Nail Ozboya

Associate

Data Management for a

Triple Pressure HRSG with

Canadian HRSG Forum

Oakville, Ontario
October 20-22, 2014

www.STRUCTINT.com Please note that the information contained in this presentation is not to be copied or
disseminated without the permission of Structural Integrity Associates, Inc.
877-4SI-POWER
 Overview

Why we need data management?

Considerations for a data management system

Application to HRSGs

PlantTrack features and demonstration

PlantTrack - SLIDE 2
 Why We Need Data Management?

Lifetime management of key plant assets requires tracking

and analysis of a vast amount of data
Design drawings / specifications / fabrication records
Replacements and modifications
Failures (what failed, where, why and when)
Inspections (data, reports)
Key operating events (chem. cleans, fuel switches, hanger resets)

Track data
Make data available
Gain insight and understanding from data
Help optimize future availability and reliability

PlantTrack - SLIDE 3
 The Challenge!

Data is everywhere and we create more of it every day

but is it making us smarter?

can we even find it!

Lets explore the five Ws of data management

PlantTrack - SLIDE 4
 1. What data do you have?

Design information
Drawings, specs, fab. records, material certs,
Replacements and modifications
Design, installation, reasons for change,
Failures
What failed, where, why and when
Inspections
Visual, NDE, assessments, metallurgical reports,
Operating events
Chemical cleans, valve rebuilds, hanger resets,

PlantTrack - SLIDE 5
 2. Where do you keep it?

In my head!
File cabinets
On my desk
On my hard drive
On a jump drive
One a network drive
In companies data archive
In various spreadsheets
In a database
Dispersed data: many inconsistent/incompatible formats, between
many people and places

PlantTrack - SLIDE 6
 3. How is it organized?

Badly / Its not

By date
By system component
By type of data (drawing, inspection, reports, )
By vendor / organization performing the work

Depending on circumstances we often want to search / mine

the data in different ways

PlantTrack - SLIDE 7
 4. When do you access it?

Management requests for information

Inspection scope development
Failure reporting
Root cause analysis
Capital planning

How quickly could you find a drawing, NDE report or

calculation if you need it?

PlantTrack - SLIDE 8
 5. Why Do You Need It?

To answer the endless questions

What alloy is that tube supposed to be made from?
What is min wall?
What did we see at that weld last time?
Have we had failures due to that mechanism before?
Did we get this many failures after the last chemical clean?

Because life is getting more complex

The guys that remembered everything have retired!
Different operating regimes (load following, not base load)

PlantTrack - SLIDE 9
 Gaining Insight from Data

History Geography

When did events happen? Where did events occur?

Explore trends and patterns

(Graphs, charts, visualization on geometry)

Correlations between events

Understanding and Insight

PlantTrack - SLIDE 10
Gaining Insight from Data

PlantTrack - SLIDE 11
 Implementation of a Data Management System

Four stage approach:

Planning
Searching and procurement
Implementation
Maintenance

PlantTrack - SLIDE 12
 Planning Stage
Identify needs
What data do you want to access?
How do you want to access (local computer, plant, corporate)?
What level of control do you want (read only, data entry,
configuration)?
What degree of scalability are you looking for (other components)?
Data import / export needs?
Interoperability / data exchange with other systems?

Identify resources
Budget available
Manpower available
Infrastructure, software upgrade possibilities
Collaborate with IS/IT group

PlantTrack - SLIDE 13
 Searching and Procurement Stage
Evaluation criteria
Graphics capabilities: Interact with data through a graphical interface
Access data from anywhere, with everyone working from the same data
Access from mobile devices
Ease of use:
How long is the learning curve?
Ease of populating the database (leverage existing data)
Interconnectivity and integration with existing applications
Security: How is proprietary information handled? User roles?
Flexibility: Customizable to meet your needs
Scalability: Modular approach to expand to different areas
Data quality: ensure correct and up-to-date data is available
Offline data access and data entry
Close integration with Excel because
Support: What kind of support options available?
Long term maintenance: Update and upgrade paths

PlantTrack - SLIDE 14
 Implementation Stage

Installation and setup

Training, training the trainers
Setting up users and roles
Setting up procedures and responsibilities
Customizing the application
Populating the database

PlantTrack - SLIDE 15
 Maintenance Stage

Ensure that all new information is entered consistently

Install any updates and upgrades
Upgrade support systems, if necessary
Periodical refresher training

PlantTrack - SLIDE 16
 Data Management For HRSGs

Triple-pressure HRSGs have many materials, components and

failure mechanisms that should be tracked for effective life
management

Focus on the systems with the leading damage mechanisms

FAC, HP evaporator deposits, Thermal Fatigue, ...

Drive a programmatic approach to known

industry issues:
FAC, Grade 91, High Energy Piping (CPS)

Dont forget some of the related systems

Flow controls, burners,
attemperators, valves,

PlantTrack - SLIDE 17
 HRSG Tubing

Track FAC thickness measurements

Track tube failures by date, location, mechanism
Track HP Evaporator deposit analysis
Track materials: grade 91, grade 23, DMWs,
Track inspection results: tube-to-header indications
Create outage inspection reports
and more

PlantTrack - SLIDE 18
 Interconnecting Piping, Headers and HEP

Track FAC thickness measurements

Track desuperheater inspections and spray valve
maintenance
Track Grade 91 material condition (pipe spools, welds,
valves, )
Track pipe spools, welds, hangers, insulation, etc.
Track inspections, hanger readings, walkdown
observations
Produce color coded diagrams
Trend inspection data
and more

PlantTrack - SLIDE 19
Scalable, Web-Based, Graphical Data Management Solution for Power Plants

PlantTrack - SLIDE 20
 Ease of Use
Easy to use
Intuitive interface
Navigation
Data sorting
Filtering data
Quick lists, charts, reports
User guides, support, training

PlantTrack - SLIDE 21
Graphical Interface
Component Navigation Event List Graphics Record Details/Specifications

Grid View
Apply Filters

PlantTrack - SLIDE 22
Color Coded Record Display

Click on the node on

Display records color coded graphics, and display the
based on any field. This record details.
example shows the location
of different types of repairs
made.

Easily create and apply

filters/easels.

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 Ease of Access
Easy to access
Web-based
Multiple platforms
Add users/privileges

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Graphics Options
- 2.5D (Ortho views) or 2D Isometric CAD Drawings

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Graphics Options
- Scanned images, PDF/TIFF/JPEG Files

User relocatable labels. This

feature could be used to
attach quick notes, as well as
to display certain field values.

Add multiple levels of detail

drawings/images. Record
display propagated to higher
level drawings.

PlantTrack - SLIDE 26
Quick Record Lists and Charts

Easy record filtering,

display and bar/trend
charts.

PlantTrack - SLIDE 27
Reports

Standard and custom

reports/charts.

PlantTrack - SLIDE 28
 Why You Need It
Big Data
Increasing volume of data being acquired requires systematic
approach
Maximize reliability and availability
Increase productivity
Minimize errors
Optimize outage scope by pinpointing problem areas
Mine data to find correlations between events and
observations

PlantTrack - SLIDE 29