November/December 2008 Human Error Plays a Big Part in Many Equipment Losses Push the Wrong Button, Turn the Wrong Switch, it Doesn't Take Much for an Accident to Happen We all make mistakes. When it happens in the workplace, however, equipment can break down and a business may experience a loss. HSB claim data shows that human error, including operator error, contractor mistakes, and poor maintenance practices, plays a role in at least 35 percent of equipment breakdown claims. HSB HELPS COVER LOSSES It doesn't take much for an accident to happen. The result can be costly repairs, lost business income and extra expense. HSB's equipment breakdown coverage can pay for losses caused by human error, such as these claim examples. NO TORTILLAS A mechanic for a Mexican-style food company left a wrench inside a dough-dividing machine. When the machine started up, the wrench passed through and severely damaged its parts. Workers on overtime made tortillas by hand until repairs were complete. The total paid loss of $58,079 included almost $16,000 in extra expense. "POUR" JUDGMENT Workers were performing maintenance on a department store's air conditioning system when a 450-ton chiller broke down. The loss totaled thousands of dollars and repairs took six weeks. It turned out that bottles of industrial cleaner were stored with similar size bottles of lubricating oil in a dimly lit room. Technicians had mistakenly poured detergent in the chiller instead of oil. A COSTLY LESSON School personnel thought they had found a way to save on heating costs. They turned the boiler off at night when the building was empty. However, the sudden rush of cold water when it was restarted each morning eventually caused overload and thermal shock. The boiler broke down in a $60,000 paid loss. THEY FORGOT TO PLUG IT IN A new hospital reported three big losses in four months involving a backup generator and other electrical system components. The grounding system and state-of-the-art surge suppression equipment should have contained the damage. HSB investigated and found that the protection systems were never connected. MAKING A POINT A maintenance supervisor was showing a new worker around an industrial laundry. He pointed to a circuit breaker with a small aluminum flashlight but touched the components. Arcing destroyed the breaker for a total paid loss of $35,000. PRESSING HIS LUCK A boiler shut down and the operator hit the reset button. It tripped again and he pressed the button again and then twice more. He kept pushing the button until there was a small explosion as accumulated fuel ignited. There was only slight damage, but the operator suffered a minor burn and was badly shaken. Hartford Steam Boiler - One State Street - P.O. Box 5024 - Hartford, CT 06102-5024 Phone: 860-722-1866 - Fax: 860-722-5106 ©1996-2008 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.