bv ctg - boiler health care service (plant care) - revc

Boiler Health Care Service

October 2015

Erik van der Linde & Rudi Smit

2Bureau Veritas Presentation – Boiler Health Care Service

Boiler Health Care Philosophy

To execute and monitor a plant specific maintenance plan in a consistent manner.

The service comprises of two main disciplines:

► Engineering

► Shut Down / Outage Management


Contents

► Boiler Health Care Advantages

► Boiler Health Care Services

► Inspection and Repair Process

► Outage Process Detail

► Repair Process Detail

► Service Modules


Boiler Health Care Advantages

►Engineering:

Allows a large number of components to be evaluated simultaneously.

Provides a structured approach, for assessing the financial and safety risk associated with plant failures

Demonstrates a clear link between:• the assessed risk• the requirement for a control / inspection• the timescales of the proposed control / inspection

Provides an audit trail for the basis of maintenance decisions

Detailed history of failure data, inspections and repairs are stored in a central database

Owner has full control over inspection and repair scope

Reduce the risk of unplanned outages


Boiler Health Care Advantages (continued)

► Shut Down / Outage Management:

Management of planned shut downs or outages the right actions at the right time looking for the right correct information with the right equipment

Reduces repair program slippage – assists in managing the critical path

Assists in outage budgeting for: • Finances• Material and Equipment• Manpower• Scaffolding


Boiler Health Care Advantages (continued)

► Shut Down / Outage Management:

Real time repair tracking allows:

• Structured workflow forces all role players to work together

• Effective communication between role players

• Closed loop tracking of every repair

• Accountability via digital signatures

• Faster more cost effective outage execution

• Increased confidence in quality of repair work

Tracking welder performance allows for focused action:

• Reasons for weld rejections identified and addressed

• Less rejections leads to less rework


Boiler Health Care Service

The Boiler Health Care Service strives to ensure reliable boiler operation and maintenance and comprises mainly of the following services:

► Master Test & Inspection Plan

► Detailed boiler mapping

► Management of inspection and repair data

► Evaluation of inspection results

► Outage planning and tracking

► Budgeting

► Welding production tracking


Master Test & Inspection Plan

► A master test and inspection plan is drawn up based on:

Previous experience (BV’s and the boiler unit in question)

Failure history (types of damage mechanisms, location of failures, etc.)

Age of the boiler unit (e.g. creep failures unlikely to manifest early in boiler life)

Boiler maintenance plan fit in with overall plant maintenance plan

► Plan contains details on:

Where to inspect and what to look for

When to inspect

Threshold values when repairs should be done

► Plan is updated and refined over time:

Continued optimisation of boiler unit maintenance

Less down time and increased reliability

Reducing the risk of boiler unit related failures


Detailed Boiler Mapping

► The boiler units are mapped out in 3D models

► The 3D models are used to create 2D Map Drawings:

Inspection areas are clearly numbered and indicated

Repair areas are clearly indicated

► Detailed inspection instructions are created:

Inspections matched to pre-determined outage frequencies

Higher areas get more attention

Clear inspection instructions

► Inspection templates are created onto which inspection data is captured


Management of Inspection & Repair Data

► The inspection and repair data is captured within the Boiler Health Care database.

► Captured inspection data can be reviewed and analysed.

► Tube wall loss data can be plotted graphically to understand wear trends

► A recommended repair scope can be issued for the client’s acceptance and approval

► Previous history can be captured into the database as a starting point


Evaluation of Inspection Results

►The inspection results are captured within the Boiler Health Care Database from where:

The inspection results are validated:

• A percentage of random back-up inspections are issued for comparison with primary results

• Poor quality results can be identified and queried by comparing with historical results

Engineering expertise is applied to determine a recommended outage repair scope of work.


Outage Planning & Tracking

► Pre-outage:

Planning of outage activities starts well in advance based on outage duration and scope

All documentation related to outage scope is compiled and communicated to all role players:

• Detail inspection and repair descriptions

• Applicable map drawings

• Applicable diagrams (scaffolding, grit blasting, refractory replacement, skyjack requirements, etc.)

• Budget

• Preliminary SOW (out of the ordinary outage scope to be executed)


Outage Planning & Tracking

► During Outage:

Outage activities are tracked and reported:

• Inspection progress

• Repair progress:

• Welds are allocated a barcoded number

• Individual welder repair rates and reasons for weld rejection can be tracked

• Progress updated and tracked instantaneously

• Duration between steps are tracked – identify bottle necks

• Accountability of all role players are ensured via digital signatures


Issued months before outage:• Inspection SOW• Pre-Repair SOW• Cut-for-access SOW• SOW Budget

Resource / Material

Requirements Planning

SOW Freeze one month

before Outage

Data Capturers & Inspector

Training

Outage Start

Outage Process

Closeout SOW(CLIENT Final)

Inspection and Repair Process Diagram

Next Slide


Outage Process Diagram

Inspections and QC

Capture and QC Data

Data Integrity and Analysis (Engineering

creates SOW)

IssueRepairSOW

Repair Process

Closeout SOW (CLIENT Final)

Engineering Functions

Next Slide

CLIENT Inspection

Co-ordinator

CLIENT Repair

Co-ordinator


Repair Process Diagram

Repair Contractor

Accepts Work

RepairContractorComplete& QC

Repair Contractor

Request RT

RT CompanyAccepts

RT Complete

Repair Contractor QC

CLIENT Approval


1. Boiler Pressure Parts

2. High Pressure Piping

Boiler Health Care Modules


4. Welding Tracking Module

3. Thick Wall Components

Boiler Health Care Modules


Barcoded Repair via Welding Tracking Module

To view and/or change the progress of a specific repair scope, the barcode of that scope can be scanned in from either the Scope of Work issued or the label that has been printed from the label printer. This allows the progress of any scope of work to be tracked in real time, right up to the close-out stage.

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bv ctg - boiler health care service (plant care) - revc

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