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Preventing Equipment Failures

Preventing Equipment Failures

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Preventing Equipment Failures

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  1. Preventing Equipment Failures Boilers Electrical Distribution Systems Air Conditioning Equipment

  2. Any Questions? Then let’s get started! The Hartford Steam Boiler Inspection and Insurance Company

  3. Preventing Equipment Failures The Hartford Steam Boiler Inspection and Insurance Company

  4. Boiler Maintenance The Hartford Steam Boiler Inspection and Insurance Company

  5. 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. The Hartford Steam Boiler Inspection and Insurance Company

  6. Boiler Categories • Power Boiler • High Temperature Hot Water Boiler • Heating Boiler The Hartford Steam Boiler Inspection and Insurance Company

  7. Watertube Boilers Components: • Steam drum • Water (mud) drum • Tubes The Hartford Steam Boiler Inspection and Insurance Company

  8. Watertube Boilers The Hartford Steam Boiler Inspection and Insurance Company

  9. Firetube Boilers The Hartford Steam Boiler Inspection and Insurance Company

  10. Firetube Boilers Components: • Shell (Drum) • Tube Sheets, Front & Rear • Tubes (Flues) • Furnace • Stays (Stay Bolts) The Hartford Steam Boiler Inspection and Insurance Company

  11. Firetube Scotch Marine The Hartford Steam Boiler Inspection and Insurance Company

  12. What could possibly go wrong with my boiler? Let’s take a look at some typical boiler failures!

  13. Major Causes of Boiler Failures • Low Water • Poor Maintenance • Failure of Controls and Safety Devices The Hartford Steam Boiler Inspection and Insurance Company

  14. Low Water • Results in over temperature condition • Can cause extensive damage to boiler Or • Catastrophic failure of the boiler The Hartford Steam Boiler Inspection and Insurance Company

  15. The Hartford Steam Boiler Inspection and Insurance Company

  16. The Hartford Steam Boiler Inspection and Insurance Company

  17. The Hartford Steam Boiler Inspection and Insurance Company

  18. Poor Maintenance The Hartford Steam Boiler Inspection and Insurance Company

  19. The Hartford Steam Boiler Inspection and Insurance Company

  20. The Hartford Steam Boiler Inspection and Insurance Company

  21. The Hartford Steam Boiler Inspection and Insurance Company

  22. Failure of Controls and Safety Devices The Hartford Steam Boiler Inspection and Insurance Company

  23. The Hartford Steam Boiler Inspection and Insurance Company

  24. The Hartford Steam Boiler Inspection and Insurance Company

  25. The Hartford Steam Boiler Inspection and Insurance Company

  26. The Hartford Steam Boiler Inspection and Insurance Company

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  28. The Hartford Steam Boiler Inspection and Insurance Company

  29. The Hartford Steam Boiler Inspection and Insurance Company

  30. Preventing Boiler Failures • Proper Operation • Proper Maintenance • It’s all up to you! The Hartford Steam Boiler Inspection and Insurance Company

  31. Boiler Operation • Prepare the boiler for operation • Starting the boiler • Regular operation • Controls and safety valves • Feedwater treatment The Hartford Steam Boiler Inspection and Insurance Company

  32. Boiler Logs • Why use them • What to include • How to use them The Hartford Steam Boiler Inspection and Insurance Company

  33. Boiler Codes • ASME Boiler & Pressure Vessel Code • ASME Controls and Safety Devices • National Board Inspection Code • Jurisdictional Rules The Hartford Steam Boiler Inspection and Insurance Company

  34. Jurisdictional Rules • Inspection Frequencies • Inspection types • Installation requirements • Rules for repair The Hartford Steam Boiler Inspection and Insurance Company

  35. Housekeeping • Safety • Fire Prevention • Combustibles • paint, oil, gas and cleaning products • Flammables • wood, paper and cardboard • keep at least 8 to 10 feet from the boiler • Emergency Access The Hartford Steam Boiler Inspection and Insurance Company

  36. Controls & Safety Devices • Maintain control over boiler operation • Monitor operating conditions • Protect boiler from failure The Hartford Steam Boiler Inspection and Insurance Company

  37. 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 The Hartford Steam Boiler Inspection and Insurance Company

  38. 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 The Hartford Steam Boiler Inspection and Insurance Company

  39. 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. The Hartford Steam Boiler Inspection and Insurance Company

  40. Siphon Loops The Hartford Steam Boiler Inspection and Insurance Company

  41. Safety Valve • Body • Seat • Disc • Stem • Spring • Blow-Down Ring • Huddling Chamber The Hartford Steam Boiler Inspection and Insurance Company

  42. Low Water Fuel Cutoffs The Hartford Steam Boiler Inspection and Insurance Company

  43. Low Water Fuel Cutoffs The Hartford Steam Boiler Inspection and Insurance Company

  44. Low Water Fuel Cutoffs The Hartford Steam Boiler Inspection and Insurance Company

  45. Low Water Fuel Cutoffs The Hartford Steam Boiler Inspection and Insurance Company

  46. Conclusion • Follow proper operating procedures • Regular maintenance • Be prepared • Above all …Work Safely! The Hartford Steam Boiler Inspection and Insurance Company

  47. Electrical Maintenance The Hartford Steam Boiler Inspection and Insurance Company

  48. Electrical Distribution System The Hartford Steam Boiler Inspection and Insurance Company

  49. 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.”

  50. Preventing Electrical Failures • Clean • Cool • Dry • Tight The Hartford Steam Boiler Inspection and Insurance Company