1. Computerized Maintenance Management System (CMMS)
November 5, 2007
PSE&G INTERNAL USE ONLY

2. Agenda Business Overview Functional Areas Condition Assessment
Criticality
Electronic Inspection Process
Reporting
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3. Why CMMS?
Calendar-based preventive maintenance & Reactive corrective maintenance faced the following challenges
No predictive maintenance program or strategy
Standardizing the equipment replacement strategy
Significant liability risk and system outage potential from old equipment vulnerable to failure
Limited assessment tools for determining asset condition and maintenance efficiency
Decreasing expertise in both field maintenance and engineering
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4. Evolution of CMMS
Preventive
Maintenance
Corrective
Capital Rep.
Calendar-Based
Failures
Condition Based
Past
Present
Capital Rep
CMMS brings together existing and new technologies to address these challenges, as well as, providing the mechanism to shift maintenance activities from reactive to proactive through the use of multiple-method condition monitoring and trend evaluation
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5. Opportunity for savings
Motivation
Opportunity for savings
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6. (Transformers, Load Tap Changers, High-Voltage Breakers and Relays)
Role of CMMS
CMMS is a decision support system that assists in making repair/replace/maintain decisions.
(Transformers, Load Tap Changers, High-Voltage Breakers and Relays)
PSE&G INTERNAL USE

7. Actions Collect data Centralize data Analyze data
Create Actionable Information
Drive Results
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8. Benefits of CMMS Centralized Asset Registry
More effective work scheduling
Accurate repair histories
More time on PM work than on costly emergency repairs
Better utilization of capital budgets
Improve Productivity
Equipment Visibility
Better Analysis of Asset Performance
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9. Users System Matter Experts SAP Administrators LOB Administrators
Delivery Management
Maintenance Managers
Maintenance Supervisors
Planner / Scheduler
Maintenance Mechanics
Substation Operators
Chief Substation Operator / Operating Supervisor
System Planners
PSE&G INTERNAL USE

10. CMMS Systems SAP PM Module CAD PI Historian (UDS) PI Module Database
PI Interfaces (PI-Batch, COM Connector, OPC)
Sharepoint Services/RtWebParts
SQL Server
Business Object/Web Intelligence
PI Client Applications (Datalink & Process Book)
PSE&G INTERNAL USE

11. SAP PM Module Asset Registry Generate Maintenance Plans (56k Plans)
Calendar-based
Counter-based
Condition-based
Notifications
Damage Codes grouped by Equipment
Cause Codes
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12. Primary Functional Areas of CMMS
Data Collection and Consolidation
Diagnostic and Inspection Data
Time-series Data
Relational Data
Asset Analysis and Reporting
Condition & Criticality Assessment
Equipment Ranking
Work Priorization
Maintenance Management
Measurement Points
Work Order Generations
Maintenance Planning
Data Collection
Analysis & Reporting
Maintenance Management
Raw data
Measurement points
Notification
Feedback
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13. Data Collection
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14. Interfaces
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15. Analysis CM/PM Maintenance Analysis
Counter-based Conditions
Condition-Based Indicators
Peak Load Evaluation
Ad-Hoc Reporting Analysis
Maintenance Program Effectiveness Analysis
Asset cost profile
Asset maintenance profile
Asset Failure-Code Analysis
Capital replacement candidate identification
Preventive Maintenance Prioritization
Key Performance Indicators
PSE&G INTERNAL USE

16. Maintenance Management
SAP Counter-based Plans
Define Measurement Points
Create CBM Rules
Activate Maintenance Plans
Work prioritization
Drive work planning
Drive replacement planning
Analyze Contingencies to determine impact of work
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17. Condition Assessment (CA)
Analysis of available data to measure equipment condition
Equipment Classes
Transformers, Voltage Regulators & Phase Angle Regulators (981)
Breakers (26kv and above – 1,400)
Relays (11k)
Load Tap Changers (420)
Circuit Switchers (400)
Each class consists of 1 or more peer groups
Each peer group has a unique set of factors & weights
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18. CA (Cont’) Equations Example factors include:
CA = F1(M1) + F2(M2) + F3(M3) + …
Example factors include:
Average Load over time period
Last oil test results
Total CM cost over 6 months
Number of operations
Factor components dependent on peer group
Multiplier used to weight factor result
Very flexible in terms of definition and composition
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19. CA Requirements
Correlate Operational and Relational Data to Equipment and Functional Locations
Define peer groups and IPE asset registry
Automatically update Equipment modules from SAP weekly download
Automatically update peer group equipment from SAP weekly download and CMMS Business rules stored in SQL server
Schedule calculations to be run on a periodic basis or on demand
Store output results in SQL server or reporting purposes
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20. Data Correlation
Operational Data
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21. Data Correlation (Cont)
Characteristic Data
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22. CA Algorithms
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23. CA Peer Groups
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24. CA – Generator
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25. Factor Types DB-SQL Query
PI Calculation (max, min, total, stdev, average, etc.)
PI Counter (rollover & filter)
PI Time Filter (transformer % normal load rating)
Relay Order Costs (average cost to schema)
PM Performance (PM performance compared to expected cycle)
LTC Thru Neutral
Fixed Value (constant)
Passed Value (same DB-SQL w/no interpretation)
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26. CA Data Sources SAP PM Module DeltaX Doble Diagnostic Data Collection
CM Order History
Equipment Characteristics
Measurement Documents
Cause and Damage Codes
Diagnostic Data Collection
Megger, Ductor and Timing Tests
PI Historian
Weekly Inspection Counter and Runtime Readings
Weekly Inspection Transformer Top Oil Temps
Weekly Inspection Transformer Peak Amp Readings
ESOC and MV90 Load Data
Hydran PPM
DeltaX
Gas and Fluid Tests
Doble
Electrical Tests
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27. CA Summary Report
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28. CA Detail Report
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29. CA Work Flow SME Review Top 10/20 Worst Assets SMEs Investigate
or Verify Data
Results
CA & Criticality
Monthly Reports
are Posted
SME Works with
the SAP LOB
Admins. to Create Type C
PM Work Orders
Maintenance Department
Schedules and Completes
the Work
Maintenance Supervisors
Report their findings
back to the SMEs
SME Document Findings
& Determine if Algorithms
Need Updating
PSE&G INTERNAL USE

30. Criticality Equipment Classes
Transformers, Voltage Regulators & PARs (981)
Breakers (all breakers – 4,900)
Relays (11,000)
Factors and weights are the same for each class
Calculated via DTS from SAP data
Algorithm
F1(M1) + F2(M2) + F3(M3) + …
Factors
Age
Size
Voltage
Load in # Normal Rating
Type of Customer Impacted
Replacement Cost
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31. Work Prioritization
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32. Diagnostic Data Collection
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33. Electronic Station Inspections
Triggers
PIML/CAD
Station Inspection
- Measurement
Points
CBM Rules
- Equipment
SAP PM
PM Orders
Measurement Document Interface
CMMS
PI UDS
PI ACE
RLink
Notifications
MDT
AT&T Wireless GPRS
PSE&G INTERNAL USE

34. Station Inspection Requirements
CAD/SAP
Auto-generate weekly inspection orders with a due date of +7 days (SAP)
Auto-generate monthly (customer) inspection orders with a due date of +30 days (SAP)
Auto dispatching of inspection orders with attached route to MDT (CAD)
Group inspection orders by division/reporting location (CAD)
Suspend data entry for a given route (CAD)
PI ACE/RLink
Evaluate raw data (ACE)
Trigger SAP notifications
Transfer measurement documents to SAP PM Module
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35. Station Inspection Req. (cont)
PIML Administrator
Create, modify and delete routes
Access and search time-series tag definition library for assigning points to a route
Group points by equipment
Assign alarm limits to each point (high, low, high high & low low)
Assign system states to a route (Broken, Unable to Read, etc.)
Define digital state sets (Open/Closed)
PSE&G INTERNAL USE

36. Station Inspection Req. (cont)
Operator
Require user ID when accepting route
Default all tags within the route to the same timestamp (time the route was accepted)
Allow for viewing of previous values
Allow for entry of station comments
Prompt for conformation when analog values are entered outside of limits
Does not allow input of analog values outside of instrument's range
Provide data validation for each point
Provide a means for downloading and uploading routes within a truck or station (CAD-GPRS)
PSE&G INTERNAL USE

37. CGI-CAD Inspection Process
SAP PM Module
Operator
Completion Records
Orders
CAD Module
Job and Status
MDT
Route and Values
CAD PI
Route Requests
XML
PI Manual Logger
Chief Operator
Create SAP Order
Create CAD job
Get PI-ML Tour
Send Job to MDT
Accept Job
Send Tour
Conduct Tour
Send Tour to CAD
Complete order in SAP
Send Tour to PI-ML
Update PI UDS
XML
CDPD over RF
Point Values
PI UDS
Point Definitions
Engineer doing analysis
ML Database
PI Archive
PSE&G INTERNAL USE

38. Advanced Computing Engine (ACE)
VB Environment for developing sophisticated equations
Group equipment by aliases (reading)
Apply set of equations to groups of equipment
Create notification or trigger RLink for transfer of measurement docs or creation of notifications
Allow calculation to be run on a periodic basis or based on a change to the raw value
Turn on or off equations for individual equipment
PSE&G INTERNAL USE

39. Notification Calculations
Hydran PPM Rate of Change
Excessive LTC Operations
Excessive Runtime Readings
High Breaker Temperatures
Breaker Filling Pressure
High or Low Transformer Oil Levels
Low Transformer Nitrogen Cylinder Pressure
Low Transformer Nitrogen Pressure
PSE&G INTERNAL USE

40. PI RLink – SAP PM Interface
RLink triggers notifications in SAP and sends measurement documents that drive Counter-based maintenance plans.
RLINK
Service
Measurement Document
State tag & Current Value
Tag references
Measurement Point
FLOC or Equipment
PI – UDS
ACE
RLINK Configuration
Maintenance Plan
RLINK Configuration
ACE Event-based Equations update state tag from raw value
State tag determines when to send MD
RLink updates point configuration: short text, priority and raw value
RLink triggers notification in SAP or sends measurement document
Notification
or Order
PSE&G INTERNAL USE

41. Reporting Requirements
Periodically extract relational data from the SAP PM module and place in a relational database for reporting
Provide the capability to create Lists, Bar charts, Trends and attribute frequency reports
Allow for multiple points and multiple data sources to be used in the creation of a single report.
Allow multiple graphs to be placed on the same report.
Save and execute report definitions by schedule or on demand
Accept parameters from the user at run-time such as sort criteria, query filters
Provide the capability to perform drill-downs
Allow for grouping and sorting
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42. Platforms Web Intelligence Platform Datalink Process Book Displays
Inspection Data
Equipment Characteristics
Condition & Criticality
Diagnostic Data Collection
Datalink
Low Transformer Nitrogen Cylinder Pressures
Excessive LTC Counts
Excessive Breaker Runtimes
Substation Loading
Process Book Displays
Trending
On-line Diagrams
PSE&G INTERNAL USE

43. RCM Reports Business Object Platform Age Profile
CM Calls within PM Cycle
Code Analysis
Maintenance Cost
Maintenance Cost Performance
Percent PM Complete
PM-CM Cost Ratio
Repeat Calls
Replacement Cost Profile
Work Orders Due and Overdue
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44. PM/CM Cost Ratio
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45. Maintenance Performance
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46. RCM Reports - Benefits Sophisticated RCM analysis of SAP data
Provides Equipment Visibility
Optimize PM $ and Reduce CM $
Measure maintenance plans effectiveness by:
equipment class,
manufacturer,
models,
age, etc..
Identify specific problems areas
Revise maintenance plans
Implement corrective program
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47. Process Book Displays
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48. Another Process Book Example
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49. PSE&G INTERNAL USE ONLY
Questions?
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