ASSET INTEGRITY
& OPTIMISATION

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Specialist Engineering Solutions

BOILER PRESSURE PARTS MODULE

Bureau Veritas Industry - BOILER PRESSURE PARTS MODULEBoiler Pressure Parts includes all thin walled components related to the boiler pressure envelope (e.g. superheaters, reheaters, economizers and evaporators). Typical damage mechanisms recorded, monitored and trended are: tube fretting, tube misalignment, tube thinning from erosion, corrosion and visual inspection results. Pressure parts failure have a big impact on plant availability and it is not always possible to do maintenance on predefined scheduled times.

The Carab Pressure Parts module manages the inspection and repair process and provides the following features:

  • Data is QA checked with expected values & recaptured when needed to ensure quality
  • Wear Rates are calculated and the data is trended to asset the risk of cut lines
  • Scope is available before start of outage
  • Great savings because of better quality data - less chances of failures
  • Great savings because of faster plant condition assessment – more time available for repair work

Inspection values can be captured on the Inspection Results screen or can be imported from Excel spreadsheet Templates (after a linking process). The flow of data is bi-directional and the original templates can be generated for final QA procedures.

The Boiler Pressure Parts module is currently in use at all of the 13 coal power stations.


 

U-FI INSPECTION TEMPLATES MODULE

Bureau Veritas Industry - U-FI INSPECTION TEMPLATES MODULECapturing of inspection data on templates introduce many errors and an error of 0,1% error on 90 000 readings correlates to 90 tube leaks. Effective capturing of inspection information at source is critical in order to do accurate predictions and engineering risk analysis.

The U-Fi technology enables a MG2DL or 45MG Gauge to wirelessly connect to rugged tablet PC. Data is captured directly on custom Excel templates, QA and checked during the inspection process. Repair scope of work can immediately be given if required by the outage process. The Inspection data is then uploaded electronically from tablet into the Carab pressure parts system where it is checked against history information, expected values and trended to minimise future risks.

U-Fi Inspection Templates module is currently in use at Kendal and Matimba power stations.


 

REPAIR AND WELDING MANAGEMENT MODULE (WELDING)

It is very difficult to track repair progress from issuing to close-out. Accurate contractor’s feedback is essential. It is very difficult to answer essential questions like:

  • Is the repair process on track?
  • Who is waiting for who and why is there a delay?
  • What is the Welder weld repair rates?
  • Are all the different role players effective and productive?
  • Were all the repairs that were issued executed on the plant?

Bureau Veritas Industry - REPAIR AND WELDING MANAGEMENT MODULE (WELDING)The Repair and Welding Module answers all of the above questions on a daily basis and there is complete accountability between role players. Reasons for weld rejections are known and inefficiencies can be corrected during the outage. Repair work is scheduled effectively and bottlenecks are identified and removed.

The Welding module can use the asset breakdown and corrective action information of other modules and add custom  flow management processes to them. It is a module that is normally added on to an ‘already developed’ database of pressure parts, thick wall or pipe work components. It is thus the purpose of this module to track the work issued from these already existing databases. This will provide better control and management of all work done.

Bureau Veritas Industry - REPAIR AND WELDING MANAGEMENT MODULE (WELDING)In order to track the process at ground level, unique barcodes are allocated to all scope of work to be scanned into the system (and is used in the repair and X-Ray processes). When a process is closed out the relevant corrective action status will also be updated in the module where the work was scheduled.

The flow of information is bi-directional. Corrective actions are scheduled in a module and the process and rules are tracked in the welding module. At the finish of a process the status of the corrective action is automatically updated.

The repair and welding module is currently in use at Kendal and Tutuka power stations together with the pressure part modules.


 

ELECTRONIC DATABOOK (ADD-ON TO WELDING)

Databooks of repairs are not available immediately after repairs that have been performed and are only available sometime after start-up of the unit. Information collected in the Repair and Welding Management module can be used to produce databooks even before the startup of the boiler.

The data in the welding module is used to produce the relevant reports and documentation for the electronic databooks.

Some of the documents required to produce a databook are already being produced by the welding module. Carab Tekniva are in the process of including the rest of the requirements on an “as needed base” by the contractor.


 

THICKWALL COMPONENTS MODULE

Thickwall components include all headers, the steam drum, attemperators & integral piping that form part of the boiler proper system. Typical damage mechanisms recorded, monitored and trended are: fatigue cracking, creep damage (remaining life), thinning from replication, corrosion, visual inspection results and results from metallurgical surveys.

The Thickwall components module captures the Thickwall asset breakdown. All inspection and repair information is captured for the different components helping the engineer in risks assessments.

Information flow is bi-directional between Thickwall components and the repair and welding module as described earlier if used as an add-on.

The Thickwall components module is currently in use at all of the 13 power stations.


 

HIGH PRESSURE PIPING MODULE

HIGH PRESSURE PIPING MODULEHigh pressure piping includes all the high pressure piping systems external to the boiler pressure envelope (e.g. main steam, hot & cold reheat, feedwater, link piping & turbine loop piping).  Typical damage mechanisms recorded, monitored and trended are: fatigue cracking, creep damage (remaining life), thinning from replication, weld condition, elevation surveys, hanger condition, visual inspection results and results from metallurgical surveys.

The High Pressure piping module captures the asset breakdown structure. All inspection and repair information is captured for the different components helping the engineer in risks assessments.

Information flow is bi-directional between High pressure piping and the repair and welding module as described earlier.

The High Pressure piping module is currently in use at all of the 13 power stations.


 

2D CUTTING INSTRUCTIONS FOR BOILER PRESSURE PARTS

With the help of the Carab 2D - Cutting Instruction module, Matimba power station issues a repair instruction on average within 8 minutes after the inspection of the element. The process focuses mainly on improving the speed of the inspection and repair process to the point where full scope execution is possible during all outage durations. This process reduces the maintenance risks exponentially as every single point in the boiler is inspected at least once every 3 years. In order to achieve execution of full scope without compromising on quality, the inspections are captured on 2D drawings and the repairs are electronically added.


 

3D SOFTWARE INTERFACING

Carab 3D – FAC module provides our clients with the ability to manage plant visually in 3D space. This module makes it possible to link the plants 3D CAD/ Models to an engineering and management database. The following features are supported:

  • Connect the plant’s CAD designs to databases.
  • Link Images and Videos to specific Hotspots or Points of Interest within your 3D designs.
  • The 3D interface can be used as a Supervisory Control and Data Acquisition interface (SCADA).
  • The fully customisable 3D environment enables users to add, move and rotate 3D drawings to form a cohesive virtual world.
  • Open and view 3D CAD models without the need for any CAD software licensing.
  • Supports several of the most widely used 3D file formats.

3D SOFTWARE INTERFACING

3D SOFTWARE INTERFACING


 

CONTACT

For details about this service, please contact Bureau Veritas Industry:

Cobus Olivier - Research, Development & Innovation Manager - Bureau Veritas IndustryCobus Olivier
Research, Development & Innovation Manager

Mobile: +27(0) 82 450 3224
Office: +27(0) 12 841 3955 (CSIR Pretoria)
Office: +27(0) 13 932 5449 (Bronkhorstspruit) 
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