Using PI for Back Testing Usage-Based and Condition-Based Maintenance Strategies Prior to Deployment in Asset Management

Gopal GopalKrishnan, P.E.

OSIsoft, Inc.Larry Hruby

Basin Electric

Mark Blaszkiewicz

Sebastien Cournoyer, CMRP

DTE Energy

Agenda

• About Basin Electric, About DTE Energy• History of PI System at Basin Electric and DTE Energy• History of maintenance systems:

– Basin has Ventyx AssetSuite (aka Indus Passport)– DTE has IBM Maximo

• Case studies for back-testing:– Usage-based strategies– Condition-based strategies

• Q & A

Sebastien Cournoyer, CMRP

DTE Energy

What You Can Expect

• Talk is not product specific – use several tools available in the PI Infrastructure

• Start with maintenance tasks and work backward to see if data exists in operations history that can be used– Collect additional equipment inspection data for proactive

maintenance

• Use PI tools and in-house resources in small increments without new capital outlay

Coal-fired Power Plant

http://en.wikipedia.org/wiki/Fossil_fuel_power_plant

Basin Electric Power Cooperative

• HQ – Bismarck, North Dakota, wholesale provider (generation and transmission) of power to 126 Rural Electric Systems covering portions of 9 states

• Operate coal, wind, gas, oil based power generating facilities and a synthetic natural gas production facility

• Capacity– 3623 MW (Base load)

– 405 MW (Peaking – CTs)

– 136 MW (Wind)

Basin - Leland Olds Station (LOS)Fuel:

Lignite with PRB (Powder River Basin)

blending

Unit 1: 220 MW - 1966

Pulverized Coal Boiler (Babcock & Wilcox)

Turbine, GE

DCS, Emerson Ovation 2007 upgrade

Unit 2: 440 MW - 1975

Cyclone boiler (Babcock & Wilcox)

Turbine, Alstom

DCS, Emerson Ovation 2006 upgrade

Under Construction:Limestone Scrubbers for SO2 capture

($410MM capital project)Leland Olds, Stanton, North Dakota

Leland Olds Station (LOS)– Software Infrastructure

OSIsoft PI (piloted in 2005)• 20,000 tags

• Emerson Ovation DCS, Rockwell PLCs, GE relays

Ventyx Asset Suite (previously Indus Passport)• Started using in 1998 as Passport, has evolved into Asset

Suite in 2008

• Used for Work Management, PM’s, Inventory, Equipment spec’s & history, Purchasing, Contracts

Leland Olds – Maintenance Initiatives

• Working toward condition based maintenance (CBM) for years– Vibration, oil analysis, thermography etc.

• Investigated Rockwell and OSI PI as platform to feed CBM and operational data to AssetSuite

• PI data reviewed:– Standard PM work orders usage based

– Machine status work order management

– Sensor drift and calibration

– Control Loop Health

– Condition-based notification

DTE Energy – Detroit Edison

Detroit Edison

• Michigan’s largest electric utility with 2.2

million customers

• Over 11,000 MW of power generation

from 7 plants - mostly coal fired

• 54,000 GWh in electric sales

• $4.7 billion in revenue

DTE Energy - Detroit Edison

DTE - Plants and Performance Center

Greenwood – 785 mwRiver Rouge - 527 mw Fermi – 1,100 mw

Monroe – 3,135 mw

Trenton Channel - 730 mw

Belle River – 1,260 mw

St Clair – 1,417 mw

Harbor Beach – 103 mw

Performance Center – 11,588 mw

DTE – History of PI and Maximo

• PI is a key infrastructure and technology enabler for real-time operations data as part of the “Enterprise Business System” at DTE

Additional details from a Nov. 2008 presentation at:

www.osisoft.com/osisoft/downloads/Regional_Seminars/Detroit/DTE%20Energy%20(John%20Kapron).pps

• IBM-Maximo is a key application for work management as part of the “Enterprise Business System” at DTE

Additional details at:

http://www-03.ibm.com/press/us/en/pressrelease/21649.wss

Success!

DTE – Details of PI usage

• In use since 1998 –started with a pilot at Monroe in 1998

• Enterprise Agreement for corporate wide use

• PI is an infrastructure product – magnitude of use and functionality is expanding

DTE - Total Fleet Management

Real-time

Process Applications

Distributed Control Systems (DCS)

Distributed PI Historians

WEB Portal

SME Status Displays

Applications

Expert Systems

Financials

Work Management

SAP

Maximo

Market

MISO,

Fuel Coat Framework

Unit Capacity Framework

Drives Performance ExcellenceProcess Costs

Asset Health

Operational Performance

Market Value

Fleet Optimization

Discrete data

Limited value

Actionable

Information – KPI’s

Distributed Control Systems (DCS)

Distributed OSIsoft PI Historians

Large Population of Data

Post Event AnalysisDCS, PLC & PI

90%

Business IntelligenceOutage & De-rate (UCF)

Maintenance & Market

Relate all Data Sources

ProcessNet Framework(PI, ProcessGuard, Maximo, SAP, UCF, P3M,

Predictive Monitoring, NeuCo, LIMS, Plant View ..)25%

% Complete

ABB

System DashboardsFleet Status Assessment

Fleet Drill downSubject Matter Experts90%

WEB VisualizingPlant Alarm, DCS Real-time WEB Graphics

Easy Access to Information

Standard User InterfaceWEB Visualization

100%

Engineering ApplicationsPMAX, Digital Fuel Tracking, Fuel Cost Framework

Process Discrete Data

Process Discrete DataEngineering ApplicationsRFID, PMAX, DFTS, eNote,

Fuel Cost Framework,

Alarm Management 90%

Expert SystemsPredictive Monitoring, Optimization

MBO/PdM/Risk Assessment

Advanced Analysis & Process OptimizationReliability Academy

Equipment, Process, Performance, Reliability ModelsClosed Loop Process Optimization60%

DTE - Control & Technology Framework

Fossil Generation

Business Unit Strategy

PeopleMaking right decisions when it matters!

Fleet

OptimizationProcess Costs

Asset Health,

Market Value

Drives Performance ExcellenceFleet Optimization

Process Costs, Asset Health,

Reliability

Operational Performance, Market Value

15%

Link Operations and Maintenance

• Business goals– Usage based maintenance (UBM) strategies

• Mostly, data is already in PI

– Condition-based maintenance (CBM) strategies• When relevant data not in PI, collect equipment inspection

specifically designed to drive maintenance benefits

• Business justification– Calendar-based maintenance strategy := Amount of

maintenance will be same as last year – UBM and CBM:= Opportunities for savings– Use PI history and Maintenance history to:

• Back-test calendar based PM for conversion to UBM • Back-test corrective work order (CM) events for conversion

to CBM

Usage-based Criteria

• Run-hours -– Coal feed conveyor

– Pulverizer

– High pressure service water pumps

• Run-modes - number of starts, number of trips – Peaker CT blades

• Run-weight - tonnage processed (mining industry), flow-rate (time-integral) converted to volume

• PI totalizer

• PI time-filtered conditional expressions (time-weighted and event-weighted)

Service Water Pump – Usage BasedPumps were off for extended period, however the PM WO still went out - 28 PM hours

Fuel Conditioner – Usage BasedEquipment runs about 80% of total year; usage based maintenance can save 152 PM hours

Coal Conveyor - Usage BasedMaintenance: 60 PM hours per conveyor per year; 22 conveyors per site, 6 sites

Actual runhours: 25% based on PI data, implies a 75% savings

Projected savings: 900+ PM hours (approx. $45,000 at $50/hr) per year per site

Pulverizer - Usage BasedMaintenance: 160 PM hours per pulverizer per year; 16 pulverizers per site, 6 sites

Actual runhours: 80% based on PI data, implies a 20% savings

Projected savings: 480+ PM hours (approx. $25,000 at $50/hr) per year per site

Condition-based Criteria

• Equipment failure is known to be correlated to a slowly degrading metric that can be monitored

– Temperature (Motor windings, Bearing)

– Pressure or DeltaP (heat-exchanger plugging, filters)

– Vibration – Amplitude, FFT etc. ; Also interpret along with operations data in PI

• Instrument and transmitter calibration

• Control loop health

Secondary Air Heater PluggingAir heater tube plugging causes DeltaP (green line)

to increase over several months and is a trigger for

maintenance

Boiler (convection section) Tubes - PluggingRapid rate of change of Delta P over several days

is a trigger for maintenance

Steam Condenser FoulingSteam condenser fouling causes condenser

pressure to rise (blue line), note the rapid rise in a

matter of few days. Threshold is 4 inHg.

Green line shows the inlet water temperature which

is relatively constant

Vibration – Conveyor Motor - Note the rapid rise in vibration amplitude in Jan.

and Feb.; also shown in the trend.

- Resolved by a shaft re-alignment – see next slide

Vibration – Conveyor Motor Shaft realignment resolves the vibration issue

Instrument Drift – O2 Analyzer – U2-E

Based on redundant dual sensors

Transmitter Drift

Good

Not Good

Boiler feedwater pump discharge pressure

Based on redundant triple transmitters (PressA,

PressB and PressC)

XY Plot, PressA (X) vs. PressB (Y1), PressC(Y2)

Transmitter Drift – U1 – Spray FlowGreen – Delta between the transmitters

Blue – Unit 1 is at about 220 MW

Firing Rate Control Loop – Boiler Exit O2O2 set point: Approx. 3.2%

Actual process value (green line): Varies from 1% to 5.5%

Firing Rate Control Loop – See NotesAt purple crosshair, air (red) peaks when coal (yellow) dips causing

O2 (green) to peak after 30-40 secs.

At white crosshair, air (red) dips when coal (yellow) peaks causing

O2 (green) to fall below 1% after a lag of 30-40secs, and so on….

Manual Inputs – Operator Rounds in PI

Source:

www.aeec.com/conveyor/Belt_Cleaners/Vplow.

aspx (retrieved Jan 2009)

Operator Rounds: V-PLOW status on a coal conveyor belt

Equipment inspection data collection specifically designed to help maintenance

tasks (data not already in PI)

Benefits: Proactive maintenance for increased MTBF (mean-time-between-failure)

Breaker Inspection SheetEquipment inspection data specifically designed to help with maintenance

tasks (data not already in PI)

Data collection includes numeric values such as resistance, clearance etc.

• Breaker inspection – 80 attributes per breaker, 1000 breakers – annual inspection or after a trip• Dust Collector• Screw conveyor• Electric motor• Reducer • Bearings• Transfer point / chute liner condition• Limit-torque actuator• Hydraulic cylinder, Pneumatic cylinder• Pumps• Mechanical seals• Conveyor skirting• Conveyor scraper, primary and secondary• Idler, roll assembly• Pulley• Lube system• Coupling• Torque coupling• Valve• Piping

Manual Inputs – Operator Rounds in PIEquipment inspection data specifically designed to help with

maintenance tasks (data not already in PI)

Everything we visually inspect, measure or observe can be recorded in PI

to track, trend and monitor

Findings

• Operations history and maintenance history can validate and quantify benefits for usage-based criteria prior to deployment

• Use manual input data (Manual Logger) to supplement condition-based strategies

• Review control loops, including the instruments, transmitters and calibrations

• Vibration data – combine with equipment operating conditions for better diagnostics

Enterprise GatewaySOA (service oriented architecture) to exchange information

between the PI System and any external system via web services.

Questions?

Thank you

www.osisoft.com