APPLICATION OF A BOILER INTEGRITY MANAGEMENT SYSTEM FOR MANAGING OUTAGE INSPECTIONS AND WORKFLOW Indian Power Station 2012 13-15 February, 2012 Delhi/Noida By: Rana Ghosh Automation Technology, Inc. +1-408-350-7020 ranag@atinet.com www.atinet.com 2012 Automation Technology, Inc.
Automation Technology, Inc. Software company with focus on power generating equipment Founded in 1989 Headquarters in San Jose, CA, USA Aware product introduced in 1996 Work closely with industry experts www.atinet.com
Current Aware Install Base Boiler Aware Module Over 650 units Piping Aware Module - Over 350 units HRSG Aware Module - Over 100 units Mobile Aware for Boilers - Over 200 units Turbine Aware Module Over 150 units Installed at NTPC Sipat and Adani Mundra. Implementing at Bahr Other Modules include: Pulverizer, Scrubber,Pressure Vessels
Benefits of Using Boiler Integrity Management System During Outages Reduce forced outages Allows decision makers to make more accurate repair decisions during planned outages Reduction in outage duration Streamlined flow of information allows work to progress at faster pace More visibility into issues Dashboards/Portals allows all level of management to view status
Map of Outage Process With Boiler Integrity Management System Technology Based Outage Process Diagram Chief Boiler Management QA / QC Boiler Maker NDE Team Inspectors Planners Engineer 1 Define Outage Scope based on past recommendations, inspection history in the software and the Outage check list. 2 Use Mobile Computer to 3 4 Add pictures, attachments 5 Check in the document the inspection and any other relevant Bulk UTT findings to the findings and spot UTT information regarding the Required? software. readings. inspection to the software. 6 7 Import UTT data into the 8 Perform UTT software and calculate wear on desired rates. View projected areas. thickness in a Visual Tool. 9 10 Review work scope and assign priorities. 11 12 Start work. 14 Print Work Report. Send report to Boiler Maker for execution. The management can start reviewing data in the software. Add additional work to the work scope using Software/ Mobile Computer. Update the status of the work completed in the software. Work that could not be completed is marked for the future. 13 Track the progress of the outage. Analyze data using the software dashboards to get an estimate of the work required. View current reports including the latest status updates made by the boiler maker. 15 No Verify that all the work was completed. 16 Yes Document Assessments and Future Recommendations. Generate exception report for work that could not be completed. Print the Final Outage Report. Review: Work Cmpleted Exception Reports Future Recommendations Final Report
Step 1: Plan Use software to find all required actions (or recommendations) whether unfinished from last outage or emerged since (e.g. permanent fix to temporary repairs).
Step 1: Plan (continued) Map locations of work or high priority areas to inspect
Steps 2 through 5: Inspect
Steps 6 8: NDE Mapping tube thickness on drawings. Same can be done for Oxide scale, remaining life, etc.
Steps 9 & 10: Assign Priorities and Assign Work Chief Boiler Engineer reviews required actions and assigns priorities to work.
Steps 11 12: Make Repairs
Step 13: Quality Assurance & Control Verify welds are completed document using handheld computer
Steps 14 & 16: Management Oversight Review required actions, work completed, work remaining, etc. At the conclusion of outage, review final report(s)
Step 15: Final Report
Conclusion Benefits of implementing Boiler Integrity Management System Planning is made easier More work is accomplished during outages Recommended and necessary actions no longer fall through the cracks Boiler Reliability is improved Management dashboards or portals enable seeing issues earlier in the outage to determine course of action and resolution