11

Optimize Asset Implementation and Availability Optimize Asset Implementation and Availability Using Condition Based MaintenanceUsing Condition Based Maintenance

Tom Hosea, OSIsoft

2

AgendaAgenda

Objective & Evolution of Asset Management

CBM Drivers

Why use real-time data

Implementation example & deployment results

SDG&E RtCBM Program

OSIsoft Enabling Technology

– Business Process

– Sample Capabilities

3

Asset Management : Objectives and GoalsAsset Management : Objectives and Goals

Maximize asset performance at lowest life-cycle cost

– Reduce maintenance and corresponding O&M expense

– Dispatch skillful technicians for specific problems

– Manage trouble response to minimize cost

Maximize equipment performance

– Utilization

– Reliability

Optimize asset replacement strategyand

Eliminate or reduce catastrophic equipment failures

4

Reactive Proactive Diagnostic/Analytic

Reactive MaintenanceService assets as needed

Preventive Maintenance

Condition Based Maintenance

Maintenance at a specific frequency

Maintain when a potential failure is identified

1980’s 1990’s 21st Century

Calendar based MaintenanceMaintenance at a fixed frequency

Evolution of Asset MaintenanceEvolution of Asset Maintenance

5

Why Integrate Real-time Data? Why Integrate Real-time Data?

Better automated processes for CBM

Operations Benefits – provides access to the real condition of the asset, better utilize the asset

Maintenance Benefits – facilitates fine tuning of maintenance processes

– Drill down to what is really driving the condition

– Determine whether to send someone now or later

66

San Diego Gas & ElectricSan Diego Gas & Electric(SDG&E) (SDG&E)

RtCBM Program

7

Workstations

RtPortal Thick (Smart) Clients

RtPortal Thick (Smart) Clients

PI Manual Data

Logger

PI Manual Data

Logger

Workstations

RtPortal Web-based Clients

RtPortal Web-based Clients

Typical Implementation OverviewTypical Implementation Overview

RLINK Bi-directional

Gateway

RLINK Bi-directional

Gateway

Standard InterfacesPI to PI - OLEDB - OPC - COM connectors - Batch

Standard InterfacesPI to PI - OLEDB - OPC - COM connectors - Batch

Measurement Points

Measurement Points

WorkOrders

WorkOrders

AssetDefinitions

AssetDefinitions

Maintenance Plans

Maintenance Plans

TasksTasks

ERP / MMS

Order HistoryOrder History

OSIsoft TechnologyOSIsoft Technology

PITime Series

Database

PITime Series

Database

RtPortal Web-Server

RtPortal Web-ServerContext

Database

Context Database

Analytical Analytical Tools Tools

Substation Gateway Server

Substation Gateway Server

Substation Gateway Server

Substation Gateway Server

Substation Gateway Server

Substation Gateway Server

Substation Gateway Server

Substation Gateway ServerSubstation

Gateway Server

Substation Gateway Server

TransmSCADA

TransmSCADAMV 90MV 90Distr

SCADA

DistrSCADAHydranHydran DobleDobleDeltaXDeltaX

8

PSE&G’s Estimated Savings with OSIsoft-based CBM DeploymentPSE&G’s Estimated Savings with OSIsoft-based CBM Deployment

2003 - $264,600

– 9 LTC’s and 2 GCB’s 2004 - $800,000

– 5 Transformers 2005 Projected ~ $1M

Notification

With real-time data, we can do even better!

2003 - $300,000– Oil Diagnostics targeted 16 LTC’s, 5

had contact problems

2004 - $1.2M– 5 Transformers were targeted and 2

were identified to have major issues

– 10 LTC’s were targeted and 1 had the potential to create major damage.

2005 Projected ~ $2M

Assessment

9

SDG&E System StatisticsSDG&E System Statistics

2 Generation Facilities (590 MW)

1,805 Electric Transmission Miles

18,000 Transmission Structures

120 Substations

906 Distribution Circuits

7,941 Underground Circuit Miles

6,875 Overhead Circuit Miles

220,362 Distribution Poles

145,764 Distribution Transformers

1,315,134 Electric Meters

CPUC

CAISO

FERC

10

SDG&E RtCBM ObjectivesSDG&E RtCBM Objectives

Minimize personnel dependency (resources & training needed for asset data analysis)

Provide a equipment monitoring and analysis platform for access to all data

Provide drill down navigation abilities through data integration

Notify personnel to respond to equipment conditions

– Automated analysis

– Automated trigger

– Automated notification

• Pager, Email, & Investigating Work Orders

– Reporting capabilities

11

RtCBM Process Enhancement and MoreRtCBM Process Enhancement and More

Benchmark Equipment (with normalized data) Refine equipment specifications Design validation and equipment procurement practice Provide insights into substation design & configuration

geographical variations Standardize Analysis – design trigger algorithms Consider factors like asset age, environment, customer

impact Enhance operational and planning decision support –

e.g. equipment impact due to load transfer Enhance equipment utilization, performance trade-offs

12

RtCBM – Data IntegrationRtCBM – Data Integration

Weekly general inspections– LTC operations

– Alarms, temperature, visual

Monthly equipment inspections– Operation counters

– Temperature, Pressure

– Voltage

– Functional check

General asset – Rating

– Age, Type, Design

– Operating limits

Operational – Relays & Digital fault recorders

– PQ Monitors

Specific equipment – Operating conditions

– Stress factors

– Trouble history

– Maintenance data

– Oil test data

– Electrical test data

– Operating speed

Real-time – Voltage & Current

– Temperature

– Bushing On-line Power Factor

– Hydrogen in Oil

Simulated System & Engineering

13

SDG&E RtCBM ArchitectureSDG&E RtCBM Architecture

Microsoft SharePoint Server

RtWebParts

Operations PI Server

Maintenance PI Server•Algorithms•Email Alerts

SCADAMaintenance

SystemDissolved

Gas Analysis Others

16 Port Ethernet Gateway (DNP3)

WiMax/ Wired LAN Connection

Real-time Equipment DataTemperature-Winding,-Top Oil, -LTC

Bushing Monitors Phase A, B & C

Hydrogen/Water in Oil Monitor

LTC Tap Position Indicator

On-line Monitors / IEDs

Relational Databases

User Interface andAnalysis Tools

14

Time-based to RtCBM – Circuit BreakersTime-based to RtCBM – Circuit Breakers

Data Available Weekly safety inspections Monthly equipment insp. Asset Data Historical Data

– Operating conditions– Stress factors– Trouble – Maintenance data– Test data (insul & elec)

Operational data– Relays & Digital fault recorders– PQ Monitors

Real-time data– Voltage & Current

– I2T and Contact Wear

– Operations Counter

Planned

Approach

Maintenance Intervals

3 6 9 Yr.3 6 9 Yr.

3 6 9 Yr.3 6 9 Yr.

15

Circuit Breaker OperationsCircuit Breaker Operations

Concerns Proper fault clearing Fault testing with a circuit

breaker

Solution Verify the health of CB

– Contact wear

– Insulation medium integrity

– Bushings and accessories

– Operating history

Use historical and real-time contact wear data (I2T) to make a decision

Substation Relays withCircuit Breaker Monitor

Ops. & Maintenance PI Server•Algorithms•Email Alerts

16 Ports Ethernet Gateway (DNP3)

On-lineMonitors

16

Transformer at Emergency RatingTransformer at Emergency Rating

POWER TRANSFORMER

TRANSFORMER Health Indices

• Insulation Power Factor

• LTC Application & Design

• Oil Conditions

• Bushing & Accessories

• Operating History &

Conditions

Location of Paper Sample Degree of Polymerization (DP)

NLTC – Phase A 586

NLTC – Phase B 737

69kV Bushing C 688

New Insulation Paper: 1000 < DPv < 1300Middle Aged Insulation Paper: DPv = 500Old Age Insulation Paper: DPv < 251Severely Degraded Insulation Paper: DPv < 151

Paper Insulation Health

LTC Application and design analysis.

20%

Bushing & Accessories

20%

History Data Review (Oil

testing records, maintenance

records, overloading and

short circuit event)20%

DGA, DP & DOBLE TESTS

20%

Oil Analysis20%

17

Transformer at Emergency Rating Transformer at Emergency Rating

Top Oil Hot Spot LOLIEEE 105 176 .149Ptload 105 145 .039Actual HS rise 106 131 .014

Comparison of hot spot rise over top oil simulated versus actual

Decision: Based on Transformer Unit Health and Real Time Conditions

18

Summary of RtCBM Expected ResultsSummary of RtCBM Expected Results

Operations Benefits

– Avoid potential equipment failure

– Increase asset availabilities

– Respond to equipment alarms according to priorities

– Maximize asset loading capabilities

Maintenance Benefits

– Early warning and indication to address conditions

– Reduce overtime on reactive maintenance

– Minimize equipment outages

Asset Planning Benefits

– Improve future equipment specification and application to maximize utilization and performance.

1919

OSIsoft Enabling TechnologyOSIsoft Enabling Technology

20

Rule Evaluation and Alert NotificationRule Evaluation and Alert Notification

Rule Evaluation

– Configurable environment for “Knowledge Capture”

– Algorithms should scale when adding assets

– Flexible scheduling of algorithms

Alert Notification

– Exception reporting

– Email notification with escalation

– Postmortem reporting with comments and sign off

21

Visualization, Integration and NavigationVisualization, Integration and Navigation

A web-based presentation is preferred

Scalable: minimize the number of web pages

Reuse of existing ProcessBook graphics

Integration amongst data sources

Navigation hierarchy and drill-down

Benchmarking of assets of the same class

Intuitive: no tag names or query strings required

22

Working by ExceptionWorking by Exception

Real-time RuleAssessment

(PI ACE\PIANO)

Alert Notification(PIANO)

Work Order Generation(RLINK)

Asset Reliability(PI OLEDB and

RtReports)Improve Reliability

Integrated AssetInformation

(RtWebParts)

Asset InformationStructure

(Foundation)

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Asset Information StructureAsset Information Structure

DivisionLevel

DistrictLevel

Site

IndividualAsset

Asset Class

24

Level 1

Level 2

Level 3

Level 4

Asset Information Integration HierarchyAsset Information Integration Hierarchy

MaintenanceOverview

SiteDetail

SiteDetail

AssetDetail

RuleDetail

RuleDetail

AssetDetail

SiteDetail

SiteDetail

AssetDetail

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Level 1: Maintenance OverviewLevel 1: Maintenance Overview

26

Level 2: Site DetailLevel 2: Site Detail

27

Level 3: Asset DetailLevel 3: Asset Detail

28

Level 4 : Rule Detail (PI)Level 4 : Rule Detail (PI)

29

Rule Detail (RDB) – Level 4Rule Detail (RDB) – Level 4

30

Maintenance Alert NotificationMaintenance Alert Notification

31

Asset Reliability ReportAsset Reliability Report

32

PSE&G CBM – DashboardPSE&G CBM – Dashboard

33

PSE&G CBM – AnalysisPSE&G CBM – Analysis

34

ConclusionsConclusions

Computer Based Maintenance Applications are evolving

Significant savings are available by moving from calendar based to real-time condition based maintenance

OSIsoft offers a product suite capable of solving these problems

3535

Thanks YouThanks You

Questions?