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Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Condition-based Maintenance Regional Seminar Series Angela Rothweiler,

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Presentation on theme: "Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Condition-based Maintenance Regional Seminar Series Angela Rothweiler,"— Presentation transcript:

1 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Condition-based Maintenance Regional Seminar Series Angela Rothweiler, PSE&G Gopal GopalKrishnan, OSIsoft July 17, 2009

2 2 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI enabled maintenance for the enterprise Q & A Agenda

3 3 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI enabled maintenance for the enterprise Q & A Agenda

4 4 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. WHATOperating parameters (PI data) vibration, thermography, dissolved gas analysis… WHY Prevent failure, improve operations, reduce maintenance expenses… WHENDepends on how it changes or degrades WHERE Critical assets WHO Both operations and maintenance HOWPI enabled operations & PI enabled maintenance What is Condition-based Maintenance JIT 1 maintenance 2 based on monitored asset 3 conditions 1 JIT = just -in-time 3 include control loops Dept. of Defense quote “… CBM be implemented to improve maintenance agility and responsiveness, increase operational availability, and reduce life cycle total cost …” 2 maintenance is not repair The challenging work in a CBM deployment is in the condition assessment, i.e. the analytics

5 5 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI enabled maintenance for the enterprise Q & A Agenda

6 6 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Etiam dignissim nibh. Ac quam adipiscing iaculis. Nam malesuada consequat neque. Get started today Cytec Critical Variables Program ProcessBook multi-state symbol

7 7 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Get started today Cytec Critical Variables Program - DataLink reports Targets met 95% percent of the time vs. 67% previously Steam savings $1MM plus Equipment is run as intended

8 8 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today – Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI enabled maintenance for the enterprise Q & A Agenda

9 9 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Types of maintenance Maintenance Corrective - this is after failure Preventive - this is before failure Calendar based - ignores equipment utilization pattern Condition based – aware of equipment conditions and utilization – Usage based (via PI and analytics) – Equipment condition based (via PI and analytics)

10 Service water pump – calendar based schedule ignores equipment usage pattern Pumps were off for an extended period, however the PM WO still went out Save 28 PM hours with usage based PM instead of calendar based

11 11 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Usage based maintenance Run-hours – Coal feed conveyor – Pulverizer – High pressure service water pumps Run-modes – number of starts (peaker combustion turbine (CT) blades) – number of trips 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)

12 12 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Validate usage based strategy - Pulverizer Maintenance: 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

13 Validate usage based strategy - Coal conveyor Maintenance: 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

14 14 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Equipment condition based strategies Failure or performance correlated to a slowly degrading metric – Temperature Bearings Motor windings – Pressure or DeltaP Heat-exchanger plugging Filters – Vibration, amplitude (need to interpret along with operations data in PI) Instrument and transmitter drift Control loop health

15 15 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Secondary air heater plugging Air heater tube plugging causes DeltaP (green line) to increase over several months and is a trigger for maintenance Ad hoc time-filter expressions as PI Calculations

16 16 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Boiler (convection) tubes plugging Rapid rate of change of Delta P over several days is a trigger for maintenance Delta P (PI expression calculation, ad hoc plot)

17 17 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Instrument drift – O2 analyzer Based on redundant dual sensors Delta approx. zero is GOOD Delta drifting from zero is NOT GOOD

18 18 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. 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)

19 19 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Firing rate control loop Boiler exit O2 set point: Approx. 3.2% Actual process value (green line): High variability from 1% to 5.5%

20 20 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. Firing rate control loop At purple crosshair, air (red) peaks when coal (yellow) dips causing O2 (green) to peak after 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….

21 21 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI aware Maintenance for the Enterprise Q & A Agenda

22 22 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. PSE&G use case

23 23 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Energy use case – fully real-time enabled (2008) PI enabled maintenance for the enterprise Q & A Agenda

24 24 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. How CBM PI System is used Collects and stores time-series data Controls communication from Enterprise level Gateway to PI Provides Analytics (ACE) and Visualizations (WebParts) Visualizes graphing, trending and analytics Maps data points automatically from Enterprise level Gateway Integrates with T&D Operations PI System Integrates with Legacy applications (Phase 2) Sends PI Notifications and Acknowledgement Serves as a CBM Model server Sempra Energy use case Real-time CBM project is the first-of-its-kind in the industry – end-to-end from substation sensors to back-office analytics and visualization

25 Dissolved Gas Analysis Sempra Energy use case Online DGA can be as frequent as one hour

26 26 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Utilities use case – fully real-time enabled PI enabled maintenance for the enterprise Q & A Agenda

27 Manual inputs – Operator rounds in PI Source: 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)

28 PI to Maximo data flow Maximo EQUIPMENT OPERATING PARAMETERS Running or Idle PressureTemperatureRpmVibration Oil level PI server Portal PI System Gateway to IBM Maximo server PI Alerts WORK ORDER Measurements PI Process Book and Web based RtWebparts Integrated view of Operations and Maintenance Process Analysis Data or WorkOrder trigger Meter Acknowledgment Work Order Number and Status. GAUGE CHARACERTISTIC CONTINUOUS Condition Assessment Meter Acknowledgment Work Order Number and Status.

29 Common equipment names in PI and Maximo PI Module DB Maximo Equipment Drilldown

30 PI RLINK-Maximo Combined Maintenance and Operations Microsoft SharePoint - Browser View - shows the alarm history for one or more equipments and the actual measurements generating the alarm. WO details (history and their statuses) for PUMP1 are also listed. Equipment listing with CBM Alarm points WO details from Maximo Operations history CBM Alarms

31 PI enabled maintenance for the enterprise Maximo_Asset_Registry and WorkOrder_Demo Hyperlink launches the demo only during a live session

32 32 Empowering Business in Real Time © Copyright 2009, OSIsoft Inc. All rights Reserved. What is Condition-based Maintenance (CBM) Get started today - Cytec use case Maintenance strategies you can validate before deployment Usage based – DTE Energy use case Condition-based - Basin Electric use case PSE&G use case - fully deployed and live since 2002 Sempra Utilities use case – fully real-time enabled PI enabled maintenance for the enterprise Q & A Agenda

33 Other resources PRODUCTS and FEATURES PI Manual Logger for Operator rounds Advanced Calculation Engine PI Notification PI Web parts PI ProcessBook PI DataLink PI TimeFilter, PI Expressions, PI Performance Equations PI integration with IBM Maximo (Maintenance) PI web services (to be released later in 2009) Search for “condition based” on OSIsoft website:

34 Other resources Using PI to Back - Test Usage and Condition Based Maintenance Strategies to predict Quantifiable Benefits Prior to Deployment in Asset Management Using PI to Back - Test Usage and Condition Based Maintenance Strategies to predict Quantifiable Benefits Prior to Deployment in Asset Management (Sebastien Cournoyer, DTE Energy, Laurence Hruby, Basin Electric Power Cooperative, Gopal GopalKrishnan, OSIsoft) – PPTPPT Using Basic PI Tools to Implement a Critical Variables Program that is Inexpensive and Easy to Maintain, Cytec Industries Inc. Substation Inspection and Condition Based Maintenance using PI SDG&E PI-based Substation Real-Time Condition Based Maintenance SystemSDG&E PI-based Substation Real-Time Condition Based Maintenance System (Neal Bartek, Subburaman Sankaran, SDG&E) – PPTPPT

35 Thank you © Copyright 2009 OSIsoft, Inc. 777 Davis St., Suite 250 San Leandro, CA 94577


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