Preventing Equipment Failures
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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
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The Hartford Steam Boiler Inspection and Insurance Company
Any Questions?
Then let’s get started!
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The Hartford Steam Boiler Inspection and Insurance Company
Preventing Equipment Failures
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The Hartford Steam Boiler Inspection and Insurance Company
Boiler Maintenance
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The Hartford Steam Boiler Inspection and Insurance Company
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.
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The Hartford Steam Boiler Inspection and Insurance Company
Boiler Categories
Power BoilerHigh Temperature Hot
Water BoilerHeating Boiler
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The Hartford Steam Boiler Inspection and Insurance Company
Watertube BoilersComponents: Steam drum Water (mud)
drum Tubes
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The Hartford Steam Boiler Inspection and Insurance Company
Watertube Boilers
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The Hartford Steam Boiler Inspection and Insurance Company
Firetube Boilers
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The Hartford Steam Boiler Inspection and Insurance Company
Firetube Boilers
Components: Shell (Drum) Tube Sheets,
Front & Rear Tubes (Flues) Furnace Stays (Stay
Bolts)
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The Hartford Steam Boiler Inspection and Insurance Company
Firetube Scotch Marine
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The Hartford Steam Boiler Inspection and Insurance CompanyThe Hartford Steam Boiler Inspection and Insurance Company
What could possibly go wrong with my
boiler?
Let’s take a look at some typical boiler
failures!
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The Hartford Steam Boiler Inspection and Insurance Company
Major Causes of Boiler Failures
Low WaterPoor MaintenanceFailure of Controls and
Safety Devices
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The Hartford Steam Boiler Inspection and Insurance Company
Low Water
Results in over temperature condition
Can cause extensive damage to boiler
Or
Catastrophic failure of the boiler
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
Poor Maintenance
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
Failure of Controls and Safety Devices
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
Preventing Boiler Failures
Proper OperationProper Maintenance It’s all up to you!
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The Hartford Steam Boiler Inspection and Insurance Company
Boiler Operation
Prepare the boiler for operation
Starting the boilerRegular operationControls and safety valvesFeedwater treatment
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The Hartford Steam Boiler Inspection and Insurance Company
Boiler Logs
Why use themWhat to includeHow to use them
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The Hartford Steam Boiler Inspection and Insurance Company
Boiler Codes
ASME Boiler & Pressure Vessel Code
ASME Controls and Safety Devices
National Board Inspection Code
Jurisdictional Rules
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The Hartford Steam Boiler Inspection and Insurance Company
Jurisdictional Rules
Inspection Frequencies Inspection types Installation requirementsRules for repair
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The Hartford Steam Boiler Inspection and Insurance Company
HousekeepingSafetyFire PreventionCombustibles
•paint, oil, gas and cleaning productsFlammables
•wood, paper and cardboard •keep at least 8 to 10 feet from the
boilerEmergency Access
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The Hartford Steam Boiler Inspection and Insurance Company
Controls & Safety Devices
Maintain control over boiler operation
Monitor operating conditionsProtect boiler from failure
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The Hartford Steam Boiler Inspection and Insurance Company
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
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The Hartford Steam Boiler Inspection and Insurance Company
Pressure GagesVisual 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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The Hartford Steam Boiler Inspection and Insurance Company
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.
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The Hartford Steam Boiler Inspection and Insurance Company
Siphon Loops
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The Hartford Steam Boiler Inspection and Insurance Company
Safety Valve Body Seat Disc Stem Spring Blow-Down Ring Huddling
Chamber
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The Hartford Steam Boiler Inspection and Insurance Company
Low Water Fuel Cutoffs
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The Hartford Steam Boiler Inspection and Insurance Company
Low Water Fuel Cutoffs
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The Hartford Steam Boiler Inspection and Insurance Company
Low Water Fuel Cutoffs
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The Hartford Steam Boiler Inspection and Insurance Company
Low Water Fuel Cutoffs
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The Hartford Steam Boiler Inspection and Insurance Company
Conclusion
Follow proper operating procedures
Regular maintenanceBe preparedAbove all …Work Safely!
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The Hartford Steam Boiler Inspection and Insurance Company
Electrical Maintenance
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The Hartford Steam Boiler Inspection and Insurance Company
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.”
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The Hartford Steam Boiler Inspection and Insurance Company
Preventing Electrical Failures
CleanCool
DryTight
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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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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
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The Hartford Steam Boiler Inspection and Insurance Company
Everything “Looks Okay”
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The Hartford Steam Boiler Inspection and Insurance Company
…However!
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The Hartford Steam Boiler Inspection and Insurance Company
Infrared Thermographic
Imaging Detects Hot
Spots Dirty, Loose,
Oxidized, or Corroded Connections.
Finds Phase Imbalance Problems.
Finds Undersized Wiring Problems.
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The Hartford Steam Boiler Inspection and Insurance Company
Surge ProtectionSurge Protection Device (SPD)Transient Voltage Surge
Suppressor (TVSS)Diverts surge currents to
groundLimits the voltage across the
terminals of the equipment being protected
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The Hartford Steam Boiler Inspection and Insurance Company
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 EquipmentThird line of defenseProtects against internally generated surges
Grounding System is key to protection
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The Hartford Steam Boiler Inspection and Insurance CompanyThe Hartford Steam Boiler Inspection and Insurance Company
Above all else…..
SAFETY FIRST!
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The Hartford Steam Boiler Inspection and Insurance Company
Have a Safe Trip Home!