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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
3© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
A Short Primer – Boiler Categories
4© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
5© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
6© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
Why do Inspections?
7© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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?
8© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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?
9© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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?
10© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
11© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
Helping our Partners and Customers
12
Our Resources
Inspection Field Force Customer Solution Center
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
Helping our Partners and Customers
13© 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’
Helping our Partners and Customers
14© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
15© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
The Inspection Process
16© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
External (In-Service) Inspections
Logs
Repairs
Relief Valves
Controls
The Inspection Process
17© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
Foundation &Mounting Structure
Low watercut-off
Piping
External (In-Service) Inspections
Leaks, Corrosion, Cracking
The Inspection Process
Internal Inspections
Lockout/Tagout Waterside – Scale, Corrosion, Warping
Fireside – Cracking, Spalling, Flame Impingement Fireside – Soot, Ash, Overheating
18© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
The Inspection Process
Feedwater / makeup
Water pumps
Control air compressors
Fuel pumps
Fans & blowers
Electrical panels
19© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
What else…?
The complete spectrum…
What Do We Find?
20© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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
21© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
Regular Preventive Maintenance
The Importance of Maintenance
22© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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