© 2012 Automation Technology, Inc. automation technology, inc.
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 [email protected]
www.atinet.com
© 2012Automation Technology, Inc.
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
© 2012Automation Technology, Inc.
automation technology, inc.
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
© 2012Automation Technology, Inc.
automation technology, inc.
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
© 2012Automation Technology, Inc.
automation technology, inc.
Map of Outage Process With Boiler Integrity
Management System Technology Based Outage Process Diagram
Ch
ief B
oile
r
En
gin
ee
rB
oile
r M
ake
rIn
sp
ecto
rsN
DE
Te
am
QA
/ Q
CM
an
ag
em
en
tP
lan
ne
rs Define Outage Scope based on
past recommendations,
inspection history in the software
and the Outage check list.
Check in the
findings to the
software.
Use Mobile Computer to
document the inspection
findings and spot UTT
readings.
Bulk UTT
Required?
Import UTT data into the
software and calculate wear
rates. View projected
thickness in a Visual Tool.
Add additional work
to the work scope
using Software/
Mobile Computer.
Perform UTT
on desired
areas.
Print Work Report. Send
report to Boiler Maker for
execution. The management
can start reviewing data in
the software.
Add pictures, attachments
and any other relevant
information regarding the
inspection to the software.
Review work
scope and
assign
priorities.
Update the status of the work
completed in the software. Work
that could not be completed is
marked for the future.
Start work.
Verify that all
the work was
completed.
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.
Review:
· Work Cmpleted
· Exception Reports
· Future Recommendations
· Final Report
No
Yes
Document Assessments and
Future Recommendations.
Generate exception report for work
that could not be completed. Print
the Final Outage Report.
1
2 3 4 5
6 7 8
9 10
11 12
13
14
15
16
© 2012Automation Technology, Inc.
automation technology, inc.
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).
© 2012Automation Technology, Inc.
automation technology, inc.
Step 1: Plan (continued)
Map locations of work or high priority areas to inspect
© 2012Automation Technology, Inc.
automation technology, inc.
Steps 2 through 5: Inspect
© 2012Automation Technology, Inc.
automation technology, inc.
Steps 6 – 8: NDE
Mapping tube
thickness on
drawings. Same
can be done for
Oxide scale,
remaining life,
etc.
© 2012Automation Technology, Inc.
automation technology, inc.
Steps 9 & 10: Assign Priorities and
Assign Work
Chief Boiler
Engineer reviews
required actions
and assigns
priorities to work.
© 2012Automation Technology, Inc.
automation technology, inc.
Steps 11 – 12: Make Repairs
© 2012Automation Technology, Inc.
automation technology, inc.
Step 13: Quality Assurance &
Control
Verify welds are
completed –
document using
handheld
computer
© 2012Automation Technology, Inc.
automation technology, inc.
Steps 14 & 16: Management
Oversight
Review required
actions, work
completed, work
remaining, etc.
At the
conclusion of
outage, review
final report(s)
© 2012Automation Technology, Inc.
automation technology, inc.
Step 15: Final Report
© 2012Automation Technology, Inc.
automation technology, inc.
Conclusion
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
Benefits of implementing Boiler Integrity Management System
