April 18, 2015 Ted Heiderscheit, Director of Loss Control Hartford Steam Boiler

Efficient Boiler Operation in Fabric Care Save on this Massive Expense

Boilers . . . you don’t operate without them

Trends in Boiler Failures

Avoiding unplanned outages (and saving money while you’re at it)

Maintenance is the key to reducing boiler expense

Boiler inspections are opportunities to save money

HSB Fabric Care web portal – energy efficiency tools that can save you money

Our Agenda Today

4/10/2015 2 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Boiler statistics for Fabric Care

76%

20%

4%

Firetube

Watertube

Cast Iron

Boiler Types used in Fabric Care

Fast facts

3 out of 4 boilers in the industry are firetube type boilers

Firetube type includes flueless, vertical, scotch marine, and horizontal return tube

Based on a population of 3250 boilers

4/10/2015 4 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Boiler Age Statistics in Fabric Care Vertical and Flueless Firetube Boilers

Conclusions

64% of the boiler population is between 6 and 20 years old

25% of the boiler population is over 20 years old. WHY?

Maintenance is a key determining factor in the longevity of boilers

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80

100

120

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200

0-5 6-10 11-15 16-20 21-25 Over 25

Count

Boiler Age (Five Year Grouping)

Vertical & Flueless FT Boilers

Average Age 15.8

Based on a representative sample in Fabric Care

4/10/2015 5 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Source: Jurisdictional databases

Boiler Age at Failure Vertical and Flueless Boilers only

Conclusions

Boilers that fail are, on average, nearly 7 years newer than the average boiler

Conditions that lead to failure often result in higher cost of operation

Quality of maintenance is a key determining factor

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5

10

15

20

25

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40

45

1-5 6-10 11-15 16-20 21-25

Histogram of Boiler Age at Failure

Based on HSB fabric care claims experience

4/10/2015 6 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Average Age at Failure is 9.2 years

Leading causes of boiler failures

Leading Causes

Corrosion

Cracking / Metal failure

Scale accumulation

Controls failed or bypassed 34.1%

23.9%

15.3%

8.5%

5.1%

2.8% 2.3%

8.0%

Corrosion

Cracking / Metal failure

Scale Accumulation

Controls Failed or Bypassed

Thermal Shock

Improper Welding

Burner Malfunctions

All Other Causes

Based on fabric care claims experience

4/10/2015 7 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Corrosion leads to early failure of your boiler

Corrosion can compromise the safety and efficiency of your boiler

Leaks result in loss of steam or hot water . . . costing you money on your fuel bill

Corrosion damage can be expensive to repair and leads to early replacement of your boiler

Corrosion can be prevented by keeping the pH of your boiler water elevated through proper water treatment

4/10/2015 8 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Scale reduces efficiency

Scale accumulation reduces the efficiency of your boiler

1/32th inch of scale can increase your fuel costs by 7 percent

Effective water treatment is the key to preventing scale

Most forms of scale can be easily removed, increasing the efficiency of your boiler and reducing your energy costs

4/10/2015 9 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Boiler Efficiency Calculator

4/10/2015 10 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Cracking / Metal failure

Cracks can develop due to thermal shocking or other operational problems

Annual inspections provide opportunities to identify conditions that could lead to early boiler failure

If caught early, these conditions can often be corrected by a qualified vendor

If neglected, replacement of the boiler will be your only option

4/10/2015 11 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Boiler control failures or controls bypassed

Boiler controls protect the boiler from conditions that would lead to damage or destruction of the boiler

Low water conditions occur when the controls fail to sense the loss of water to the boiler

Low water conditions cause overheating of the boiler metal that can lead to sudden failure

Periodic testing and the use of boiler logs can help prevent low water conditions

4/10/2015 12 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Maintenance is the key to reducing cost

Proper water treatment to prevent scale accumulation and corrosion

Periodic inspection to identify conditions that require corrective action

Routine testing and logging of key boiler parameters

Annual service by a qualified vendor to ensure your boiler is running at peak efficiency

4/10/2015 13 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Leaking steam traps . . are money down the drain

Leaking steam traps are a very common condition

Leaking traps increase makeup water costs and increase the risk of scale accumulation

Periodic inspection is needed

Easily resolved / rapid payback

4/10/2015 14 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Water treatment saves money . . .

A qualified vendor evaluates your feedwater and makes recommendations that are correct for your conditions

Chemical feeds are set to maintain proper levels in the boiler, but need to be monitored and logged

Boiler blowdown reduces the build-up of solids that can lead to scale

Water softeners remove hardness from the makeup water to reduce the need for blowdown

4/10/2015 15 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Testing controls and safety devices

Weekly testing of the low water cutoff can prevent loss or damage to your boiler

Confirms your sight gauge and cutoff are working

Periodic testing of the Safety Relief Valve ensures you’re protected against over-pressure

Confirms your boiler startup sequence is correct

4/10/2015 16 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

The boiler log – simple yet effective…

Identify adverse trends / take corrective action prior to failure

Track your chemical usage to reduce over-feeding

Help your boiler inspector and water treatment vendor spot potential problems

Logging test results helps ensure they are done at the correct interval

4/10/2015 17 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

HSB.com Knowledge Center – Logs and Checklists

More HSB Resources – Boiler Operation and Maintenance Series

HSB.com

Knowledge Center – Equipment Webinar Series

Is Your Boiler Ready For Inspection? (20 minutes)

What Can Go Wrong With My Boiler? (32 minutes)

Energy Efficient Boiler Operation (52 minutes)

Critical Over Pressure Protection (25 minutes)

Unattended Operation (38 minutes)

Don't Be Left In The Cold (20 minutes)

4/10/2015 18 © 2015 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.

Tools to help you make decisions that can save you money. http://www.hsb.com/HSBExt/FabricCare.aspx

HSB’s Fabric Care Web Portal

Ted Heiderscheit Director, Loss Control Hartford Steam Boiler

Thank you very much for your attention

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