bv ctg - boiler health care service (plant care) - revc
TRANSCRIPT
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
3Bureau Veritas Presentation – Boiler Health Care Service
Contents
► Boiler Health Care Advantages
► Boiler Health Care Services
► Inspection and Repair Process
► Outage Process Detail
► Repair Process Detail
► Service Modules
4Bureau Veritas Presentation – Boiler Health Care Service
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
5Bureau Veritas Presentation – Boiler Health Care Service
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
6Bureau Veritas Presentation – Boiler Health Care Service
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
7Bureau Veritas Presentation – Boiler Health Care Service
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
8Bureau Veritas Presentation – Boiler Health Care Service
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
9Bureau Veritas Presentation – Boiler Health Care Service
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
10Bureau Veritas Presentation – Boiler Health Care Service
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
11Bureau Veritas Presentation – Boiler Health Care Service
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.
12Bureau Veritas Presentation – Boiler Health Care Service
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)
13Bureau Veritas Presentation – Boiler Health Care Service
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
14Bureau Veritas Presentation – Boiler Health Care Service
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
15Bureau Veritas Presentation – Boiler Health Care Service
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
16Bureau Veritas Presentation – Boiler Health Care Service
Repair Process Diagram
Repair Contractor
Accepts Work
RepairContractorComplete& QC
Repair Contractor
Request RT
RT CompanyAccepts
RT Complete
Repair Contractor QC
CLIENT Approval
17Bureau Veritas Presentation – Boiler Health Care Service
1. Boiler Pressure Parts
2. High Pressure Piping
Boiler Health Care Modules
18Bureau Veritas Presentation – Boiler Health Care Service
4. Welding Tracking Module
3. Thick Wall Components
Boiler Health Care Modules
19Bureau Veritas Presentation – Boiler Health Care Service
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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