Agenda

• Boiler Basics / Types and Applications in Plants

• Reliability Assets Management Process
• Maintenance Methodologies and Philosophies
• Failures Understandings
• Boilers Performance Optimization
• Boilers Material Conditions
• Boilers Conditions Assessment
• Boilers Tube Failure Analysis
• Case Study Discussion
• Cause mapping Technique – Exercise
• EPRI – Guidelines of BTFA
• RCM Program for Boilers
• Risk Assessment of Boiler / Auxiliaries & Quantification
• Reliability Programs for Boilers
• Boilers Performance and Standards Calculation Excercises
• Conclusions and Questions
Are You Satisfied with the Bearing Life in Your Plant?
 Types of Boilers and Applications
• Fire Tube
• Water Tube
• Heat Recovery
• Crude Oil Refinery Plant
• Cement Manufacturing Plant
• Petrochemical Plant
• Fertilizers Plant
• Pharmaceutical Plant
• Power Plants Fossil
Water Tube Boilers
Fire Tube Boilers
HRSG Heat Recovery Steam Generator
HRSG Heat Recovery Steam Generator
Super Critical Boilers
 What is RAMP?
Reliability Asset Management Processes

RAMP is an integrated structure of aligned processes

required to successfully yield consistently reliable
equipment at the lowest possible cost.

It serves as a tool to assist operating sites understand

and implement each of the key processes needed for
effective equipment reliability over the equipment life
cycle. Cutting Maintenance Cost , Optimizing Inventory
.
Plant Equipment Reliability Asset Management Process

Design & Construct Optimization Operate/Maintain

Design Procure Strategies Routine Mtce Turnaround Mtce

Construct Commission Operate Work ID Work ID

Plan Plan
Equipment Specific
Strategy Analysis Equipment Schedule Schedule
Functional/ Maintenance Strategy Plans
Execute Execute
Criticality
Analysis Turnaround Strategy Equipment Document Document
and/or Performance
Risk Based Spare Parts Strategy
Data
Inspection
Training Strategy

Eliminate Root Cause Select Prioritize Based Data Analysis

Leverage
System Failure What to On Business to Determine
Learnings
Other
Defect Analysis Work on Impact Stake
Sites

Defect Elimination
Maintenance Methodologies and
Philosophies
&
Maintenance Program
Types of Maintenance Methodologies

Failure Based or Break down

Maintenance FBM

Scheduled or Preventive
Maintenance PM

Predictive Maintenance
PDM

Proactive Maintenance
PAM
Strategic Maintenance Philosophies

Condition Based
Maintenance CBM

Reliability Centered
Maintenance RCM

Total Productive
Maintenance TPM
Maintenance is Used to Manage Risk
Risk = Failure X Consequence ( $$$ )

Precision Maintenance
Design-out Reliability Centred Maintenance
Maintenance Predictive Maintenance
Frequency

Design-out
Preventive Maintenance
Maintenance
Breakdown
Maintenance

Consequence
Maintenance Program Adjustments
 Boiler Failure Modes Exercise
• Electrical
• Mechanical
• Instrumentation
• Others
 Types of Corrosion
• Chemical • Required Conditions
– Oxygen
• Galvanic
– Moisture
• Localized Pitting
• Accelerants for Corrosion
• Embrittlement – Salts
• Intergranular – Chemicals
• Yellow Metal – Temperature
– Environment
• High Temperature Oxidation
– Dissimilar Metals
• Abrasive Corrosion
Boiler Performance Optimization
 Concept Videos

https://www.youtube.com/watch?v=nL-J5tT1E1k

https://www.youtube.com/watch?v=Tea6e7AmZFs

https://www.youtube.com/watch?v=KIgmgo72kJU

https://www.youtube.com/watch?v=yUe2LDQ9uGw

https://www.youtube.com/watch?v=I6FHJg9ZIlI

https://www.youtube.com/watch?v=IWLtfspNzTQ

https://www.youtube.com/watch?v=uVPp8wml9iU

https://www.youtube.com/watch?v=kMY0zG0sFps

https://www.youtube.com/watch?v=ap8Ki1hhq24
 Boiler
Optimization
Overview
Boiler Performance Goal Tree
Assessment Scoring Criteria
Assessment Spider Chart
 Data
Information
Action Flow
Key Elements of Boiler Reliability Assessment
Reliability Optimization Structure
Preventive Maintenance Program Base Criteria
Work Process Assessment Criteria
Technical and Interpersonal Training Criteria Criteria
Management Assessment Criteria
CMMS Criteria
Predictive Maintenance Criteria
 Operator
Involvement
Assessment
Criteria
Reliability Management Assessment Criteria
Data Integration Criteria
Boiler Material Condition
Boiler Material Condition
Continuous Improvement Criteria
Detailed Discussion on Boiler Materials
 Property Requirements of Component
Materials
Critical
General Requirements
Components

Pipework/ High creep strength

Headers Thick Sections-Low expansivity

Good weldability (Non-heat-treatable) and

Waterwalls
good high temperature strength

Superheaters/ High creep strength and good corrosion

Reheaters Resistance Thin section
 Typical Materials

Critical
General Requirements
Components

Pipe-work/ ½Cr½Mo ¼V or 2¼Cr 1 Mo Steel

Headers Now 9-12%Cr steels

C-Mn steels -No PWHT

Water walls
Once through plant up to 2¼Cr1Mo

Super heaters/ Low alloy, / Co-extruded tubing 9-12 Cr steels

Re-heaters Esshete 1250 and up to Austenitic TP 316
Comparison Creep Strength
of Different Matrices
IN625 (Austenitic,
Nickel base)
E1250 (Austenitc Creep
resistant)
TP 316 (Austenitic)

P91 (Martensitic

P22 (Ferritic)
Permissible stresses for P22, P91 and P92 steels
(ASME :100,000hrs)

Temperature (C)
Approx Cost Per Ton of Tube
Change in Temperature and Materials
 Detailed Discussion
Practical Boiler Tubes Failure RCA Study
Boiler Condition Assessment
Remaining Life
Assessment
Preliminary
issues
Level I , II , III
Boiler Tube Failure Mechanism
Guidelines for the Nondestructive Examination of
Boilers

Detailed Discussions as Per EPRI

Recommendations
( Soft Copy )
Susceptible Areas in High Temperature Headers
Header Damage Mechanism
Boiler In-service Inspection
Boiler RCM Program
 Standards for Petrochemicals /Boilers
RCM Implementation

• MIL – STD – 785B ( Reliability Programs for Systems and

Equipment Development )
• MIL - STD – 1629A ( Procedures for FMECA )
• MIL – STD – 3034 ( RCM Process )
• SAE JA 1011 / JA 1012 Evaluation Criteria for (RCM) Processes.
• OREDA Off-shore reliability data handbook
• PAS 55 – 1 Recommendations for Asset Management
• PAS 55 – 2 Implementations of Recommendations
• ISO 55000 ( Asset Management Standard )
 Documents Requirement per Asset ( Boilers ) as per
Industry Standards for RCM Study Implementation

• Maintenance Planning Document OEM

• Specific Equipment Operating Instructional manual OEM
• Trouble Shooting / Fault Isolation Manuals OEM
• Overhaul Manuals for Systems , Components OEM
• Work-Scope Planning Guide for as above OEM
• Repair History Since Commisioning
• Last heavy Maintenance Scope
• Last Shut Down / Turn Around Scope
• Performance data base .
 Boiler Performance Trends Assessments
• Maintenance History
• Performance Parameters Trends / Analysis
• Condition Monitoring Analysis
• Software Exercise using Six Sigma Tools
• FMECA Exercise
• Criticality detailed Discussion
• SAP System Integration
• Notifications / Workorders
• Process Trends Regression / Normality Analysis
 What is RAMP?
Reliability Asset Management Processes Power
Generation and Petrochemical Boilers
RAMP is an integrated structure of aligned processes required
to successfully yield consistently reliable equipment at the
lowest possible cost.

It serves as a tool to assist operating sites understand and

implement each of the key processes needed for effective
equipment reliability over the equipment life cycle. Cutting
Maintenance Cost , Optimizing Inventory .
Petrochemical Plant Equipment Reliability Asset
Management Process
Design & Construct Optimization Operate/Maintain
Design Procure Strategies Routine Mtce Turnaround Mtce

Construct Commission Operate Work ID Work ID

Plan Plan
Equipment Specific
Strategy Analysis Equipment Schedule Schedule
Functional/ Maintenance Strategy Plans
Execute Execute
Criticality
Analysis Turnaround Strategy Equipment Document Document
and/or Performance
Risk Based Spare Parts Strategy
Data
Inspection
Training Strategy

Eliminate Root Cause Select Prioritize Based Data Analysis

Leverage
System Failure What to On Business to Determine
Learnings
Other
Defect Analysis Work on Impact Stake
Sites

Defect Elimination
 What is Functional/Criticality Analysis?

“Criticality analysis defines the equipment whose failure

has the highest potential impact on the business goals of
the company”
Frequency of Failure

5+ Equipment
Strategy Analysis
4
Maintenance Strategy
y

Functional/
it
al

3
tic

Criticality Turnaround Strategy

ri
C

Analysis
g
sin

2 and/or
ea

Risk Based Spare Parts Strategy

cr
In

1 Inspection
Training Strategy
10 20 30 40 50

Business Impact
(Consequence of Failure)
Frequency of Failure
How is Criticality Analysis Used?

5+
High criticality - requires thorough reliability analysis.
4
Medium criticality - Failure Modes and Effects Analysis.
ity
al

3
tic

Low criticality - generic strategies.

ri
C
g
sin

2
ea
cr
In

10 20 30 40 50 Equipment
Business Impact Strategy Analysis
(Consequence of Failure)

High Criticality Maintenance Strategy

Different criticality levels
Functional/
Alert Criticality Turnaround Strategy
require different analysis
Criticality
Analysis
and different tactics
Medium Criticality Spare Parts Strategy
in each strategy area
Low Criticality Training Strategy
 How is Criticality Analysis Used?
Frequency of Failure

5+

4
High criticality - requires thorough reliability analysis.
Medium criticality - Failure Modes and Effects Analysis.
l ity
ca

3
ti
ri
C

Low criticality - generic strategies.

g
sin

2
ea
cr
In

10 20 30 40 50

Business Impact
(Consequence of Failure)

Equipment
Strategy Analysis
Maintenance Strategy
Functional/ Specific
Criticality The combination of these
Turnaround Strategy Equipment
Analysis strategies form the
and/or Specific Equipment Plan Plans
Risk Based Spare Parts Strategy (SEP)
Inspection or SEP
Training Strategy
 FULL RCM PROGRAM TASK SEQUENCE FLOWCHART FOR PETROCHEMICAL
PLANT / EQUIPMENT .
STEP 1
Develop/update
RCM Program Plan

STEP 2A STEP 2B STEP 7 STEP 9

Current New Perform Identify

Equipment Design Equipment Design Functional Significance Determination for each function All failure modes and
Recommended their failure effects
FUNCTIONAL SIGNIFICANCE DETERMINATION LOGIC (Local, Next Higher &
End Effects)
Does the loss of function have an adverse effect
On safety or environment? YES
STEP 3 NO STEP 10 SSWG
Does the loss of function have an adverse effect
Complete On operation? YES Select System Safety input to
End Item & Level 1 NO Severity Class for the Severity Classification
Breakdown Does the loss of function have an adverse effect Failure mode of failure modes
On economic? YES
NO
STEP 4 Is this function protected by an existing PM task? YES STEP 11 STEP 13
Complete NO Complete Calculate or estimate
Level 2 Breakdown NON-SIGNIFICANT FUNCTION SIGNIFICANT FUNCTION FMECA failure distribution
curve

STEP 5 Select a failure mode

for RCM Analysis and
perform STEP 14
Complete
Levels 3 and 4
Step 8 and up step are not to be
STEPS 11 thru 23 Calculate or
Breakdowns STEP 8
Performed for this function estimate time to
Identify first failure
Perform STEP 7 for next function all functional failures STEP 12
STEP 6 and Compensating
Provisions Collect failure and
Identify Test data
All functions

RCM ANLYSIS TASKS RELIABILITY ANALYSIS

A
IMPLIMENTATION TASKS REDESIGN / CIP TASKS

OPERATION OTHER EVENTS

FMECA TASKS FEEDBACK TASKS

 FULL RCM PROGRAMM TASK SEQUENCE FLOW CHART
STEPS 8 A

Answer
failure Consequences Questions?
(MODULE 10)
Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties STEP 15
Will this failure mode
YES NO happen within the
service life of the NO
EVEDENT HIDDEN
Does the failure mode cause a function loss or secondary damage that Does the occurrence of the hidden failure mode in combination with a second equipment?
Could have an adverse effect on operating safety or lead to serious Failure/event cause a function loss or secondary damage that could have an
Environmental violation? Adverse effect on operating or lead to serious violation safety? YES Step 16 and up
steps are not to Be
YES NO NO YES performed for this
Evident Evident Hidden Hidden failure Mode.
Safety/Environment Economic/Operational Economic/Operational Safety/Environment GO TO STEP 23

STEP 18A STEPS 18A STEP 18A

STEP 16
Develop Develop
PHM task PHM task Determine weather
Description for each task failure has PF, wear
out, or random type
STEP 18B STEP 18B Failure characteristics
Develop Servicing/ Determine Develop Servicing/
Lubrication PM task Number of OC or PHM Lubrication PM task
tasks required during PF
STEP 18C Interval to meet pacc STEP 18C
STEP 17
Develop Develop
On-Condition task Determine On-Condition task Determine or estimate
PM interval s for all tasks PF condition, PF-FF
STEP 18D STEP 18D interval or wear
out/life limit age
Develop Determine Develop
Hard time PM task Single task total man- Hard time PM task
Hours and costs
STEP 18E STEP 18E
Develop Develop
Other action Other action

STEP 18F
B C Develop E
D Failure Finding PM task
 FULL RCM PROGRAMM TASK SEQUENCE FLOW CHART
B C D E

STEP 19 STEP 19 STEP 19 STEP 19 STEP 23

Determine cost
associated with each
STEP 18A THRU 18E item
Determine cost Determine cost Determine cost Repeat
associated with each associated with each associated with each STEP 11 thru 23 until all
STEP 18A THRU 18E item STEP 18A THRU 18F item STEP 18A THRU 18F FM(s) have been analyzed
+ + item
No action taken costs No action taken costs
Is hardware in-service or under going design testing

STEP 20 STEP 20 STEP 20 STEP 20 Design Testing In-Service

Analysis/select Analysis/select Analysis/select Analysis/select
which option or which option or which option or which option or
combination of Options combination of Options combination of Options combination of Options STEP 24 STEP 24
is best at meeting RCM is best at meeting RCM is best at meeting RCM is best at meeting RCM Review RCM results with Review RCM results with
metrics metrics metrics metrics designers and potential SSWG, SG maintainers and
operators/maintainer for operators for inputs
output MODULE 14
*PM task/s Redesigned Redesigned No action
*PM task/s *PM task/s Redesigned
required required required required required required required
Recommended PM
Acceptable?
Go TO STEP 21
YES NO
Go TO
STEP 2B Provide STEP 2B
usage prediction data (STEP 13) to STEP 25
logistics to ensure adequate
replacement parts are available Perform GO TO
Packaging Process STEP 2B

No additional analysis is required

GO TO STEP 23 STEP 26
STEP 22
Develop Perform LORA and update
Was engineering judgment/estimated values
Age exploration task Maintenance plan
Used during any part of the RCM analysis YES
NO
* - Direct PM task to be implemented
F
Regardless of RCM results
FULL RCM PROGRAMM TASK SEQUENCE FLOW CHART

STEP 26

Implement
PM tasks

STEP 26
Collect
Test and in-service data

STEP 26
Does new data support
current FMECA and RCM
entries?

YES NO

GO TO GO TO
STEP 28 STEP 6
 Maintenance Risk Matrix for Boilers
Maintenance Risk matrix / Calculations Plant Failure Breakdown

8 1 1 1 5 1 1 1 1 12 Low risk 62 $756,000 Failures Distrbutions

Medium High
7 0 2 1 3 1 1 1 1 10 42 $7,752,000 Electrical Systems 4 3 2 1 1
Risk
Probabaility of Failures
Frequency of Failures

6 1 1 1 1 1 1 1 1 8 Medium Risk 24 $12,310,000 Mechanical Systems 3 3 6 2

5 1 2 1 3 2 4 1 1 15 High Risk 12 $5,460,000 Rotating Equipment 2 3 9 2 1

4 0 1 1 1 4 0 4 2 13 Totals 140 Pipeline , wells , Tanks 7 4 2 1 2

Risk Costs Critical Systems /

3 3 1 1 1 3 0 2 3 14 $26.28 $26,278,000 8 2 8 2 1
$M Pressure Equipment

2 3 4 5 7 9 3 2 3 36 Non Critical Systems 3 2 1 4 1

1 1 3 5 6 7 1 1 8 32 Structures / Civil Work 2 3 5 1

10 15 16 27 28 11 13 20 140 Totals 29 20 28 15 9
$1,000,000
$100,000

$300,000
$10,000

$30,000
$1,000

$2,000

$8,000

Consequence of a Failure
 Reliability Statistical Model for Boilers
Calculating Reliability Alert levels For Plant and Its Critical Equipment

No of Failures / Moving
Months
Failure Rates Averages
Sep-12 3
Oct-12 5
Nov-12 7 5.00
Dec-12 6 6.00
Jan-13 5 6.00
Feb-13 9 6.67
Mar-13 1 5.00
Apr-13 4 4.67
May-13 7 4.00
Jun-13 9 6.67
Jul-13 2 6.00
Aug-13 13 8.00
Sep-13 23 12.67
Oct-13 9 15.00
GPL Good
SD Standard
Performance
Deviation of 5.791 7.14
level 12 Months
Failure rates
Running Average

Alert level GPL + 2 SD 18.721

Calculation
Status Color Actual Compared with Results
Method
If Current Month
Green Status 9 7.14
Rate is <= GPL
If Three Months
Amber Status Running Avg 15.00 7.14
> GPL
If Three Months
Running Avg
Red Status 15.00 7.14 18.721
> GPL & Alert
Level
Boiler Standards and Performance Calculations
Detailed Exercise ( As Required )
 Boiler Health Indicators
• Additional Equivalent Operating Hours
• Thermal Excursion Index
• Chemical Excursion Index
• Trip Index
• Corrosion Rate
• Scaling Rate
• Combustion Efficiency
• Thermal Efficiency
• Fuel to steam Efficiency
• In-Service Efficiency
• Stack Temp & Losses
• Excess Air ratio
• Radiation and Convection Losses
• Flue Gas Passes
 Boiler Codes & Standards
ASME Boiler and Pressure Vessel Code
Section I Rules for Construction of Power Boilers
Section II Materials
Section III Rules for Construction of Nuclear Power Plant Components
Section IV Rules for Construction of Heating Boilers
Section V Nondestructive Examination
Section VI Recommended Rules for Care and Operation of Heating Boilers
Section VII Recommended Guidelines for Care of Power Boilers
Section VIII Rules for Construction of Pressure Vessels Division 1, 2 and 3
Section IX Welding and Brazing Qualifications
Section X Fiber-Reinforced Plastic Pressure Vessels
Section XI Rules for Inservice Inspection of Nuclear Power Plant Components
Section XII Rules for Construction and Continued Service of Transport Tanks
ASME Pressure Piping Codes
B31.1 Power Piping
B31.3 Process Piping
B31.5 Refrigeration Piping and Heat Transfer Components
B31.9 Building Services Piping
Conclusion & Questions