1. Boiler Health Care Service
October 2015
Erik van der Linde & Rudi Smit

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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.

12. 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)

13. 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

14. 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

15. 15Bureau Veritas Presentation – Boiler Health Care Service
Outage Process Diagram
Inspections
and QC
Capture and QC
Data
Data Integrity
and Analysis
(Engineering
creates SOW)
Issue
Repair
SOW
Repair Process
Closeout SOW
(CLIENT Final)
Engineering
Functions
Next Slide
CLIENT
Inspection
Co-ordinator
CLIENT
Repair
Co-ordinator

16. 16Bureau Veritas Presentation – Boiler Health Care Service
Repair Process Diagram
Repair
Contractor
Accepts Work
Repair
Contractor
Complete
& QC
Repair
Contractor
Request RT
RT Company
Accepts
RT Complete
Repair
Contractor QC
CLIENT
Approval

17. 17Bureau Veritas Presentation – Boiler Health Care Service
1. Boiler Pressure Parts
2. High Pressure Piping
Boiler Health Care Modules

18. 18Bureau Veritas Presentation – Boiler Health Care Service
4. Welding Tracking
Module
3. Thick Wall Components
Boiler Health Care Modules

19. 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.
Or