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
2011 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
A Short Primer Definition
Boiler
Boiler
A
A closed
closed vessel
vessel in
in
which
which water
water is
is heated,
heated,
steam
steam is
is generated
generated or
or
steam
steam is
is superheated
superheated
for
for use
use external
external to
to itself
itself
by
by the
the application
application of
of
heat
heat
A Short Primer Boiler Categories
Heating
Heating Boilers
Boilers
Steam
Steam is
is generated
generated at
at or
or below
below 15
15 psig,
psig,
or
or water
water is
is heated
heated at
at or
or below
below 160
160 psig
psig
and/or
and/or 250F
250F
Power
Power Boilers
Boilers
Steam
Steam is
is generated
generated above
above 15
15 psig
psig
Steam
Steam boilers,
boilers, high
high temperature
temperature water
water
boilers,
boilers, electric
electric boilers,
boilers, miniature
miniature boilers
boilers
psig
psig == pounds
pounds per
per square
square inch
inch gage
gage
A Short Primer Boiler Types
Firetube Boiler
Watertube Boiler
Cast Iron Boiler
A Short Primer Boiler Applications
Utility
Utility Boilers
Boilers
Industrial
Industrial Boilers
Boilers
Large
Large field
field erected
erected units
units (~1M10M
(~1M10M
lbs/hr)
lbs/hr)
Used
Used to
to generate
generate electricity
electricity
Sometimes
Sometimes referred
referred to
to as
as steam
steam
generators
generators
This
This category
category includes
includes heat
heat recovery
recovery
steam
steam generators
generators
Packaged
Packaged or
or field
field erected
erected units
units
(~5,0001M
(~5,0001M lbs/hr)
lbs/hr)
Used
Used to
to drive
drive production
production machinery,
machinery,
pumps,
pumps, electric
electric generators,
generators,
compressors
compressors and
and provide
provide heat
heat for
for
manufacturing
manufacturing processes
processes
Commercial
Commercial Boilers
Boilers
Small
Small capacity
capacity steam
steam (~1005,000
(~1005,000
lbs/hr)
lbs/hr) or
or hot
hot water
water boilers
boilers (~100,000
(~100,000 -5M
5M Btu/hr)
Btu/hr)
Hospitals,
Hospitals, schools,
schools, govt.
govt. //
commercial
commercial // residential
residential real
real estate
estate
settings,
settings, commercial
commercial laundries
laundries and
and dry
dry
cleaners
cleaners
Why do Inspections?
Legal Requirement
Most
Most states
states or
or jurisdictions
jurisdictions require
require periodic
periodic
inspections
inspections
Accident Prevention
Boilers
Boilers and
and pressure
pressure vessels
vessels represent
represent explosive
explosive
potential
potential and
and can
can cause
cause serious
serious damage
damage
Efficiency & Cost

Savings
Systems
Systems degrade
degrade over
over time
time and
and can
can result
result in
in
significant
significant loss
loss in
in efficiency
efficiency and
and extra
extra cost
cost
Why do Inspections?
Legal Jurisdictional Inspection Requirements

Most
Most states
states or
or
jurisdictions
jurisdictions require:
require:
Requirements
Requirements vary
vary by
by
state
state or
or jurisdiction:
jurisdiction:
Periodic
Periodic inspections
inspections of
of
boilers
boilers by
by aa commissioned
commissioned
inspector
inspector
Frequency
Frequency of
of low
low pressure
pressure
boiler
boiler inspections
inspections may
may vary
vary
(e.g.,
(e.g., annual,
annual, biennial)
biennial)
Current
Current certificates
certificates of
of
operation
operation or
or inspection
inspection
There
There are
are over
over 65
65
jurisdictions
jurisdictions in
in the
the
continental
continental USA
USA
External
External and/or
and/or internal
internal
inspections
inspections may
may be
be
performed:
performed:
External
External inspections
inspections mainly
mainly
address
address service
service
requirements
requirements
Internal
Internal inspections
inspections
principally
principally address
address
certificate
certificate requirements
requirements
Why do Inspections?
Accident Prevention
The
The Explosive
Explosive Potential
Potential of
of
Boilers
Boilers
IfIf you
you could
could capture
capture all
all the
the
energy
energy released
released when
when aa 3030gallon
gallon home
home hot-water
hot-water tank
tank
flashes
flashes into
into explosive
explosive failure
failure at
at
332F
332F you
you would
would have
have enough
enough
force
force to
to send
send the
the average
average car
car
(weighing
(weighing 2,500
2,500 pounds)
pounds) to
to aa
height
height of
of nearly
nearly 125
125 feet
feet or
or
more
more than
than the
the height
height of
of aa 1414story
story
building
building starting
starting with
with aa
lift-off
lift-off velocity
velocity of
of 85
85 miles
miles per
per
hour!
hour!
Why do Inspections?
Improve Efficiency & Save Costs

Effect of Boiler Scale Buildup on Fuel Efficiency
80%
70%
60%
% Fuel Cost Increase
50%
40%
30%
20%
10%
0%
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
Scale Thickness (mm)
10
Helping our Partners and Customers
Need an inspection?
1.
1. Do
Do you
you have
have any
any
2.
2. Do
Do you
you have
have any
any large
large
3.
3. Do
Do you
you have
have any
any
4.
4. Do
Do you
you have
have air
air
heating
heating or
or process
process
boilers
boilers at
at your
your location?
location?
pressure
pressure vessels
vessels at
at
your
your location
location such
such as
as
commercial
commercial air
air tanks
tanks or
or
hot
hot water
water tanks?
tanks?
water
water heaters
heaters >>
200,000
200,000 Btu/hr
Btu/hr at
at your
your
location?
location?
conditioning
conditioning //
refrigeration
refrigeration units
units at
at
your
your location
location other
other than
than
household
household refrigerators
refrigerators
and
and freezers
freezers or
or window
window
unit
unit air
air conditioners?
conditioners?
IfIf the
the answer
answer is
is Yes
Yes to
to any
any of
of the
the following
following questions,
questions, an
an inspection
inspection may
may be
be required
required
11
Our Resources
Inspection Field Force
Customer Solution Center
Nationwide
Nationwide force
force of
of over
over 200
200 qualified
qualified inspectors
inspectors
serving
serving every
every jurisdiction
jurisdiction
Certified
Certified by
by the
the National
National Board
Board of
of Boiler
Boiler and
and
Pressure
Pressure Vessel
Vessel Inspectors
Inspectors
Most
experienced
Most experienced staff
staff in
in the
the industry
industry averaging
averaging
14
years
on
the
job
14 years on the job
Rigorous
Rigorous training
training and
and testing
testing of
of staff
staff and
and solid
solid
reputation
for
thoroughness
and
know
how
reputation for thoroughness and know how
Cross-trained
Cross-trained in
in property
property and
and electrical
electrical exposures
exposures
Proprietary
Proprietary work
work management
management system
system for
for
optimized
optimized auto-scheduling
auto-scheduling of
of inspections
inspections
Staff
Staff of
of over
over 70
70 qualified
qualified professionals
professionals located
located at
at
Valley
Forge,
PA
center
Valley Forge, PA center
Location
Location Processing
Processing unit
unit reviews
reviews and
and vets
vets
incoming
data
against
over
12
million
locations
incoming data against over 12 million locations in
in
our
database
our database
Inspection
Inspection Support
Support group
group schedules
schedules // dispatches
dispatches
selected
inspections
and
addresses
regulatory
selected inspections and addresses regulatory
issues
issues
Location
Location Qualification
Qualification unit
unit generates
generates service
service
orders
orders and
and resolves
resolves service
service issues
issues
Technical
Technical Support
Support unit
unit conducts
conducts EB
EB telephone
telephone
surveys,
processes
loss
prevention
reports
surveys, processes loss prevention reports and
and
follows
up
on
recommendations
and
compliance
follows up on recommendations and compliance
matters
matters
12
What do we do?
Identify
Identify and
and vet
vet customer
customer locations
locations with
with jurisdictional
jurisdictional objects
objects
requiring
requiring inspections
inspections
Automatically
Automatically schedule,
schedule, prepare
prepare the
the customer
customer for,
for, and
and perform
perform
boiler
boiler // pressure
pressure vessel
vessel external
external and/or
and/or internal
internal certification
certification
inspections
inspections in
in accordance
accordance with
with jurisdictional
jurisdictional requirements
requirements
Provide
Provide recommendations
recommendations and
and advice
advice to
to customers
customers regarding
regarding
hazardous
hazardous conditions
conditions noted
noted and
and opportunities
opportunities to
to improve
improve
equipment
equipment operation,
operation, maintenance,
maintenance, reliability
reliability and
and efficiency
efficiency
Make
Make occupancy,
occupancy, property
property and
and electrical
electrical observations
observations for
for
selected
selected locations
locations while
while on
on site
site and
and provide
provide recommendations
recommendations
where
where conditions
conditions or
or opportunities
opportunities are
are noted
noted
What does it cost?
All
All of
of the
the above
above included
included as
as part
part of
of the
the equipment
equipment breakdown
breakdown
coverage
coverage at
at no
no extra
extra cost
cost to
to our
our partners
partners or
or customers
customers
Customer
Customer pays
pays equipment
equipment certificate
certificate fees,
fees, any
any inspection
inspection costs,
costs,
and
and fines
fines for
for missed/late
missed/late inspections
inspections that
that are
are not
not HSBs
HSBs fault
fault
13
Requesting Inspections
Our Inspection Hotline

1.800.333.INSP (4677)
8 a.m.8 p.m. EST
E-mail:
E-mail: NSCInsp_Hotline@HSB.com
NSCInsp_Hotline@HSB.com
Fax:
Fax: 1.484.582.1838
1.484.582.1838
Request
Request certificate
certificate inspections
inspections
Questions
Questions about
about our
our services
services
Customers
Customers should
should provide
provide the
the following
following information
information when
when
calling
calling to
to schedule
schedule an
an inspection:
inspection:
Location
Location Name
Name &
& Address
Address
Contact
Contact Name
Name &
& Telephone
Telephone
Policy
Policy Number
Number &
& Period
Period
HSB
HSB case
case or
or Service
Service Order
Order Number
Number
14
The Inspection Process
External (In-Service) Inspections
Schedule
Schedule appointment
appointment when
when boiler
boiler operator
operator or
or maintenance
maintenance personnel
personnel are
are available
available to
to
perform
perform any
any required
required testing
testing of
of controls
controls and
and safety
safety devices
devices
Inform
Inform operator
operator of
of date
date and
and time
time
Make
Make sure
sure current
current certificate
certificate is
is posted
posted
Keep
Keep clutter
clutter and
and debris
debris out
out of
of boiler
boiler room
room to
to ensure
ensure inspector
inspector access
access
Internal Inspections
Perform
Perform the
the external
external inspection
inspection preparation
preparation steps
steps above
above plus
plus
Arrange
Arrange to
to have
have boiler
boiler shut
shut down,
down, cool,
cool, and
and manhole
manhole and
and handhole
handhole covers
covers removed
removed
Clean
Clean all
all exterior
exterior and
and interior
interior boiler
boiler surfaces
surfaces thoroughly
thoroughly
Dismantle
Dismantle low
low water
water fuel
fuel supply
supply cut
cut out
out ifif present
present
Disconnect
Disconnect feed
feed line
line connection
connection at
at the
the boiler
boiler
Preparing
Preparing for
for inspections
inspections minimizing
minimizing disruption
disruption of
of our
our customers
customers operations
operations
15

Repairs
Controls
Logs
Relief Valves
16
Low water
cut-off
Piping
Leaks, Corrosion, Cracking
Foundation &
Mounting Structure
17
Internal Inspections
Lockout/Tagout
Waterside Scale, Corrosion, Warping
Fireside Cracking, Spalling, Flame Impingement
Fireside Soot, Ash, Overheating
18
What else?
Feedwater
Feedwater // makeup
makeup
Control
Control air
air compressors
compressors
Water
Water pumps
pumps
Fuel
Fuel pumps
pumps
Electrical
Electrical panels
panels
Fans
Fans &
& blowers
blowers
19
What Do We Find?
The complete spectrum
to
Well-maintained
Well-maintained equipment
equipment and
and facilities,
facilities, all
all
required
required permits
permits and
and certificates,
certificates, regular
regular
and
and appropriate
appropriate maintenance
maintenance
Poorly
Poorly maintained
maintained and/or
and/or compromised
compromised
equipment,
equipment, inadequate
inadequate recordkeeping,
recordkeeping, code
code
issues,
issues, variable
variable maintenance
maintenance
20
The Importance of Maintenance
Regular Preventive Maintenance
Operating
Operating pressure
pressure &
&
temperature
temperature
Condensate
Condensate // return
return water
water
temperature
temperature
Stack
Stack // exhaust
exhaust gas
gas
temperature
temperature
Fuel
Fuel supply
supply pressure
pressure
Feedwater
Feedwater // makeup
makeup water
water
pressure
pressure &
& temperature
temperature
Low
Low water
water fuel
fuel cut-off
cut-off
testing
testing
Safety
Safety // relief
relief valve
valve exercise
exercise
&
testing
& testing
Flame
Flame failure
failure safeguard
safeguard
testing
testing
Water
Water treatment
treatment testing
testing
Boiler
Boiler blowdowns
blowdowns
21
The Importance of Maintenance
Pay nowor pay

more later
Accident
Accident Prevention
Prevention
Safety
Program
Safety Program Cost
Cost (
( on
on $)
$)
vs.
vs.
Injury
Injury or
or Fatality
Fatality Cost
Cost ($$$$$$)
($$$$$$)
Equipment
Equipment Life
Life
Regular
Regular Upkeep
Upkeep Cost
Cost ($)
($)
vs.
vs.
Replacement
Replacement Cost
Cost due
due to
to
Deferred
Maintenance
($$$$)
Deferred Maintenance ($$$$)
Business
Business Continuity
Continuity
Planned
Planned Downtime
Downtime Cost
Cost ($)
($)
vs.
vs.
Unplanned
Unplanned Outage
Outage Cost
Cost due
due to
to
Deferred
Deferred Maintenance
Maintenance ($$$$$)
($$$$$)
22
THANK YOU VERY MUCH

FOR YOUR ATTENTION
SORM 2014 Risk Management Symposium

SORM 2014 Jurisdictional Inspections Preparedness - Milton FINAL

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JURISDICTIONAL INSPECTION

1. Boilers a short primer

A Short Primer Definition

A Short Primer Boiler Categories

A Short Primer Boiler Types

Cast Iron Boiler

A Short Primer Boiler Applications

Efficiency & Cost

Legal Jurisdictional Inspection Requirements

Improve Efficiency & Save Costs

Scale Thickness (mm)

Helping our Partners and Customers

Helping our Partners and Customers

Customer Solution Center

Helping our Partners and Customers

What does it cost?

Helping our Partners and Customers

Our Inspection Hotline

The Inspection Process

External (In-Service) Inspections

The Inspection Process

External (In-Service) Inspections

The Inspection Process

External (In-Service) Inspections

The Inspection Process

Waterside Scale, Corrosion, Warping

Fireside Cracking, Spalling, Flame Impingement

Fireside Soot, Ash, Overheating

The Inspection Process

The complete spectrum

The Importance of Maintenance

Regular Preventive Maintenance

The Importance of Maintenance

Pay nowor pay

THANK YOU VERY MUCH

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