During my decades in the field as an inspector, I saw a lot: pressure equipment failures, close calls, near misses, and tragedies that could – and should – have been prevented.
And even with the improvements we’ve made in safety standards, technology, and training, some things still keep me up at night.
One of the biggest concerns is complacency. In too many cases, equipment is assumed to be operating safely simply because it hasn’t failed yet. That mindset is dangerous. Boilers and pressure vessels are inherently high-risk systems. When they’re overlooked or under-maintained, disaster may not be far away. A silent problem today can become tomorrow’s headline.
I’ve read several accident reports that trace back to a common root cause: someone didn’t know what they didn’t know. Whether it’s operators unfamiliar with their controls, managers unaware of required inspections, inspectors not having the experience to recognize potential problems, or technicians bypassing safety devices to save time, these aren’t acts of malice; they’re failures of awareness, of training, and ultimately, of safety culture at the system level.
Another ongoing concern is the increasing reliance on automation. Digital systems and remote monitoring absolutely have their place, but they’re not a replacement for human experience and judgment. When a boiler’s digital readout indicates everything is normal, but the gage glass tells a different story, you need to trust your eyes and have the confidence to act on it.
We also continue to see gaps in maintenance, particularly in facilities that view inspections as a checkbox exercise rather than a critical safety measure. Inspectors will tell you it’s not uncommon to see low-water cutoffs ignored, mud legs full of sludge, or relief valves installed incorrectly. These aren’t just code violations; they’re invitations for failure.
If you want a glimpse into the kinds of hazards that keep me awake at night, look no further than our “Scary Photos” on page 7. In this feature, inspectors share real-life images from the field that highlight issues they’ve seen. These photos are a powerful reminder of why our work matters. The feature is more than just eye-opening; it’s educational. It shows the dark side of the boiler room and helps others know what to look for. And in this issue, you get the opportunity to vote on the “scariest” photo from the last year.
Perhaps most troubling, I worry about knowledge loss. Many of our most experienced inspectors are nearing retirement, and we risk losing decades of field wisdom if we don’t capture it and pass it down. Our industry must prioritize mentoring, documentation, and training – not just the technical “how,” but the intuitive “why” behind safe practices.
So, where do we go from here?
First, we must remain vigilant. Inspections should never be viewed as routine. They are opportunities to catch the one thing that could go wrong.
Second, training must be invested in at all levels. Safety isn’t just a technician’s responsibility; it’s an organizational priority.
Lastly, we need to keep talking – about near misses, about lessons learned, about what’s working and what’s not.
Many dedicated people spend their careers focused on protecting lives and property, and that mission is far from over. There will always be risks, but with the right mindset, practices, and people, we can manage them and prevent failures.
We owe that to ourselves – and to every person whose safety depends on the work we do.
That will make us all sleep better.
