SORM 2014 Jurisdictional Inspections Preparedness - Milton FINAL

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°F

psig = 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 Requirement Most 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 C

ost I

ncre

ase

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

Documents

SORM 2014 Jurisdictional Inspections Preparedness - Milton FINAL