1. Condition-based Maintenance
Regional Seminar Series
Condition-based Maintenance
Angela Rothweiler, PSE&G
Gopal GopalKrishnan, OSIsoft
July 17, 2009

2. Agenda 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

3. Agenda 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

4. What is Condition-based Maintenance
Dept. of Defense quote “… CBM be implemented to improve maintenance agility and responsiveness, increase operational availability, and reduce life cycle total cost …”
The challenging work in a CBM deployment is in the condition assessment, i.e. the analytics
JIT1 maintenance2 based on monitored asset3 conditions
WHAT Operating parameters (PI data) vibration, thermography, dissolved gas analysis… WHY Prevent failure, improve operations, reduce maintenance expenses… WHEN Depends on how it changes or degrades WHERE Critical assets WHO Both operations and maintenance HOW PI enabled operations & PI enabled maintenance
1JIT = just -in-time
2maintenance is not repair
3 include control loops

5. Agenda 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

6. Get started today Cytec Critical Variables Program
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7. 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. Agenda 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

9. 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. Usage based maintenance
PI totalizer
PI time-filtered conditional expressions (time-weighted and event-weighted)
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

12. 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. 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. 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. 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. Instrument drift – O2 analyzer
Based on redundant dual sensors
Delta approx. zero is GOOD
Delta drifting from zero is NOT GOOD

18. Transmitter drift Boiler feedwater pump discharge pressure
Based on redundant triple transmitters (PressA, PressB and PressC)
XY Plot, PressA (X) vs. PressB (Y1), PressC(Y2)
GOOD
NOT GOOD

19. 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. 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….
Screen shows a 15 minute chart (each grid is 1 minute) for the firing rate control parameters – i.e. fuel, airflow, airflow to fuel ratio, and BoilerExitO2.
At the purple cross-hair, fuel (yellow) has dipped, but air flow (red) has gone up and hence the air-to-fuel (blue) shows a sharp jump. After about 30-40s lag (width of each grid is 60s), the boiler exit O2 (green) shows a peak.
At the white cross-hair, fuel (yellow) has peaked, but air flow (red) has dipped and correspondingly, the air-to-fuel (blue) shows a sharp dip. And, predictably, after about 30-40s lag, the boiler exit O2 (green) shows a sharp dip.
This pattern, i.e. the air flow dipping when the fuel peaks and vice-versa, causes the O2 to vary from the lows of about 1% to highs of about 6%, even though the average value stays nominally around 3 to 3.5%. With such high variability, O2 is above 4.5% for about 35% of the time, and below 2.5% for about 30% of the time, during hours of full load i.e. > 200MW.

21. Agenda 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

22. PSE&G use case

23. Agenda 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

24. How CBM PI System is used
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
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

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

26. Agenda 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

27. Manual inputs – Operator rounds in PI
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)
High
HiHi
Low
LoLo
Rate of Change > 3 deg in 7 days
Compressor Discharge temperature
STEP
Source: (retrieved Jan 2009)
Operator Rounds: V-PLOW status on a coal conveyor belt

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

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

30. 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.
CBM Alarms
Equipment listing with CBM Alarm points
WO details from Maximo
Operations history
PI RLINK-Maximo

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

32. Agenda 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

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 (Sebastien Cournoyer, DTE Energy, Laurence Hruby, Basin Electric Power Cooperative, Gopal GopalKrishnan, OSIsoft) – PPT
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 System (Neal Bartek, Subburaman Sankaran, SDG&E) – PPT