Boiler Safety Bureau Strategic Plan

Transcription

1 Boiler Safety Bureau Strategic Plan Boiler Safety Bureau 1101 Mail Service Center Raleigh, NC B Hillsborough Street Raleigh, NC 27603

2 Table of Contents Letter from the Bureau Chief Page 3 Organizational Overview..Page 4 Opportunities and Challenges..Page 5 Mission, Vision and Goals.Page 6 Measures and Objectives..Page 7 Operational Definitions of Key Measures...Page 11 2

3 Introduction Since 1935, the Boiler Safety Bureau, an agency of the North Carolina Department of Labor, has been charged with the inspection of pressure retaining equipment in the state. The purpose of these inspections is to endeavor to prevent the catastrophic failure of the equipment. The failure of pressure r e t a i n i n g equipment not only endangers the personal safety of citizens but also endangers the financial safety of the owners of the equipment due to significant property losses and damage. It can be found that a typical air storage tank such as those used in service stations has the same explosive potential as two sticks of dynamite. Therefore, one can only imagine the potential in a high pressure steam boiler operating at 250 pounds per square inch. Lives have been lost and property severely damaged when this equipment has failed. This presentation of the Boiler Safety Bureau's Strategic Plan for Fiscal Years reveals our efforts to increase our effectiveness and, in this time of economic uncertainty, make clear the priorities and direction that we will take. The objectives were based on an analysis of our strengths, weaknesses, opportunities and threats (SWOT). We received input from our field and office staff. This SWOT analysis lets us take a hard look at where we are strong and need to stay that way and where we need to improve. We have our goals referred to as objectives in order to meet the new and old challenges we face. Even with successes in the past, we know that there is always room for improvement. The objectives identified will enable us to move forward and conduct business with efficiency and with the safety objectives to meet the day to day schedule with safety in mind. The objectives are based on what we know, through an inside-out and outside-in look, to be keys to future successes. The objectives will have an effect on our efforts. In this plan we have included the objectives as well as success measures by which they will be accomplished. 3

4 Organizational Overview The Boiler Safety Bureau s mandate is to administer the Uniform Boiler and Pressure Vessel Act of North Carolina (GS Chapter 95, Article 7A and Article 7B) and the rules found in the North Carolina Administrative Code, 13 NCAC 13, Boilers and Pressure Vessels. This includes the inspection of boilers and pressure vessels (pressure retaining equipment) and to identify any violations that might exist. Concurrently, we work as an Authorized Inspection Agency in ASME Boiler and Pressure Vessel Code shops that construct new pressure retaining equipment and shops that conduct repairs and alterations to the equipment. As well, we administer state law and rules examinations to new inspectors and conduct quality reviews on National Board of Boiler and Pressure Vessel Inspectors R stamp (repair) programs. Additionally, if there is an incident involving a boiler or pressure vessel, our inspectors are trained to investigate the incident and report their findings. Currently, there are 91,032 items of pressure retaining equipment that are active in our data system. The equipment are broken down into boilers, pressure vessels and heat exchangers. High pressure boilers typically get two inspections per year, an internal inspection and an external inspection. Low pressure heating boilers, most pressure vessels and heat exchangers receive an inspection every two years. The one exception is that hydropneumatic water storage tanks are inspected every four years. The inspections are accomplished by 14 Boiler Safety Bureau inspectors referred to as Deputy Inspectors. Also, there are approximately 170 insurance inspectors or Special Inspectors that may inspect those equipment that their companies insure. They report their inspections to their companies and to the Boiler Safety Bureau. When either electronic reports or hard copy reports are received, three Boiler Safety Bureau processing assistants conduct quality control checks on the reports. If the report is hard copy, they enter the report into our data system. If the report is electronic, they release it to the data system. The Boiler Safety Bureau is comprised of the 14 deputy inspectors, two inspector supervisors, three processing assistants, one information processing assistant, one administrative assistant I, the assistant chief and the chief. 4

5 Opportunities and Challenges The following lists some of the opportunities and challenges facing the Boiler Safety Bureau: Opportunities The Boiler Safety Bureau has the ability to place all reports on line. Our inspectors are able to report their inspections on line, however, there are a number of reports that are still hard copy and can be electronically produced and then utilized by our staff. While we inspect most of the operating pressure retaining equipment in the state, there are still other equipment of the equipment that have not been inspected. This in most cases is due to the public s lack of knowledge about the boiler and pressure vessel law. We h a v e developed a system that helps to identify businesses that would typically have pressure retaining equipment. Those that may have pressure retaining equipment are then compared to what we already have in the data system. Challenges Because of the nature of the insurance business, often pressure retaining equipment is insured one day and not the next. This can cause equipment to fall past due on inspections unless we keep a strong eye out for those slipping past due. The Boiler Safety Bureau is a receipt funded agency meaning we charge for inspections to operate with and receive no tax monies. Therefore, the Bureau must be very frugal with every dollar and make sure that inspections are conducted and reported in a timely manner. Timely reporting enables us to invoice and receive the payments to allow us to continue to operate efficiently. 5

6 Mission, Vision and Goals Mission The Boiler Safety Bureau mission is to protect life, property and the environment from the hazards of pressure equipment failures. Vision The Boiler Safety Bureau is driven by the vision of total boiler and pressure vessel safety in North Carolina and the eradication of catastrophic failures of pressure equipment. Boiler Safety Bureau Goals GOAL 1: GOAL 2: GOAL 3: Provide for maximum public safety through a proper pressure retaining equipment safety inspection program. Provide expeditious input of hard copy inspection reports into the data system. Maintain a safe and healthy work environment for our employees. 6

7 Measures and Objectives Goal 1 Provide for maximum public safety through a proper pressure retaining equipment safety inspection program Objectives # Measure Objective Target Date(s) % of combined State and insurance inspection backlog of equipment due 30 days after certificate of inspection expiration. % of State inspection backlog of equipment due 30 days after certificate of inspection expiration. Backlog 1.5% Each month Backlog 0.9% Each month 1.3 % of follow-up inspections of pressure retaining equipment for which violations were identified by State inspectors. 95% within 90 days Each month 1.4 Develop a program to increase public awareness of the dangers associated with the operation of pressure retaining equipment and the inspection requirements of Chapter 95, Article 7A. Program developed to communicate in written and electronic form. December 31, Conduct training for inspection staff. Include inservice and new construction related curriculum. Conduct training twice a year in Spring and Fall May & November Notes: 1.1 Inspection certificates are issued for one, two or four years from the date of inspection. See the operational definition for Backlog on page Inspectors are expected to conduct the recurring inspection within 30 days of that expiration date. See the operational definition for Backlog on page The owner/user of the pressure retaining equipment is given 60 days to provide corrective action when a violation is identified. Inspectors are expected to conduct the follow-up inspection within 90 days of the date the violation was identified. See the operational definition for Violations and Follow-up inspection timing on page 12. 7

8 1.4 Installers and owner/operators are not always aware of the dangers associated with the operation of pressure retaining equipment and the inspection requirements under the Act. A program is needed to increase awareness and to help explain the reason for visits by Deputy Inspectors during new location visits. 1.5 It is required by the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and the National Board of Boiler and Pressure Vessel Inspectors rules that both Inservice Inspectors and New Construction Inspectors be trained and maintain competency. To get all the training necessary, the Boiler Safety Bureau will conduct a minimum of two major training sessions each year. One will be in the spring and the other in the fall. Inservice Inspector: The Inservice Inspector is commissioned by the National Board of Boiler and Pressure Vessel Inspectors and the Department of Labor to conduct first and recurring inspections of pressure retaining equipment that is being operated in North Carolina. New Construction Inspector: The New Construction Inspector is commissioned by the National Board of Boiler and Pressure Vessel Inspectors and the Department of Labor to conduct inspections of pressure retaining equipment that being constructed by manufacturing facilities accredited by the ASME to construct the equipment in accordance with the ASME Boiler and Pressure Vessel Code (Code). The inspector referred to as an Authorized Inspector signs the final manufacturer s data report when he is confident that the equipment has been constructed in accordance with the Code. 8

9 Goal 2 Provide expeditious input of hard copy inspection reports into the management information system. Objectives # Measure Objective Target Date(s) 2.1 Input of hard copy inspection reports into the data system. 5 days Each month Notes: 2.1 The insurance company that does the most inservice inspections is not a subscriber of the Boiler Safety Bureau s data system Jurisdiction Online and send in their inspection reports either by hard copy or attached to an . The Bureau processing assistants must enter these reports directly into the data system. Goal 3 Maintain a safe and healthy work environment for our employees. Objectives # Measure Objective Target Date(s) 3.1 Conduct bureau S&H committee meetings. At least quarterly July, October, January, April 3.2 Site inspections are conducted of Bureau controlled spaces in accordance with the S&H Policies using appropriate reporting forms. 3.3 S&H Policy 9 is reviewed with supervisors and staff. At least quarterly Annually July, October, January, April By July for supervisors, by September for staff 9

10 # Measure 3.4 Follow prescribed procedures for investigating and reporting injuries, occupational illnesses, violence or criminal activity Objective Investigate and report as required by policy Target Date(s) Per occurrence Notes: 3.1 The Boiler Safety Bureau and the Mine and Quarry Bureau have a joint unit safety committee. The Boiler Safety Bureau representative on the committee will take the lead to ensure that a minimum of four unit meetings per year are conducted. The committee is responsible to work in accordance with Policy 2, Designation and Responsibilities of the Safety and Health Committees. The committee will discuss any safety problems that have been identified and will review safety and health procedures for accuracy and required updates. 3.2 The unit committee is responsible to conduct safety inspections of the Boiler Safety Bureau work space to verify that the Bureau is in compliance with the safety requirements. These inspections include emergency lighting, exit signs, improper extension cords, improper storage, etc. A report of the inspection is filed with the steering committee on the day of the inspection and placed on the intranet site. 3.3 Policy 9, Investigation and Reporting of Events, involves office and field staff alike. It is important that supervisors are fully aware of their responsibilities under the policy and are able to instruct their employees on the policy requirements. 3.4 Policy 9 gives the guidelines for the investigation of events which result in: (1) injuries, (2) occupational illnesses, and or (3) violence or criminal activity to Department of Labor employees in the course of the performance of their job duties. Upon notification of an incident, the supervisor must begin an investigation within 24 hours and report that investigation in accordance with the policy. 10

11 Operational Definitions of Key Measures Backlog: Backlog refers to the percentage of active boilers and pressure vessels overdue for inspection by greater than 30 days after the due date for recertification. The measure pertains to the back log of inspections for boilers and pressure vessels hereinafter referred to as pressure retaining equipment, which includes: high pressure boilers, low pressure boilers (i.e., heating boilers and hot water supply boilers) and pressure vessels (i.e., air storage tanks, dye kiers and chemical reactors). Pressure retaining equipment is inspected by Boiler Safety Bureau inspectors and certain insurance companies that are licensed to write boiler and pressure vessel insurance. The equipment is regulated in accordance with North Carolina General Statutes Chapter 95, Article 7A and the North Carolina Administrative Code, Title 13, Chapter 13. The source of the data is a third-party data management information system, managed by Praeses, Inc. Currently, eleven insurance companies subscribe to the system and it is provided at no charge to the Bureau. State inspectors and subscribing insurance inspectors query the system to determine what equipment in their territories are due for inspection. The Bureau provides a listing of pressure retaining equipment due for inspection to the non-subscribing insurance companies. In each case, the inspectors visit the locations and conduct inspections of the equipment according to the North Carolina Administrative Code and the National Board Inspection Code (NBIC). When insured pressure retaining equipment go beyond 60 days past due, state inspectors inspect the equipment to bring it current. Upon satisfactory inspections (no violations), high pressure boilers are issued one-year certificates of inspection. Low pressure boilers and pressure vessels except hydro-pneumatic tanks are issued two-year certificates of inspection. Hydro-pneumatic tanks (water storage) are issued four-year certificates of inspection. The data is entered from inspections conducted by state and insurance inspectors. Currently 14 state inspectors and eleven of twelve insurance companies inspectors enter data directly into the system. One of the insurance companies inspectors produce hard copy reports which they mail to the Bureau. Three Bureau Processing Assistants enter those inspections into the system since these inspectors do not have access to the system. In each case the data is entered in the same formatted entry screens. Additionally, the Processing Assistants conduct quality checks of all data before it is released to the third-party data management information system. The overdue percentage is based on the total expired certificates of inspection divided by the total active equipment. The percentage overdue is calculated for each state inspector, all state inspectors as a group, each insurance company, all insurance companies as a group, and a combined percentage for both state and insurance inspections. These percentages are calculated from information entered into the data management information system. The calculated information is reported monthly and is used by Bureau management to help better manage the timeliness of inspections. In addition, Bureau management and Department of Labor senior management meet quarterly to review these percentages as well as other Bureau strategic and operational data. The percentages are also reported in the Bureau s annual report. It is important that we manage the back log to verify that equipment is still in acceptable condition for safe operations in North Carolina businesses and institutions and that problems are identified 11

12 and repaired before catastrophic accidents result. Additionally, the Bureau is totally receipt funded with no revenue received from the General Fund. Therefore, timely inspections help to ensure proper cash flow to meet Bureau daily expenses. Violations: The North Carolina Administrative Code, 13 NCAC 13,.0101 (48) defines violation as follows: "Violation" means the failure to comply with the requirements of the Uniform Boiler and Pressure Vessel Act or this Chapter. Identifying violations is important for obvious safety reasons. The follow-up inspection to verify that a violation has been corrected is also important so that the violation can be cleared, the pressure retaining equipment operated safely and the user of the pressure retaining equipment can receive their Certificate of Inspection. Follow-up inspection timing: Follow-up inspection timing, spoken to in measure 3, refers to the percentage of follow-up inspections conducted within 90 days of inspection identifying deficiency. The measure pertains to the pressure retaining equipment in which a violation was identified during the inspection. Some equipment of deficiency was identified that put the pressure retaining equipment in violation of the Uniform Boiler and Pressure Vessel Act GS or the North Carolina Administrative Code 13 NCAC 13. The source of the data is the third-party data management information system, managed by Praeses, Inc. The data is entered from inspections conducted by state and insurance inspectors. When an inspector identifies a violation, it is entered into the data system. The owner/user of the pressure retaining equipment receives a Notice of Violation letter from the bureau. The owner/user is given 60 days to complete the corrective action to remove the violation. The follow-up inspection percentage is based on the total follow-up inspection violations divided by the total violations identified. The percentage is calculated for a combined percentage for both state and insurance inspections. This percentage is calculated from information entered into the data management information system. The calculated information is reported monthly and is used by Bureau management to help better manage the timeliness of follow-up inspections. In addition, Bureau management and Department of Labor senior management meet quarterly to review these percentages as well as other Bureau strategic and operational data. It is important that we manage the follow-up inspections for two major reasons. First, timely followup inspections enable us to verify that pressure retaining equipment problems have been corrected and the pressure retaining equipment is now in acceptable condition for safe operations in North Carolina businesses and institutions. The desired result is that problems have been identified and repaired before catastrophic accidents result. 12

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