1. Optimize Asset Implementation and Availability Using Condition Based Maintenance
Tom Hosea, OSIsoft

2. Objective & Evolution of Asset Management CBM Drivers
Agenda
Objective & Evolution of Asset Management
CBM Drivers
Why use real-time data
Implementation example & deployment results
SDG&E RtCBM Program
OSIsoft Enabling Technology
Business Process
Sample Capabilities

3. Asset Management : Objectives and Goals
Maximize asset performance at lowest life-cycle cost
Reduce maintenance and corresponding O&M expense
Dispatch skillful technicians for specific problems
Manage trouble response to minimize cost
Maximize equipment performance
Utilization
Reliability
Optimize asset replacement strategy
and
Eliminate or reduce catastrophic equipment failures

4. Evolution of Asset Maintenance
Condition Based Maintenance
Maintain when a potential failure is identified
Preventive Maintenance
Maintenance at a specific frequency
Calendar based Maintenance
Maintenance at a fixed frequency
Reactive Maintenance
Service assets as needed
Reactive
Proactive
Diagnostic/Analytic
1980’s
1990’s
21st Century

5. Why Integrate Real-time Data?
Better automated processes for CBM
Operations Benefits – provides access to the real condition of the asset, better utilize the asset
Maintenance Benefits – facilitates fine tuning of maintenance processes
Drill down to what is really driving the condition
Determine whether to send someone now or later

6. San Diego Gas & Electric (SDG&E)
RtCBM Program

7. Typical Implementation Overview
PI Manual Data Logger
Workstations
Workstations
ERP / MMS
RtPortal Thick (Smart) Clients
RtPortal Web-based Clients
Measurement Points
Asset
Definitions
OSIsoft Technology PI
Time Series Database
RtPortal Web-Server
Context Database
RLINK
Bi-directional Gateway
Maintenance Plans
Analytical Tools
Tasks
Order History
Standard Interfaces
PI to PI - OLEDB - OPC - COM connectors - Batch
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Work
Orders
Transm
SCADA
MV 90
Distr
Hydran
Doble
DeltaX

8. PSE&G’s Estimated Savings with OSIsoft-based CBM Deployment
Assessment
Notification
$300,000
Oil Diagnostics targeted 16 LTC’s, 5 had contact problems
$1.2M
5 Transformers were targeted and 2 were identified to have major issues
10 LTC’s were targeted and 1 had the potential to create major damage.
2005 Projected ~ $2M
$264,600
9 LTC’s and 2 GCB’s
$800,000
5 Transformers
2005 Projected ~ $1M
Problems discovered from Assessment:
Problems discovered from Notifications:
Controls out of Calibration
Leaky Blast Valves
Incorrect CMV Setting
Defective Controls on older LTC’s (Load Tap Changer – most expensive part of a Transformer) GCB – Gas Circuit Breaker
Defective Counters
Low Oil Levels
Cylinder Leaks
Hydran PPM exceeding limits
With real-time data, we can do even better!

9. SDG&E System Statistics
2 Generation Facilities (590 MW)
1,805 Electric Transmission Miles
18,000 Transmission Structures
120 Substations
906 Distribution Circuits
7,941 Underground Circuit Miles
6,875 Overhead Circuit Miles
220,362 Distribution Poles
145,764 Distribution Transformers
1,315,134 Electric Meters
CAISO
FERC
CPUC

10. SDG&E RtCBM Objectives
Minimize personnel dependency (resources & training needed for asset data analysis)
Provide a equipment monitoring and analysis platform for access to all data
Provide drill down navigation abilities through data integration
Notify personnel to respond to equipment conditions
Automated analysis
Automated trigger
Automated notification
Pager, , & Investigating Work Orders
Reporting capabilities

11. RtCBM Process Enhancement and More
Benchmark Equipment (with normalized data)
Refine equipment specifications
Design validation and equipment procurement practice
Provide insights into substation design & configuration geographical variations
Standardize Analysis – design trigger algorithms
Consider factors like asset age, environment, customer impact
Enhance operational and planning decision support – e.g. equipment impact due to load transfer
Enhance equipment utilization, performance trade-offs
Equipment benchmarks (with normalized data)
Refining equipment specifications design validation and new equipment procurement practice
Provide insights into substation design & configuration geographical variations
Standardization of analysis – designing & adopting trigger algorithms
Flexible application of numerous factors like asset age, environment, customer impact
Enhance operational and planning decision support – e.g. equipment impact due to load transfer
Further define equipment utilization, performance trade-offs

12. RtCBM – Data Integration
Weekly general inspections
LTC operations
Alarms, temperature, visual
Monthly equipment inspections
Operation counters
Temperature, Pressure
Voltage
Functional check
General asset
Rating
Age, Type, Design
Operating limits
Operational
Relays & Digital fault recorders
PQ Monitors
Specific equipment
Operating conditions
Stress factors
Trouble history
Maintenance data
Oil test data
Electrical test data
Operating speed
Real-time
Voltage & Current
Temperature
Bushing On-line Power Factor
Hydrogen in Oil
Simulated
System & Engineering
LTC’s (Load Tap Changer – most expensive part of a Transformer)
GCB – Gas Circuit Breaker

13. SDG&E RtCBM Architecture
Microsoft SharePoint Server
RtWebParts
User Interface
and
Analysis Tools
Maintenance PI Server
Algorithms
Alerts
Operations PI Server
Relational Databases
Maintenance
System
Dissolved
Gas Analysis
SCADA
Others
LTC’s (Load Tap Changer – most expensive part of a Transformer)
GCB – Gas Circuit Breaker
WiMax/ Wired LAN
Connection
On-line Monitors / IEDs
Real-time Equipment Data
Temperature
Winding,
Top Oil,
LTC
Bushing Monitors Phase A, B & C
Hydrogen/Water in Oil Monitor
LTC Tap
Position Indicator
16 Port Ethernet Gateway (DNP3)

14. Time-based to RtCBM – Circuit Breakers
Data Available
Weekly safety inspections
Monthly equipment insp.
Asset Data
Historical Data
Operating conditions
Stress factors
Trouble
Maintenance data
Test data (insul & elec)
Operational data
Relays & Digital fault recorders
PQ Monitors
Real-time data
Voltage & Current
I2T and Contact Wear
Operations Counter
Maintenance Intervals
Planned
Approach
Yr.
I2t Ampere Squared Seconds - A measure of thermal energy associated with current flow.
PQ Monitor – Power Quality Monitor
Yr.

15. Circuit Breaker Operations
Concerns
Proper fault clearing
Fault testing with a circuit breaker
Solution
Verify the health of CB
Contact wear
Insulation medium integrity
Bushings and accessories
Operating history
Use historical and real-time contact wear data (I2T) to make a decision
Substation Relays with
Circuit Breaker Monitor
16 Ports Ethernet Gateway (DNP3)
CB (Circuit Breaker) analysis
I2t is Ampere Squared Seconds - A measure of thermal energy associated with current flow.
On-line
Monitors
Ops. & Maintenance PI Server
Algorithms
Alerts

16. Transformer at Emergency Rating
TRANSFORMER Health Indices
Insulation Power Factor
LTC Application & Design
Oil Conditions
Bushing & Accessories
Operating History &
Conditions
POWER TRANSFORMER
Paper Insulation Health
Location of Paper Sample
Degree of Polymerization (DP)
NLTC – Phase A
586
NLTC – Phase B
737
69kV Bushing C
688
LTC’s (Load Tap Changer – most expensive part of a Transformer; a mechanical switching device)
GCB – Gas Circuit Breaker
DPv – Degree of Polymerization (number of repeat units in an average polymer chain at reaction time.)
New Insulation Paper: < DPv < 1300
Middle Aged Insulation Paper: DPv = 500
Old Age Insulation Paper: DPv < 251
Severely Degraded Insulation Paper: DPv < 151

17. Transformer at Emergency Rating
IEEE provides guidelines predicting the reduction in transformer life by running the transformer oil at temperatures above specifications.
Ptload are simulation results indicating the same. The purpose of this screen is to show that the actual performance of the transformer is much better than what is indicated in either the IEEE or simulation models.
The operating company can make more effective decisions about transformer operation and maintenance based on this data.
LOL – Loss of Life (Cumulative % of the life of the Transformer)
Comparison of hot spot rise over top oil
simulated versus actual
Top Oil Hot Spot LOL
IEEE
Ptload
Actual HS rise
Decision: Based on Transformer Unit Health and Real Time Conditions

18. Summary of RtCBM Expected Results
Operations Benefits
Avoid potential equipment failure
Increase asset availabilities
Respond to equipment alarms according to priorities
Maximize asset loading capabilities
Maintenance Benefits
Early warning and indication to address conditions
Reduce overtime on reactive maintenance
Minimize equipment outages
Asset Planning Benefits
Improve future equipment specification and application to maximize utilization and performance.

19. OSIsoft Enabling Technology

20. Rule Evaluation and Alert Notification
Configurable environment for “Knowledge Capture”
Algorithms should scale when adding assets
Flexible scheduling of algorithms
Alert Notification
Exception reporting
notification with escalation
Postmortem reporting with comments and sign off

21. Visualization, Integration and Navigation
A web-based presentation is preferred
Scalable: minimize the number of web pages
Reuse of existing ProcessBook graphics
Integration amongst data sources
Navigation hierarchy and drill-down
Benchmarking of assets of the same class
Intuitive: no tag names or query strings required

22. Working by Exception Integrated Asset Information (RtWebParts)
Alert Notification
(PIANO)
Work Order Generation
(RLINK)
Asset Reliability
(PI OLEDB and
RtReports)
Asset Information
Structure
(Foundation)
Real-time Rule
Assessment
(PI ACE\PIANO)
Improve Reliability

23. Asset Information Structure
Division Level
District Level
Site
Individual Asset
Asset Class

24. Asset Information Integration Hierarchy
Level 1
Level 2
Level 3
Level 4

25. Level 1: Maintenance Overview

26. Level 2: Site Detail

27. Level 3: Asset Detail

28. Level 4 : Rule Detail (PI)

29. Rule Detail (RDB) – Level 4

30. Maintenance Alert Notification

31. Asset Reliability Report

32. PSE&G CBM – Dashboard

33. PSE&G CBM – Analysis

34. Computer Based Maintenance Applications are evolving
Conclusions
Computer Based Maintenance Applications are evolving
Significant savings are available by moving from calendar based to real-time condition based maintenance
OSIsoft offers a product suite capable of solving these problems

35. Thanks You
Questions?