Transcript jurisdictional inspections preparedness

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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
2
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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
3
A Short Primer – Boiler Categories
Heating Boilers
Power Boilers
 Steam is generated at or below 15 psig,
or water is heated at or below 160 psig
and/or 250°F
 Steam is generated above 15 psig
 Steam boilers, high temperature water
boilers, electric boilers, miniature boilers
psig = pounds per square inch gage
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
4
A Short Primer – Boiler Types
Firetube Boiler
Watertube Boiler
Cast Iron Boiler
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
5
A Short Primer – Boiler Applications
Utility Boilers
Industrial Boilers
Commercial 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

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

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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
6
Why do Inspections?
Legal Requirement
Most states or jurisdictions require periodic
inspections
Accident Prevention
Boilers and pressure vessels represent explosive
potential and can cause serious damage
Efficiency & Cost
Savings
Systems degrade over time and can result in
significant loss in efficiency and extra cost
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
7
Why do Inspections?
Legal Jurisdictional Inspection Requirements
Most states or
jurisdictions require:
Requirements vary by
state or jurisdiction:
Periodic inspections of
boilers by a commissioned
inspector
Frequency of low pressure
boiler inspections may vary
(e.g., annual, biennial)
Current certificates of
operation or inspection
There are over 65
jurisdictions in the
continental USA
External and/or internal
inspections may be
performed:
External inspections mainly
address service
requirements
Internal inspections
principally address
certificate requirements
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
8
Why do Inspections?
Accident Prevention
The Explosive Potential of
Boilers
If you could capture all the
energy released when a 30gallon 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 14story … building – starting with a
lift-off velocity of 85 miles per
hour!”
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
9
Why do Inspections?
Improve Efficiency & Save Costs
Effect of Boiler Scale Buildup on Fuel Efficiency
80%
70%
% Fuel Cost Increase
60%
50%
40%
30%
20%
10%
0%
0.0
5.0
10.0
15.0
Scale Thickness (mm)
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
10
Helping our Partners and Customers
Need an inspection?
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?
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?
If the answer is “Yes” to any of the following questions, an inspection may be required
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
11
Helping our Partners and Customers
Our Resources
Inspection Field Force
Customer Solution Center
 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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
12
Helping our Partners and Customers
What do we do?
What does it cost?

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

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
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13
Helping our Partners and Customers
Requesting Inspections
Our Inspection Hotline
1.800.333.INSP (4677)
8 a.m.–8 p.m. EST
 E-mail: [email protected]
 Fax: 1.484.582.1838
 Request certificate inspections
 Questions about our services
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’
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
14
The Inspection Process
External (In-Service) Inspections

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
Internal Inspections

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
Preparing for inspections – minimizing disruption of our customer’s operations
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15
The Inspection Process
External (In-Service) Inspections
Repairs
Controls
Logs
Relief Valves
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16
The Inspection Process
External (In-Service) Inspections
Low water
cut-off
Piping
Leaks, Corrosion, Cracking
Foundation &
Mounting Structure
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17
The Inspection Process
Internal Inspections
Lockout/Tagout
Waterside – Scale, Corrosion, Warping
Fireside – Cracking, Spalling, Flame Impingement
Fireside – Soot, Ash, Overheating
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The Inspection Process
What else…?

Feedwater / makeup

Control air compressors

Water pumps

Fuel pumps

Fans & blowers

Electrical panels
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
19
What Do We Find?
The complete spectrum…
to
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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
20
The Importance of Maintenance
Regular Preventive 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
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
21
The Importance of Maintenance
Pay now…or pay
more later
Accident Prevention
Safety Program Cost (¢ on $)
vs.
Injury or Fatality Cost ($$$$$$)
Equipment Life
Regular Upkeep Cost ($)
vs.
Replacement Cost due to
Deferred Maintenance ($$$$)
Business Continuity
Planned Downtime Cost ($)
vs.
Unplanned Outage Cost due to
Deferred Maintenance ($$$$$)
© 2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
22
THANK YOU VERY MUCH
FOR YOUR ATTENTION
SORM 2014 Risk Management Symposium