Page 237 - Boiler_Operators_Handbook,_Second_Edition

222 Boiler Operator’s Handbook

MAINTAINING EFFICIENCY mented proof you did it. Be careful, however, that it’s
done consistently or the entire log is questionable. Do
An important part of maintaining the plant is what you say you will and say what you did consistent-
maintaining efficiency. Since the cost of fuel is the largest ly for the protection of your employer, your job, and the
single expense in a boiler plant activity it’s essential to health and welfare of you and your fellow employees.
prevent that cost getting out of control. Efficiency main-
tenance relies on two activities; monitoring to detect any
changes and tune-ups when a problem arises. Monitor- Welding
ing is the boiler operator’s responsibility; tune-ups are While I had the perception for years that a certified
usually performed by outside contractors that have the welder was always part artist, part perfectionist, and
necessary equipment and skills to perform that work. I extremely skilled at the craft my later years in semi-
would prefer to do my own tuning but there’s nothing retirement exposed me to another world that clearly
wrong in having an outside contractor do the work in revealed my perception to be wrong. I will limit my
small plants where the energy saved cannot justify the description of that other world to most federal contrac-
purchase and maintenance of the equipment required tors and trust that the few that really do comply with
to tune up a boiler. An operator should know enough the applicable codes aren’t insulted. Welding of boilers
about tuning to ensure the contractor is doing a proper (including attached piping on high pressure boilers)
job and the sections on combustion and controls in this and pressure vessels must be performed by a Company
book are sufficient to impart that knowledge. that is authorized by ASME to do that work. Welding on
ductwork and other containments that operate at very
low pressures are not covered by the ASME Code but
RECORDS all piping is. Piping for steam at pressures over 15 psig
and hot water operating at pressures over 160 psig or
How do you remember when it’s time to change 250°F must comply with the ASME B31.1 Power Piping
the oil in your automobile? That sticker on the wind- Code. Piping for other services inside your facility must
shield or side of the door is a record that gives you that comply with the ASME B31.9 Building Services Piping
information. I don’t know about you but I can never Code. Both Codes require all welding to be performed
remember the mileage when I changed my oil last and in accordance with Section IX of the BPVC (ASME Boiler
that record is important because without it I may fail to and Pressure Vessel Code) which describes the require-
change the oil until the engine lets me know I should ments for qualifying welding procedures and welding
have. operators. The Piping Codes also contain requirements
Schedules for maintenance are essential to ensure for examination of welds using methods and procedures
the longevity and reliability of most equipment. Wheth- covered by Section V of the BPVC. I can’t recommend an
er you let it run until it breaks or perform significant operator read, let alone understand, the content of these
PM (preventive maintenance/predictive maintenance) codes but I will offer some advice on what to look for
documentation is essential. For breakdown maintenance when a contractor, or even your own maintenance per-
items it allows you to know about when you need to sonnel, are welding piping in your plant. After reading
order a spare device because the operating one is sched- the following you should be able to determine quickly if
uled to fail. More importantly, the documents tell you the welding is in accordance with Code.
what to buy, what oil to use, what grease to use, etc., so First there’s the requirement for materials. Inside a
you perform the maintenance in a manner that keeps the boiler plant every piece of pipe must conform to at least
equipment and systems running. an ANSI (American National Standards Institute) speci-
Maintenance isn’t complete until all the documents fication and for all high pressure work over 125 psig
are properly filed away (see the chapter on documenta- MAWP must also comply with an ASME specification.
tion). To anyone investigating your plant after an inci- The two specifications differ very little with the require-
dent a lack of maintenance records is an indication of a ment that the piping must be supplied with mill test cer-
failure on your part to see to it that the work was done. tificates when conforming to the ASME specifications.
You can say you did it, describe the day and what you Once upon a time I had a salesman call on me and claim
did, but without that documentation you can’t prove it. he could provide me with piping and all I had to do was
When a check is listed as part of an SOP then your entry tell him how it was to be labeled, clearly insinuating that
into the log that you performed the procedure is docu- he was prepared to falsely label the pipe so we could