City of Burlington v. Hartford Steam Boiler Inspection & Insurance

190 F. Supp. 2d 663, 2002 U.S. Dist. LEXIS 4956, 2002 WL 448349
CourtDistrict Court, D. Vermont
DecidedMarch 6, 2002
Docket1:00-cv-00170
StatusPublished
Cited by23 cases

This text of 190 F. Supp. 2d 663 (City of Burlington v. Hartford Steam Boiler Inspection & Insurance) is published on Counsel Stack Legal Research, covering District Court, D. Vermont primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
City of Burlington v. Hartford Steam Boiler Inspection & Insurance, 190 F. Supp. 2d 663, 2002 U.S. Dist. LEXIS 4956, 2002 WL 448349 (D. Vt. 2002).

Opinion

OPINION AND ORDER

(Papers 90 & 122; 92 & 124; 119 & 141; 137 & 166; 130 & 153)

MURTHA, Chief Judge.

Plaintiff, City of Burlington, Vermont (“the City”), brings a breach of contract claim against five insurance companies seeking declaratory judgment. The City alleges that the companies have failed to reimburse the City for repair costs and consequential damages resulting from physical damage experienced in the boiler unit of a City-owned electric energy generating facility. The Defendants — Factory Mutual Insurance Company (“Factory Mutual”), Allianz Insurance Company (“Al-lianz”), The Home Insurance Company (“HIC”), Indemnity Insurance Company of North America (“Indemnity”), and Hartford Steam Boiler Inspection and Insurance Company (“Hartford”)- — each move for summary judgment on all respective counts, 1 and the City files cross-motions for summary judgment against each Defendant. 2 For the reasons set forth below, the Court GRANTS all of the Defendants’ motions, and DENIES all of the City’s motions.

I. Background

A. The Faulty Shop Welds

In 1982, the City contracted with Zurn Industries, Inc. (“Zurn”), to design, engineer, and construct a wood-fired steam electric energy generator to be installed at the newly-constructed Joseph C. McNeil Generating Station in Burlington, Vermont. The boiler portion of the generator includes an economizer which consists of metal tubes welded together. 3 The welds are appropriately called “shop welds” since they are performed at a shop or manufacturing facility on a piece of equipment *667 prior to it being shipped and installed. The shop welds were made by Zurn at its manufacturing facility between April and August of 1982, and the completed economizers were later delivered and installed at the McNeil Station.

On April 20, 1983, pursuant to the City’s contract with Zurn and in accordance with standards set by the American Society of Mechanical Engineers (“ASME”) Boiler Code, the newly installed boiler was hydro-statically tested. See Paper 167, Ex. 13. Because none of the boiler welds showed leaks, the City concluded that the test was “an unqualified success.” Id. The generator first began operating in March of 1984.

During 1987 and 1988, the City requested maintenance on the boiler due to the discovery of two isolated leaks in the lower section of the economizer. Though maintenance reports prepared following the weld repairs indicated that the two leaks were found at the shop welds, the welding contractors did not conclude that the leaks were caused by pervasive manufacturing defects. See Paper 95, Exs. L & M; Paper 165, Ex. F, at 32. Nor did the City, during that time, know the underlying cause of the two weld leaks. See Paper 165, Ex. F, at 33-34. In the opinion of the City’s own metallurgical expert, the limited number of weld leaks occurring during the late 1980’s would not have raised a reasonable suspicion that pervasive manufacturing defects were the cause of the damage experienced in the welds. See Paper 95, Ex. N, at ¶¶ 6-7. After 1988, no weld failures were discovered until April of 1995. Between April 1995 and August 1999, more than 30 leaks were discovered and repaired in the lower economizer section of the boiler unit by City-hired welding contractors. See Paper 95, Ex. K, at 18-19.

There is no evidence that during the course of these repairs — which typically included some inspection of the failed welds by certified welding contractors hired by the City — the City learned the underlying cause of the weld failures. By the winter of 1998, because of an increase in weld failures, the City became concerned that the failures were out of the ordinary. See Paper 167, Ex. 14, at 67-68.

The City therefore hired David N. French (“French”) to study the economizer and determine the cause of the leaks. French performed a radiographic/metallo-graphie analysis on two weld samples that had been cut out and removed from the lower section of the economizer by welding contractors during a planned plant shut down. See Paper 95, Ex. J, at 1-2.

In March of 1999, French completed an expert report containing the following conclusions:

The original circumferential weld is generally of poor quality. There is a lack of full penetration which means the weld does not comply with ASME Boiler Code requirements. However, the weld metal itself is sound. Water-side pitting and corrosion are trivial with the deepest pits noted less than 4 mils deep.

Id. at 1.

Also in March of 1999, another City contractor, Power Specialist Associates, Inc. (“PSA”), performed ultrasonic thickness testing using immersion technology on selected areas of the economizer. PSA’s report, dated March 14, 1999, concluded that:

All of the tubes tested during this outage appeared to be in good condition. Tube failures were reported by plant personnel to be in the butt welds attaching the bend to the straight section of the tube. Upon visual inspection of the bends, it appeared that the failure was caused by a lack of root weld pen *668 etration, which would cause a relatively weak area in the tube.

Paper 95, Ex. J (emphasis added).

In October of 1999, having previously sought only to repair weld leaks as they were found, the City contracted with Bremco, Inc. to remove and replace all existing shop welds in the lower section of the economizer, including those that had shown no signs of leaking. In a report dated December 16, 1999, Bremco made the following finding:

Careful inspection of the removed welds revealed incomplete penetration at every joint.... The starting and stopping point of each arc in the welded joint root exhibited concavity. This is called “suck back” and as the name implies, the root is pulled back into the joint. When joints are fashioned in this manner, it will lead to premature failure as the wall thickness is drastically reduced. Common internal corrosion, coupled with a reduced wall thickness and root contamination for the arc strike in the beginning of the weld has set the stage for tube wall leaks.

Id.

In the spring of 2000, the City contracted with Vermont Nondestructive Testing (“VNT”) to perform a radiographic inspection of the center and upper tube banks of the economizer. VNT’s conclusion, dated April 10, 2000, stated as follows:

Upper Economizer Radiograph 36 is acceptable, however, 1-35 and 37 were found to have inadequate penetration at the root. Center Economizer Radio-graph 19, 35 and 36 are acceptable, however, 1-18, 2-24 and 37 were found to have inadequate penetration at the root.

Paper 95, Ex. O.

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Bluebook (online)
190 F. Supp. 2d 663, 2002 U.S. Dist. LEXIS 4956, 2002 WL 448349, Counsel Stack Legal Research, https://law.counselstack.com/opinion/city-of-burlington-v-hartford-steam-boiler-inspection-insurance-vtd-2002.