1 Boiler & Pressure Vessel Inspection discrepancies and failures
2 Water Heaters / Pressure Vessels Pressure Vessels are inspected once every three years. This requires a test of A: safety relief devices B: Temperature and Pressure controls C: External exam to check for leaks D: Testing to verify thickness of the vessel body
3 Basic Thermo Dynamics of water. Water boils at atmospheric pressure (14.7psi) at 100 deg. C or 212 deg. F.. When placed under pressure water can be heated to extremes without flashing to steam. The typical expansion rate for 1 cu. ft of water is 1700 cu ft. of steam.
4 Relief valve installed backward on a 119 gal. electric water heater. With inlet and outlet stamped into the valve.
5 Failure of Normal Operation If the relief valve does not properly function and the temperature control fails to properly control temp. The water heater will heat unchecked until catastrophic failure occurs. The routinely inspected water heater holds 119 gallons, there is considerable explosive force behind such a release of energy.
6 This is the result of a relief valve failing to lift on a 119 gal. water heater in a split level home.
7 Multiple family dwelling in Mifflinburg PA. Relief valve failed to function, Water Heater was in the basement
8 Routine Maintenance and inspections on Low Pressure Boilers Low Pressure Boilers are inspected annually while in operation and internally every 3 years, if construction permits. During this inspection all safety device function is evaluated, relief valves, Low water fuel cut outs, high temperature and high pressure switches.
9 The following photos are of a Maine boiler that failed due to mechanical issues stemming from lack of proper maintenance This boiler was added to the inspection route days before this incident. This was the initial inspection to place it in the system What follows is the list of items noted during the inspection.
10 Items noted on the inspection prior to failure A: Low water cutout both left and right sides failed to initially function. Units required multiple flushing to function. B: Relief tested and leaking steam from spindle C: Gage glass scaled, can not read water level within boiler D: Bottom connection on right side low water cutout corroded and leaking water E: Steam and water connections on water column leaking F: Left side mud drum water supply piping heavily corroded and steadily leaking water G: Left side mud drum, 3 mud drum to boiler connections heavily corroded and leaking H: Check burner operation and combustion system tuning, heavy puff of smoke on ignition of burner.
11 It is suspected that in the night the left side mud drum water supply connection that was corroded and leaking failed along with the low water cutout switch.
12 Left Mud Drum Water Inlet connection
13 These failures allowed the boiler to continue to operate without a cooling medium. Allowing the unit to overheat to the point of rupturing the left mud drum and burning off the electrical wires from the safety shutoff connections at the front of the boiler
14 Top right in photo is the point where the safety switches wiring connected to the burner controls
15 Photo of the over heated firebox. No one was injured in this event. Even though the boiler was found running in this condition in the morning.
16 Hot Water Heating Boiler failure due to non functioning low water cutout This was a domestic or residential size hot water heating boiler used for building heat. This was a Federal Facility located in Maine in which the State of Maine has no jurisdiction. This boiler does not require inspection per Maine law Failure of the Low water fuel cutout safety switch was root cause Incident occurred after normal working hours, no individuals were injured.
17 Boiler lying on its side where it landed after the explosion. Significant damage is evident throughout the room
18 Ceiling of the room where the boiler hit when it lifted from the floor
19 Exterior of the building damaged by the blast. The boiler was located in the basement.
20 Low Pressure Steam heating boiler installed in Maine. Inspection noted, leaking sections, a rusted out condensate return line and improperly operated boiler
21 Securing and opening the steam heating boiler found the boiler full of calcium hardness and scale. As the unit heated, the calcium hardness expanded and pushed the sections apart causing leakage
22 Condensate return line that should have been returning reclaimed water to the boiler was pouring on the floor due to rusted out piping.
23 With lack of blow down, nearly 100% make up, and lack of proper operation and service this unit pushed itself apart. These units are serviced on an annual basis by properly licensed technicians
24 The following photos are of boilers and items found during routine annual inspections of low pressure boilers in Maine.
25 Corroded water inlet line. Incident waiting to happen
26 Mud Drum to Boiler connection, corroded and leaking.
27 Corroded mud drum and boiler connections. Hazard is boiler explosion.
28 Leaking and corroded safety valve.
29 Discolored lagging top left and bottom background is soaked with fuel oil from a leaking fuel oil supply fitting.
30 Hot Water system circulating pumps corroded and leaking inlet and outlet connections
31 Bad refractory causing hot spots and fire hazard along with bad door seals allowing CO into the building
32 Missing insulation causing fire hazard, and allowing exhaust gasses into the building
33 Bad door gaskets creating fire hazard, heat damaged pipe insulation, exhaust gasses allowed into building.
34 Domestic hot-water heating boiler in NJ. Came up through the floor, out the side of the house and.
35 Into the neighbors house 60 feet away.
36 One individuals solution to a leaking relief valve. Last resort? Place an isolation valve in the system. Refer back to the 119 gal water heater.
37 Boiler explosion caught on video in Maine. Note the items on the desk bottom right. These 3 photos watched in series will show the first few seconds of a boiler event
38 The operator had just exited the scene heading to the left. Note fireball top of the screen, burner on front of boiler twisting to the right, ladder twisting and items lifting of the desk bottom right
39 These 3 photos were taken from a continuous feed video. Elapsed time is split seconds.
40 A situation where an air tank had been welded in place of a Steam Jenny Boiler and used for thawing culverts by a Public Works dept in Maine. This is not built to code.
41 The vessel is clearly ASME stamped U, non fired pressure vessel, max temp 650 deg. F.
42 It had been fitted with a hot water boiler relief valve not a steam safety valve, was manually filled with 5 gallons of water
43 Then a gas rosebud torch was placed underneath the vessel to boil the water and bring the pressure to 15 psi. At that point they would open the isolation valve and force steam into frozen culverts. The perfect IED
44 The gas bottle and rosebud torch used to bring the vessel to a boil.
45 In Closing There are many, many more pictures to show, we are limited only by time. We have situations where no one is monitoring the boiler in schools and minucipalities on a regular basis. Sometimes the inspector is the only individual looking at the boiler. There have been instances where a school has needed to be closed early due to conditions found during the inspection. In this case relief valves on two water heaters and the heating boiler were found to be non-functioning.
46 Frequently noted items Low water fuel cutouts, stuck safety and relief valves in day care buildings on college campuses. Due to these units not requiring annual inspection by State of Maine Law, controls and safety devices such as low water fuel cutouts, high temperature and high pressure switches are often found not installed to current requirements. These items were found during consult inspections as requested by Risk Management
47 Routine annual heating boiler maintenance. Most owners are under the assumption that the technician servicing their boiler on an annual basis is somehow taking care of the testing of devices and inspection. This is not always the case. This service normally entails servicing the combustion and burner fuel systems, change of fuel filters, clean the fuel pump housing, nozzles, check the igniter, vacuum the gas passes of the boiler and perform an efficiency test of the unit, etc. An evaluation of the pressure containing capability of the boiler is not made. That is the primary purpose of the annual boiler inspection.
48 Inspections Routine inspections are considered critical to ensure proper safety of the boiler. The inspector may be the only one to look at these boilers. If conditions go un-noted it may lead to catastrophic results. This is why we do inspections.
Boiler Preparation, Start-Up and Shutdown Learning Outcome When you complete this module you will be able to: Describe the basic preparation of a boiler for start-up, and the start-up and shutdown procedures.
Preventing Overheated Boiler Incidents PSE&G Appliance Service October 2012 Runaway Boiler Explosion Review Items Hazard Background Past Incidents PSE&G Emergency Response Future Process Improvements What
Factory owners must ensure the boiler is: * Registered with the Boilers and Pressure Vessels Division, Labour Department * Examined by an appointed examiner and has a valid certificate of fitness * Supervised
Your Boiler Room: A Time Bomb? Is you boiler room a potential Time Bomb? A few basics you need to know to work safely in the boiler room: Two potentials for explosions in a boiler room: Water/steam side
RESIDENTIAL HEATING OIL SERVICE CONTRACT This service contract covers all routine service and maintenance of your residential oil fired furnace or boiler. In addition this contract covers all service calls
CASE STUDY 1 COMMISSIONING A GAS FIRED STEAM BOILER A steam boiler has been built and installed at a factory for the provision of process steam. The following lists the requirements used in the commissioning
Indirect-Fired Storage Water Heater Models WH-30 through WH-80 INSTALLATION AND OPERATING INSTRUCTIONS Contents Page Ratings and Specifications..................... 2 Installation Requirements......................
Routine and Emergency Boiler Operation Learning Outcome When you complete this module you will be able to: Describe the routine safe and efficient operation of a packaged boiler. Learning Objectives Here
SECTION 15459 PART 1 - GENERAL 1.1 RELATED DOCUMENTS: A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Division-1 Specification sections, apply to work
Value & Premier Service Plans for oil heating systems Choose the plan that s best for you and your home. Over 100 years of industry leadership. Petro Home Services. The only company you need for oil heat.
Trouble Shooting Pump Trouble Possible Cause Remedy Oil leaking in the area of water pump crankshaft Worn crankshaft seal, bad bearing, grooved shaft, or failure of retainer o-ring. Excessive play on crankshaft
Hot Water Boilers and Controls Why Condensing Boilers are Different Presented Oct. 14, 2008 Long Island Chapter, ASHRAE H.W. Boilers and Controls Major types of boilers Advantages and disadvantages Resistance
Tankless Water Heater USER S INFORMATION MANUAL Models WGRTNG199 / WGRTLP199 WGRTCNG199 / WGRTCLP199 NOTICE: Westinghouse reserves the right to make product changes or updates without notice and will not
BUILDING PERFORMANCE INSTITUTE TECHNICAL STANDARDS FOR THE HEATING PROFESSIONAL Health and Safety Personal Safety All technicians performing diagnostic tests, inspections, or installations, must have access
SIOUX Hybrid Water Heater for the Concrete Industry SIOUX HYBRID WATER HEATER Patent Pending Maximizing the Benefits of Coil and Direct-Fired Heating Technologies Higher Discharge Temperature True High-Efficiency
Evaluate, Clean, and Tune Guidance The Evaluate, Clean and Tune (ECT) process serves three essential purposes in the Weatherization Assistance Program (WAP). The first is to evaluate the existing system
Chapter 2 Boiler 101: typical NYC residential heating system One and two family homes often use forced-hot-air heating systems, which include a burner, heat exchanger and blower(s). In these types of systems,
PLP - TERMS AND CONDITIONS 2014-2015 Philadelphia Gas Works Residential Parts & Labor Plan Contract This Residential Parts & Labor Plan Contract (this Plan ) is available to customers of the Philadelphia
Sample Written Program For Flammable Liquids 1 Flammable Liquids. (YOUR COMPANY NAME) Purpose Proper Storage and use of flammable liquids can significantly reduce the possibility of accidental fires and
CHAPTER 10 BOILERS, WATER HEATERS AND PRESSURE VESSELS SECTION 1001 GENERAL 1001.1 Scope. This chapter shall govern the installation, alteration and repair of boilers, water heaters and pressure vessels.
SECTION 23 81 03 - PACKAGED ROOFTOP AIR CONDITIONING UNITS NON-CUSTOM PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Packaged rooftop air conditioning unit (5 tons and smaller). 2. Roof curb. 1.2
Some Criteria for Choosing a Steam Boiler for a Microbrewery Jack Coe Rite Engineering and Manufacturing Corporation Breweries rely on steam heating for a number of functions, primarily to heat the brew
Air Conditioner Water Heater - A Product of HotSpot Energy LLC PLEASE READ THIS BEFORE YOU INSTALL THE UNIT 1. This air conditioner must be installed and/or repaired by a qualified technician. If you perform
A cure for water damage in real estate Presented for BC Non-Profit Housing Association by Jeff Shearman, Zurich Services Corporation 2010 Zurich Canada Focused on our customer Reduce overall risk by reducing:
Condensing Boiler Efficiency Date: July 17, 2012 PRES E NT ED BY DO N L E O NA RDI LE O N A RD I I NC. HV AC T RAI N I N G & C ON SU LT IN G Concepts 1 The current state of evolution in boiler design 2
BOXXER TROUBLESHOOTING 1.0. Will not turn over SECTION I. ENGINE 1.1. There is a loose or corroded battery terminal. Clean and tighten the battery terminal connections. 1.2. The battery is dead. Recharge
COMMERCIAL COOKING HOODS, VENTILATION & FIRE SUPPRESSION SYSTEM GUIDELINES AND PROCEDURES These guidelines are to be used for ALL commercial cooking hoods, ventilation systems and related fire suppression
I. STEAM GENERATION, BOILER TYPES and BOILER PLANT SYSTEMS 1 Steam Generation Water s Unique Properties: High Thermal Capacity (Specific Heat) High Critical Temperature Ideal Medium for Heat Delivery High
Vaillant s plain English guide to simple, concise and precise Introduction Contents Installing a new boiler 05 Servicing and repairing 13 What s a diverter valve? Why do you need a TRV? And happens when
REHABILITATION OF MOBILE HOMES R4 34 606 PURPOSE The purpose of this program is to provide minimum safety standards for homes manufactured before the implementation of the HUD Manufactured Home Construction
The city of Milwaukee s Sample Preventative maintenance manual for Electronically monitored boilers Table of Contents Introduction... 1 Intention... 2 Authority and responsibility letter... 3 Organizational
CONDUIT PIPE DRYING This Presentation will guide you to why systems fail! This will also provide you with the knowledge to insure long life for your Investment Drainable and Dryable System Design Trough
Arapahoe County Residential Water Heater Installation and Inspection Guide The attached handout is designed to be a general permit submittal and inspection guide covering most installation instances, however
INSTALLATION & MAINTENANCE MANUAL TURBOPOWER GAS, OIL & GAS/OIL WATER HEATER Installation and service must be performed by a qualified service installer, service agency or the gas supplier. Oil Gas/Oil
INTEC Engineering GmbH Heating Solutions for the Marine Industry Thermal Oil Heaters Heating Solutions for the Marine Industry Compared to conventional plants using hot water or steam, thermal oil as a
Purpose Responsibilities Proper Storage and use of flammable liquids can significantly reduce the possibility of accidental fires and injuries. To minimize risk to life and properly, the requirements of
coaching Whitepaper: Home Maintenance Tips for First Time Homebuyers By: John B. Elson Technical Leader and Director of Education Inspect-It 1 st Property Inspection March, 2010 Inspect-It 1 st Property
May 2010 DEPARTMENT OF CODES AND BUILDING SAFETY FLOOD RECOVERY INFORMATION GUIDELINES FOR PERMITS ASSOCIATED WITH THE REPAIR OF FLOOD DAMAGED HOMES AND BUILDINGS The Department of Codes and Building Safety
Crawford Inspection Services C.C.B. # 76914 www.crawfordinspections.com Portland Area PO Box 665 West Linn, OR 97068 Ph: (503) 650-6957 Salem Area 5434 River Rd. N; #192 Keizer, OR 97303 Ph: (503) 362-5809
28 2. Connect DHW (domestic hot water) piping to indirect storage water heater. L. ZONING WITH CIRCULATORS 1. Connect the boiler to the system when using circulator zoning as shown in Boiler Piping Details.
CDS TROUBLESHOOTING SECTION I. VACUUM 1.0. Weak vacuum at wand. Gauge reads normal (10hg to 14hg) 1.1. Clogged hoses or wand tube. Disconnect hoses and carefully check for an obstruction. 1.2. Excessive
Protect your home s major mechanical systems with Main Street Mechanical s Home Service Agreement. The benefits of a Home Service Agreement Provides peace of mind Regularly scheduled maintenance will keep
HS-901(A) BASIC HEATING SYSTEMS One-Pipe Two-Pipe Basic Steam Heating Systems One-pipe steam heating system EQUALIZER SAFETY FACTOR STATIC HEAD PRESSURE DROP 2" HEATING UNIT 15" DRIP CONNECTION In a one-pipe,
RIELLO BURNER SYSTEM mectron 3M TYPE 215 OWNER MANUAL INSTALLATION INSTRUCTIONS We are delighted that you have chosen the Riello burner. It is modern. clean, efficient and like any quality product. must
FACILITY FIRE PREVENTION AND EMERGENCY PREPAREDNESS INSPECTION CHECKLIST Date of Inspection: Conducted by: Location: Reviewed by: Date of Review: Comments or additional corrective action taken as a result
OPERATION AND MAINTENANCE MANUAL PowerFlex he Index A. Introduction... 1 B. Warranty... 2 C. Description and features of your unit... 3 1. General description... 3 2. Flue gas circuits strategy... 3 3.
Oil and Coolant Circulating Heating System Model - OCSM Installation & Operation Manual 216280-000 REV 2 Identifying Your System The HOTSTART heating system is designed to heat fluids for use in marine
BRYAN FLEXIBLE WATER TUBE AB SERIES STEAM AND WATER BOILER 900,000 TO 3,000,000 BTUH FORCED DRAFT GAS, OIL OR DUAL FUEL FIRED Water Boiler AB120-W-FDGO Steam Boiler AB250-S-150-FDG Originators of the Flexible
Operator: Save these instructions for future use! FAILURE TO READ AND FOLLOW ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR OPERATING THIS CONTROL COULD CAUSE PERSONAL INJURY AND/OR PROPERTY DAMAGE. DESCRIPTION
This boiler was too small for inspection An investigation into a boiler explosion by State Boiler Inspectors David Gonsoski and Tom Boyle and insurance company inspector John Glynn The following investigation
to Bulk Milk Coolers and Other System Page 1 of 5 Overall reliability can be enhanced if there exists a complete understanding of the features, system design, installation requirements, processing, charging
Elite Fire Tube Combi Floor and Wall Mount Models USER S INFORMATION MANUAL Models EFTC-140F / 199F EFTC-140W / 199W NOTICE: HTP reserves the right to make product changes or updates without notice and
GENERAL: This section provides general standards for overall sizing and design of Heating, Ventilating, and Air Conditioning (HVAC) systems. Other sections contain specific standards for each system per
BP WIND ENERGY POLICIES AND PROCEDURES Document Control Details 1.0 Purpose/Scope 1.1 This procedure provides the minimum requirements to be followed for the storage of flammable or combustible materials
4658.4500 PLUMBING SYSTEMS; NEW CONSTRUCTION. Subpart 1. Installation. All plumbing systems must be installed and tested according to this chapter and chapter 4715, the Minnesota Plumbing Code. Subp. 2.
Service Bulletin DATE: June 18, 2008 TO: All Service and Parts Managers SUBJECT: Flood Damaged Appliances SA-008 Due to the unfortunate flooding experienced by many areas in the Midwest in recent months,
67 This section gives you some helpful information and tips on running your home and the equipment in it. Electricity Fuse board (electrical consumer unit) Make sure you know where your fuse board is and
Hot Work Permit Policy Environmental Health and Safety Department 800 West Campbell Rd., SG10 Richardson, TX 75080-3021 Phone 972-883-2381/4111 Fax 972-883-6115 http://www.utdallas.edu/ehs Modified: May
User's Instructions Alpha HE CB25/33 and HE SY25 Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Boiler Range For Technical help or for Service call... ALPHA HELPLINE Tel:
Chapter 9: Water Heating 145 CHAPTER 9: WATER HEATING Energy costs for water heating can be as great as the costs for heating, for an energy efficient house, in a mild climate. Estimating hot water usage
National Competency Based Skill Training Refrigeration and Air-conditioning Mechanic Logbook Trainee:... Training Provider:... Year:... Trainee Contact no:... Competency Based Skill Training Logbook Introduction
Chicago Stationary Engineer Licensure Examination Information This candidate guide should help you prepare for the Chicago Stationary Engineer licensure examination. Part I contains general information
GUIDELINES - Gas Inspection Regulations 1. Recommendations for camping site owners Offer gas tests by recognized experts for camping guests. Keep a record for gas tests. Write down the date and who tested
OTF Oil Fired Pool Heater Installation Operation Maintenance Manual Service Policy 722010 Congratulations on the purchase of your new pool heater. In order to maintain peak performance of your pool heater
Annual Service Agreement 462 Main Street P.O. Box 130 Royersford, PA 19468 610-948-7220 www.plottsenergy.com GAS OIL HEAT PUMP AIR CONDITIONING A family owned and operated business since 1949. We are here
PART 1 - GENERAL 1.01 OVERVIEW A. This section addresses domestic cold, hot and hot water return distribution systems within and to five feet beyond building perimeter. PART 2 - DESIGN CRITERIA 2.01 GENERAL
. RFP: Attachment J-C18.1 HVAC Work Instructions NNC13ZFD017J SOW Item No. Title Page C18-02 Control Air Systems Annual PM 2 C18-03 Split System AC Indoor Section Annual PM 3 C18-04 Condensing Unit Semi-Annual
Electric Water Heater OWNER S MANUAL FORCE 10 MARINE COMPANY 23080 HAMILTON ROAD RICHMOND, BC CANADA V6V 1C9 TEL: (604) 522-0233 FAX: (604) 522-9608 If your water Heater is Damaged or you have questions
healthy homes assessment Date of Inspection: Inspector s Name: Agency: Address of Property: Resident s Name: Phone Number: Primary Reason for Visit: Asthma Lead Poisoning Voluntary Referral Other: GENERAL
Energy Saving Fact Sheet Boilers Turn a burning issue into real energy savings You need a boiler to heat your premises and provide hot water or to generate steam for use in industrial processes. Unfortunately,
ENGINE COOLING SYSTEM 1988 Toyota Celica 1987-88 TOYOTA Engine Cooling Systems Celica DESCRIPTION The basic liquid cooling system consists of a radiator, water pump, thermostat, cooling fan, pressure cap,
UNDERSTANDING CENTRAL HEATING SYSTEMS This advice guide is part of a series of free guides produced by the Association of Plumbing & Heating Contractors Ltd. which provide consumers with essential basic
Air Conditioner Water Heater Model ACWH18 Installation Guide IMPORTANT! READ THIS FIRST! Commissioning of this unit must be done by a licensed HVAC technician. Commissioning includes making the electrical
Plumbing Installations A homeowner guide to the City of Winnipeg plumbing requirements for a single-family dwelling February 2001 contents General Information 3 Inspection 4 New Drain and Vent Installations
1.0 IMPORTANT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. Shipping Damage is not covered by warranty. If shipping damage is found, notify carrier at once. The carrier is
Water Damage Prevention Risk Management Guidebook PIC Loss Control Services IMPORTANT NOTICE: The enclosed loss control information is for your consideration in your loss prevention efforts. They are not
GUIDELINES FOR LOGBOOKS COMPLIANCE TO BOILER REGULATIONS N.J.A.C. 12:90 Department of Labor and Workforce Development Labor Standards & Safety Enforcement Division of Public Safety and Occupational Safety
Hartford Steam Boiler One State Street P.O. Box 5024 Hartford, CT 06102-5024 Tel: (800) 472-1866 www.hsb.com July 2014 Safety should only be inspected, tested and maintained by qualified trained personnel.
Consulting, Resource, Education, Training, and Support Services for Home Inspectors A candle loses no light when it lights another candle. Gas-Fired, Residential Storage Type Water Heaters Most inspectors
Air Sealing Air Infiltration Reduction/Blower Door Guided Program Operations Air Sealing Door Weatherstrip Kit Program Operations Air Sealing Exhaust Fan Damper Incidental Repair Air Sealing Dryer Duct
Your consent to our cookies if you continue to use this website.