boiler inspection process loss prevention - ucip.utah.gov

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The Hartford Steam Boiler Inspection and Insurance CompanyThe Hartford Steam Boiler Inspection and Insurance Company

Preventing Equipment Failures

BoilersElectrical Distribution Systems

Air Conditioning Equipment

The Hartford Steam Boiler Inspection and Insurance Company

Preventing Boiler Failures

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What is a 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.


Boiler Categories

Power Boiler

High Temperature Hot Water Boiler

Heating Boiler

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Watertube BoilersComponents:

Steam drum

Water (mud) drum

Tubes


Watertube Boilers

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Firetube Boilers


Firetube Boilers

Components:

Shell (Drum)

Tube Sheets, Front & Rear

Tubes (Flues)

Furnace

Stays (Stay Bolts)

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Firetube Scotch Marine


What could possibly go wrong with my boiler?

Let’s take a look at some typical boiler

failures!

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Major Causes of Boiler Failures

Low Water

Poor Maintenance

Failure of Controls and Safety Devices


Low Water

Results in over temperature condition

Can cause extensive damage to boiler

Or

Catastrophic failure of the boiler

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Poor Maintenance


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VALUE ADDED SERVICE

Optimization


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Failure of Controls and Safety Devices


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Preventing Boiler Failures

Proper Operation

Proper Maintenance

Routine Inspections

Final Location of Boiler after Explosion (Roll Up Door on Boiler)

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Final Location of Boiler after Explosion (Exposed Furnace Tube)

Final Location of Boiler After Explosion

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Hole Created by Boiler through Roll Up Door Wall (West Wall)

Knocked Down Exterior Wall Viewed from Inside Boiler Room (East Wall)

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View of East Wall from Outside Plant

View of East Wall from Outside Plant (Note Rear Boiler Door in Ditch)

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Interior Wall of Boiler Room (South Wall)

Modulating Feed Controller, Valve, and Bypass (Note Disconnected Operating Arm)

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Modulating Feed Controller and Valve with Disconnected Operating Arm

Bypass to the Modulating Feed Valve. Valve was found in the half open position

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– Bent and Broken Spring on (M&M) Mechanical Combination Low Water Cut-Off/Pump Controller

Mechanical Combination Low Water Cut-Off/Pump Controller stuck in the up position

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Aux LWCO Relay


Water Heater Explosion

MythBusters

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Boiler Operation

Prepare the boiler for operation

Starting the boiler

Regular operation

Controls and safety valves

Feedwater treatment


Boiler Logs

Why use them

What to include

How to use them

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Boiler Codes

ASME Boiler & Pressure Vessel Code

ASME Controls and Safety Devices

National Board Inspection Code

Jurisdictional Rules


Jurisdictional Rules

Inspection Frequencies

Inspection types

Installation requirements

Rules for repair

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HousekeepingSafetyFire PreventionCombustibles

• paint, oil, gas and cleaning productsFlammables

• wood, paper and cardboard • keep at least 8 to 10 feet from the

boilerEmergency Access


Controls & Safety Devices

Maintain control over boiler operation

Monitor operating conditions

Protect boiler from failure

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Controls and Safety Devices

Controls and safety devices are installed on boilers to monitor, indicate, regulate, or control:

• Pressure

• Temperature

• Water Level

• Combustion

• Auxiliary Equipment


Pressure Gages

Visual display of operating pressures.

Most accurate in their mid-range.

Dial range:

• Power Boilers: 1.5 – 2 times lowest safety valve setting

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Control Water Seals Most controls are

designed to be subjected to water pressure.

A “loop” or trap is installed to protect controls from direct contact with steam.

Condensate fills the lines during normal operation.


Siphon Loops

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Safety Valve Body

Seat

Disc

Stem

Spring

Blow-Down Ring

Huddling Chamber


Low Water Fuel Cutoffs

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Sum It All Up

Follow proper operating procedures

Regular maintenance

Be prepared

Above all …Work Safely!

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Electrical Maintenance


Electrical Distribution System

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Common Electrical Failures

“Figure illustrates specific causes of electrical failures and the individual contribution of each cause. This list is based upon twenty years of HSB claims data.”


Preventing Electrical Failures

Clean

Cool

Dry

Tight

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Yes

No

Yes

No

Did you observe any combustible material in the electrical room?

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Yes

No

Changes to electrical system

Such as loads added or relocated or equipment upgraded or replaced.

Yes

No

Changes to electrical system

Such as loads added or relocated or equipment upgraded or replaced.

Have there been any changes to the electrical system in the last three (3) years?


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Everything “Looks Okay”

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…However!


Infrared Thermographic Imaging

Detects Hot Spots

Dirty, Loose, Oxidized, or Corroded Connections.

Finds Phase Imbalance Problems.

Finds Undersized

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Surge Protection

Surge Protection Device (SPD)

Transient Voltage Surge Suppressor (TVSS)

Diverts surge currents to ground

Limits the voltage across the terminals of the equipment being protected


SPD - Zones of Protection

Zone 1: Service Entrance EquipmentIntercept surges before they enter the building

Zone 2: Distribution PanelSecond line of defense for each panel supplying critical or sensitive electronic equipment Protects against internally generated surges

Zone 3: Locally at Each Piece of Equipment

Third line of defenseProtects against internally generated surges

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Above all else…..

SAFETY FIRST!


Have a Safe Trip Home!

boiler inspection process loss prevention - ucip.utah.gov

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