jurisdictional inspection preparedness sorm 2014 risk management symposium

JURISDICTIONAL INSPECTION PREPAREDNESS

SORM 2014 Risk Management Symposium

Agenda

1. Boilers – a short primer

2. Why do inspections?

3. How do we and our customers know an inspection is needed?

4. How do we help our partners and customers with inspections?

5. The inspection process

6. What do we find and how do we follow up?

7. The importance of maintenance

2© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

A Short Primer – Definition

Boiler A closed vessel in

which water is heated,

steam is generated or

steam is superheated

for use external to itself

by the application of

heat


A Short Primer – Boiler Categories


Heating Boilers

Steam is generated at or below 15 psig,

or water is heated at or below 160 psig

and/or 250°Fpsig = pounds per square inch gage

Power Boilers

Steam is generated above 15 psig

Steam boilers, high temperature water

boilers, electric boilers, miniature boilers

A Short Primer – Boiler Types


Firetube Boiler

Watertube Boiler

Cast Iron Boiler

A Short Primer – Boiler Applications

Utility Boilers Large field erected units (~1M–10M

lbs/hr) Used to generate electricity Sometimes referred to as steam

generators This category includes heat recovery

steam generators

Industrial Boilers Packaged or field erected units

(~5,000–1M lbs/hr) Used to drive production machinery,

pumps, electric generators,

compressors and provide heat for

manufacturing processes

Commercial Boilers Small capacity steam (~100–5,000

lbs/hr) or hot water boilers (~100,000 -

5M Btu/hr) Hospitals, schools, govt. /

commercial / residential real estate

settings, commercial laundries and dry

cleaners


Why do Inspections?


Legal RequirementMost states or jurisdictions require periodic inspections

Efficiency & Cost

Savings

Accident PreventionBoilers and pressure vessels represent explosive potential and can cause serious damage

Systems degrade over time and can result in significant loss in efficiency and extra cost

Why do Inspections?


External and/or internal inspections may be performed:

External inspections mainly address service requirements

Internal inspections principally address certificate requirements

Most states or jurisdictions require:

Periodic inspections of boilers by a commissioned inspector

Current certificates of operation or inspection

Requirements vary by state or jurisdiction:

Frequency of low pressure boiler inspections may vary (e.g., annual, biennial)

There are over 65 jurisdictions in the continental USA

Legal Jurisdictional Inspection Requirements

Why do Inspections?


Accident Prevention

The Explosive Potential of Boilers

If you could capture all the energy released when a 30-gallon home hot-water tank flashes into explosive failure at 332°F you would have enough force to send the average car (weighing 2,500 pounds) to a height of nearly 125 feet – or more than the height of a 14-story … building – starting with a lift-off velocity of 85 miles per hour!”

Why do Inspections?


0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.00%

10%

20%

30%

40%

50%

60%

70%

80%

Scale Thickness (mm)

% F

uel

Co

st I

ncr

ease

Improve Efficiency & Save Costs

Effect of Boiler Scale Buildup on Fuel Efficiency

Helping our Partners and Customers


2. Do you have any large water heaters > 200,000 Btu/hr at your location?

4. Do you have air conditioning / refrigeration units at your location other than household refrigerators and freezers or window unit air conditioners?

1. Do you have any heating or process boilers at your location?

3. Do you have any pressure vessels at your location such as commercial air tanks or hot water tanks?

Need an inspection?

If the answer is “Yes” to any of the following questions, an inspection may be required

Nationwide force of over 200 qualified inspectors

serving every jurisdiction Certified by the National Board of Boiler and

Pressure Vessel Inspectors Most experienced staff in the industry averaging

14 years on the job Rigorous training and testing of staff and solid

reputation for thoroughness and know how Cross-trained in property and electrical exposures Proprietary work management system for

optimized auto-scheduling of inspections

Staff of over 70 qualified professionals located at

Valley Forge, PA center Location Processing unit reviews and vets

incoming data against over 12 million locations in

our database Inspection Support group schedules / dispatches

selected inspections and addresses regulatory

issues Location Qualification unit generates service

orders and resolves service issues Technical Support unit conducts EB telephone

surveys, processes loss prevention reports and

follows up on recommendations and compliance

matters


12

Our Resources

Inspection Field Force Customer Solution Center

© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.



What do we do? Identify and vet customer locations with jurisdictional objects

requiring inspections

Automatically schedule, prepare the customer for, and perform

boiler / pressure vessel external and/or internal certification

inspections in accordance with jurisdictional requirements

Provide recommendations and advice to customers regarding

hazardous conditions noted and opportunities to improve

equipment operation, maintenance, reliability and efficiency

Make occupancy, property and electrical observations for

selected locations while on site and provide recommendations

where conditions or opportunities are noted

What does it cost?

All of the above included as part of the equipment breakdown

coverage at no extra cost to our partners or customers

Customer pays equipment certificate fees, any inspection costs,

and fines for missed/late inspections that are not HSB’s fault

Customers should provide the following information when

calling to schedule an inspection:

Location Name & Address

Contact Name & Telephone

Policy Number & Period

HSB case or Service Order Number’



Requesting Inspections

E-mail: [email protected]

Fax: 1.484.582.1838

Request certificate inspections

Questions about our services

Our Inspection Hotline 1.800.333.INSP (4677)

8 a.m.–8 p.m. EST

The Inspection Process


Preparing for inspections – minimizing disruption of our customer’s operations

Schedule appointment when boiler operator or maintenance personnel are available to

perform any required testing of controls and safety devices

Inform operator of date and time

Make sure current certificate is posted

Keep clutter and debris out of boiler room to ensure inspector access

Perform the external inspection preparation steps above plus…

Arrange to have boiler shut down, cool, and manhole and handhole covers removed

Clean all exterior and interior boiler surfaces thoroughly

Dismantle low water fuel supply cut out if present

Disconnect feed line connection at the boiler

Internal Inspections

External (In-Service) Inspections




Logs

Repairs

Relief Valves

Controls



Foundation &Mounting Structure

Low watercut-off

Piping


Leaks, Corrosion, Cracking


Internal Inspections

Lockout/Tagout Waterside – Scale, Corrosion, Warping

Fireside – Cracking, Spalling, Flame Impingement Fireside – Soot, Ash, Overheating



Feedwater / makeup

Water pumps

Control air compressors

Fuel pumps

Fans & blowers

Electrical panels


What else…?

The complete spectrum…

What Do We Find?


Well-maintained equipment and facilities, all

required permits and certificates, regular

and appropriate maintenance

Poorly maintained and/or compromised

equipment, inadequate recordkeeping, code

issues, variable maintenance

to

The Importance of Maintenance

Operating pressure &

temperature

Condensate / return water

temperature

Stack / exhaust gas

temperature

Fuel supply pressure

Feedwater / makeup water

pressure & temperature

Low water fuel cut-off

testing

Safety / relief valve exercise

& testing

Flame failure safeguard

testing

Water treatment testing

Boiler blowdowns


Regular Preventive Maintenance

The Importance of Maintenance


Pay now…or paymore later

Business ContinuityPlanned Downtime Cost ($) vs.Unplanned Outage Cost due to Deferred Maintenance ($$$$$)

Equipment LifeRegular Upkeep Cost ($) vs.Replacement Cost due to Deferred Maintenance ($$$$)

Accident PreventionSafety Program Cost (¢ on $) vs.Injury or Fatality Cost ($$$$$$)

THANK YOU VERY MUCH FOR YOUR ATTENTION

SORM 2014 Risk Management Symposium

jurisdictional inspection preparedness sorm 2014 risk management symposium

Documents

statement steam

insurance company

short primer boiler

inspection processwhat

external inspections

steam generatorsthis

electric boilers

hot water boilers