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© 2008 OSIsoft, Inc. | Company Confidential Asset Management, Decision Making and Counter/Condition Based Maintenance at PSE&G Richard Wernsing – PSE&G Reliability Centered Maintenance - Expert Ann Moore - OSIsoft Business Development Executive
3 © 2008 OSIsoft, Inc. | Company Confidential Today’s Agenda Electric T&D Utility Industry Overview PI Enterprise Infrastructure Counter/Condition Based Maintenance (CBM) Why do we need CBM Benefits of PI-based CBM The Future
4 © 2008 OSIsoft, Inc. | Company Confidential T&D Utility Business Drivers Workforce Going Gray Implication: Higher expectations knowledge-based intelligent tools in PI Compliance Enforcement Implication: PI to provide the secured data and architecture Green Initiatives and Social Programs –Distributed resource activity (DSM, DG, PV, PHEV, appliance automation, etc.), reinforce deployment of AMI, even BPL –Millions of tags Implication: PI to manage smart grids and standards (IEC Standards, i.e. CIM) for interoperability. Driving AF – metadata, context, and enterprise. Grid Expansion –Renewables, WAMS, new operational scenarios, e.g. more HVDC, FACTS superconducting lines, etc. Implication: PI with a new generation of visualization and user experience
5 © 2008 OSIsoft, Inc. | Company Confidential PI T&D New Trends Asset Management –Equipment Health Monitoring –Condition Based Maintenance Smart Grid/Intelligent Grid –Substation Automation –Distribution Automation –Distributed Generation –Demand Side Management –AMI (Advanced Metering Infrastructure) Power System Monitoring –Power Quality, Event and Disturbance Analysis –SynchroPhasor for Grid Stability
6 © 2008 OSIsoft, Inc. | Company Confidential Challenges/Solutions Challenges : –Integration of disparate systems and diverse data sources –Unified modeling of power network and assets –Advanced analysis –Enhanced visualization Solutions : –Centralized data repository/analysis engine –A single version of the truth –Intelligent event-driven working by exception action –Enabling the desktop data access throughout enterprise –Reliability and quality through greater situational awareness
7 © 2008 OSIsoft, Inc. | Company Confidential PI: An Open and Scalable Environment Real-time Rule Assessment (PI ACE and Analytics) Alert Notifications Event Triggering Maintenance or Work Order Generation Asset Reliability (PI OLEDB and Reporting) Integrated Asset Information KPI Dashboard Visualization (RtWebParts) Asset Information Structure (PI Metadata and RDB) Improve Reliability and Quality
8 © 2008 OSIsoft, Inc. | Company Confidential How we use PI? T&D Users Group Activity
9 © 2008 OSIsoft, Inc. | Company Confidential
10 © 2008 OSIsoft, Inc. | Company Confidential PSE&G Company Background Philadelphia New York City One of the largest combined electric and gas companies in US 323 municipalities 70% of New Jersey’s population 2.1 million Electric customers 1.6 million Gas customers 2,600 Square Miles * (between New York and Philadelphia)
11 © 2008 OSIsoft, Inc. | Company Confidential What is Asset Management? Managing anything of value: Protective Relays Gas Mains Transformers Bucket Trucks Circuit Breakers Hydraulic Pumping Plants
12 © 2008 OSIsoft, Inc. | Company Confidential Why Asset Management? US$ (Million) Years Savings Future Benefits
13 © 2008 OSIsoft, Inc. | Company Confidential CBM is a decision support system that assists in making: Repair Replace Maintain Decisions (Transformers, Breakers and Relays) Counter/Condition Based Maintenance (CBM)
14 © 2008 OSIsoft, Inc. | Company Confidential It does this by correlating operational, diagnostic and work management data and turning this data into actionable information. Counter/Condition Based Maintenance (CBM) It is NOT a “crystal ball” ball” that predicts failures It does NOT put the process on “cruise control” It is NOT a “budget slashing” slashing” tool
15 © 2008 OSIsoft, Inc. | Company Confidential Asset Management - Inside Plant (transformers, breaker and relays) “What do you do when… $5.4B You have $1.5B of installed plant with a replacement value of $5.4B, 40 Average age of the assets exceeds 40 years, used and useful All equipment is expected to be used and useful all the time, and… erode earnings Maintenance expenditures erode earnings and capital replacement provides for no new revenue?
16 © 2008 OSIsoft, Inc. | Company Confidential Maintenance Plan Criteria Run to failure Strategic importance of asset Acceptable level of reliability Level of business risk Appropriate annualized preventive maintenance cost Appropriate resource allocation for maintenance Appropriate replacement/re-design strategy Determine strategy for yourself on…
17 © 2008 OSIsoft, Inc. | Company Confidential Benefits Breakdown These annual expenditures protect $1.5 B of inside plant assets and full benefits after approximately five years. Note: Illustration depicts overall changes in maintenance investment strategy. Preventive Maintenance Corrective Maintenance Capital Rep. Calendar Based Preventive Maintenance Corrective Maintenance Failures Condition Based Preventive Maintenance Historical Today Failures Capital Rep 10% to 20% Overall Reduction
18 © 2008 OSIsoft, Inc. | Company Confidential People Integrated for Success System Integration Service Assurance Outage Management Work Management Crew Management Wireless Communications Graphic Information AM/FM Decision Support Data driven decisions + System + Process OSIsoft PI
19 © 2008 OSIsoft, Inc. | Company Confidential The Mission To optimize the investment in assets while the overall system reliability of Electric Delivery improving
20 © 2008 OSIsoft, Inc. | Company Confidential The Vision To perform the right maintenance at the right time, based on the consistent analysis of data to ensure a safe, reliable, and cost effective approach
21 © 2008 OSIsoft, Inc. | Company Confidential Maintenance Philosophy To Condition Based Maintenance From Calendar Based Maintenance Proactive Data Driven
22 © 2008 OSIsoft, Inc. | Company Confidential System Strategy Integrate systems and deploy technology Provide a consistent and repeatable data collection process to insure data integrity Analyze all data relevant to an individual asset in a regularly scheduled and consistent manner Maintain asset information in one accessible database Automate the data collection process
23 © 2008 OSIsoft, Inc. | Company Confidential Expectations Visibility to all key inside plant assets Consolidated asset inspection, test and maintenance data Consistent information base for comparative analysis Condition and performance algorithms to assist in decision making process
24 © 2008 OSIsoft, Inc. | Company Confidential Identify deteriorated equipment (Automatically) Pattern recognition Trending Predictive Peer group variants Work prioritization (Do the right thing first) Drive corrective action (maintenance) Drive replacement plans Condition Assessment Benefits Proactive
25 © 2008 OSIsoft, Inc. | Company Confidential Counter/Condition Based Maintenance Includes the following functions- SAP PM Module for Asset Registry Integrated Work Management System & Wireless Mobile Dispatch The PI System for Centralized Data Repository for Multiple Data Sources Analysis and Notification Engine Reporting
26 © 2008 OSIsoft, Inc. | Company Confidential Key CBM Actions in PI Collect data Correlate & Centralize data Analyze data Create Information Drive Actionable Results
27 © 2008 OSIsoft, Inc. | Company Confidential Data Collection and Correlation Time-Series Data Characteristics Relational Attributes Condition Assessment Condition Assessment = f 1 (m 1 ) + f 2 (m 2 ) + f 3 (m 3 ) … + f n (m n ) Condition Assessment = f 1 (m 1 ) + f 2 (m 2 ) + f 3 (m 3 ) … + f n (m n ) Scorin g
28 © 2008 OSIsoft, Inc. | Company Confidential Current State Where are we ? Counter Based Maintenance based on movement for mechanical devices Condition based Maintenance Auto notification process based on data analysis Auto work alerts creating to Maintenance Auto create work in SAP PM
29 © 2008 OSIsoft, Inc. | Company Confidential Future State Future State Where are we going? Monitoring Points Breaker Pressure monitoring Temperature monitoring Pump motor counter monitoring LTC counter readings monitoring Transformer Nitrogen Pressure monitoring Hydran Gas Level monitoring Increase collection rates for data Increase points measured Infrastructure is in place to do any of the following: based on absolute values and rates of change
30 © 2008 OSIsoft, Inc. | Company Confidential Executive Summary (dashboard)
31 © 2008 OSIsoft, Inc. | Company Confidential
32 © 2008 OSIsoft, Inc. | Company Confidential Dashboard
33 © 2008 OSIsoft, Inc. | Company Confidential Gas and Oil Results
34 © 2008 OSIsoft, Inc. | Company Confidential CMMS Engineering Desktop
35 © 2008 OSIsoft, Inc. | Company Confidential
36 © 2008 OSIsoft, Inc. | Company Confidential Final Configuration SAP CGISAP Enterpris e License SharePoint RtWebParts Drill Down Capability OSIsoft The PI System
37 © 2008 OSIsoft, Inc. | Company Confidential Visibility to all key inside plant assets Consolidated asset inspection, test and maintenance data Consistent information base for comparative analysis Condition and performance algorithms to assist in decision making process Condition based maintenance work notifications Baseline record for future investments Conclusions Proactive Asset Management Enables
38 © 2008 OSIsoft, Inc. | Company Confidential Conclusions Proactive Asset Management Enables: US$ (Million) Years Savings !! Opportunities
39 © 2008 OSIsoft, Inc. | Company Confidential Conclusions Proactive Asset Management Enables Savings are derived from: Maintenance Plan Extensions 36% Condition Assessment Algorithms 26 % Counter Based Notifications 39% Drive Actionable Results!
40 © 2008 OSIsoft, Inc. | Company Confidential
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