTENANCE AND REPAIR
In many cases the inspector will simply require
you show you have documented evidence that you con- You have some additional duties when a contrac-
ducted the tests. As far as I know the National Board has tor or other employees are working in the plant on main-
not added a requirement in the inspection code that says tenance or repair activities. Concerns are protecting the
the inspectors have to observe any of those tests. health and welfare of those workers, making certain
I have every respect for anyone who carries a com- they don’t do damage to the plant, and making certain
mission as a National Board Inspector. However, I’ll use they don’t disrupt normal operations inadvertently.
an old saying that those of you that also grew up on a You may be required to start and secure boilers
farm will understand; “There’s a rotten apple in every to provide access for the workmen to the equipment
bunch.” There are inspectors that will sit at their home or parts of the plant. It can be as simple as operating
office and fill out inspection reports. There are those that to reduce temperatures where they are working above
will come to the plant but, other than walking past them, a boiler. It could also be as complicated as generating
never really look at the boilers. They’ll spend all their steam required for the contractor’s operations. It isn’t
time in the chief’s office drinking coffee and talking. If uncommon to isolate sections of piping for work. What-
you have one of them, quietly report what you observed ever the activity and regardless of who does the work
to the chief boiler inspector of the state or common- the operator should be the final authority for accessing
wealth. any system and that should be made perfectly clear to
I know the feeling such a suggestion provokes— anyone that enters the plant.
it’s none of my business; we keep our boilers up so it Frequently the chief or manager of the boiler plant
doesn’t matter; I like the guy and don’t want to get him takes the attitude that an operator should have no au-
in trouble; I might be found out and lose my job… Think thority over contractors working in the plant. If that
of it another way. Think of the people that are going to happens with you it’s an indication of a lack of trust