1. Asset Optimization and Condition Based Maintenance
A mature workforce. Aging assets. That’s the reality for today’s many industries, including power industry. The utility industry is changing. They need to run the traditional regulated business in a competitive market? How do you reduce the maintenance cost? How do you manage your investment and assets strategically? The technology plays an important role. And how can technology provide the answers? Today, I’m going to show you, OSIsoft RtPM PI provides the answers. Maintenance has to be performed, that’s a given. But how do you run the maintenance efficiently, reduce the cost, at the same time, improve the safety and reliability. The answer is: Real-time Condition-base Maintenance.
Ann Moore
Business Development Executive
OSIsoft

2. Agenda Objective & Evolution of Asset Optimization CBM Drivers
Why use real-time data
PSE&G implementation & deployment results
SDG&E RtCBM Program
OSIsoft Enabling Technology
Business Process
Sample Capabilities
Asset Management, that’s the hottest topic today. How to manage your assets effectively? Why Condition-base Maintenance? Why Real-time Condition-base Maintenance? I’ll show you some industry examples and especially San Diego Gas & Electric Company’s RtCBM pilot project. And how OSIsoft technology can do the magic and help you achieve your goals.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

3. Objectives for Asset Optimization
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
Reduce cost
Utilize the equipment more efficiently and improve its performance
Strategically improve the long-tem planning
Improve the system reliability and customer service and customer satisfaction
4. Eliminate or reduce catastrophic equipment failures
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

4. Evolution of Asset Management
Traditional asset management approaches
issues
limitations
Evolution of maintenance practices
Future
Present
Past
Interval based
Time based
Counter based
Condition based
Real-time Condition based
Future Asset Management Practice
Traditional asset management has some issues…it’s time-based, and it doesn’t have data to provide equipment utilization and operating status.
Then it transitions from time-based to condition-based. Further more, with real-time data, to provide more insights of the equipment assets, it really changes the way to manage the assets
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

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
Everyone likes automated processes, no one wants to do things manually anymore. With real-time data available, it will help the operations people to make better decision, and the operators are more confident to operate the system.
On the maintenance side, you know what’s really happening out there, should I send the crew now, or can I wait?
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

6. Typical Implementation Overview
Workstations
RtPortal Thick (Smart) Clients
PI Manual Data Logger
RtPortal Web-based Clients
ERP / MMS
Measurement Points
Asset
Definitions
OSIsoft Technology
PI - Time Series Database
Contextual Database
RtPortal
Web-Server
RLink Bi-directional Gateway
Mntc Plans
Analytics Tools
Tasks
Order History
Standard Interfaces
PI to PI - OLEDB – OPC-API - COM connectors - Batch
This is the typical architecture.
In the center, that’s OSIsoft RtPM technology.
Then we have 460 standard interfaces available to connect to all different systems (like transmission and distribution SCADA), data sources or devices.
After you collect the real-time data into PI, you can use ACE-Advanced Computing Engine to calculate the algorithm, then trigger the events, through RLINK, connect to ERP system (like SAP) or MMS (Maintenance Management System), to generate maintenance work orders.
Not every site has the communication. So sometimes we send the crew out in the field to visit the site, capture the data, and feed it back to PI using Manual Logger.
Then we have SharePoint RtPoral/RtWebParts web portal to provide user interfaces (graphics or reports) to end users.
Not all the substation data is in SCADA. Actually only a very small portion is for SCADA and operations. You have lots and lots of data that is very important for planning, maintenance and system protection, but you don’t want to burden your SCADA. So you collect them directly into PI (bypass your SCADA) though the gateways.
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Substation Gateway Server
Maintenance
Orders
DeltaX
Hydran
Doble
Dist
SCADA
MV 90
Trans
SCADA
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

7. (Public Service Electric & Gas) (Computerized Maintenance
PSE&G
(Public Service Electric & Gas)
CMMS
(Computerized Maintenance
Management System)
Now I’m going to show you San Diego Gas & Electric Company’s Real-time Condition-Based Maintenance program. I used to work for SDG&E. In January, 2006, I left SDG&E and joined OSIsoft. I was in charge of SDG&E Grid Operations real-time control system and PI system. So I’m very familiar with this pilot project and SDG&E’s operations.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

8. WHY? Inside Plant (Transformers, Breakers and Relays)
What do you do when…
You have $1.1B of installed plant with a replacement value of $4.4B
Average age of the assets exceeds 40 years
All equipment is expected to be used and useful all the time, and
Maintenance expenditures erode earnings and capital replacement provides for no new revenue?
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

9. Equipment Age Profile Transformers Total – 955 units
Breakers Total – 4578
Average Age Years
Average Age Years
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

10. Annual Benefits Projected Savings Failures Corrective Maintenance
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

11. Benefits Breakdown 10% Overall Reduction
Annual expenditures protect $1.1 B of inside plant assets and full benefits after approximately five years
Capital Rep.
10% Overall Reduction
Failures
Capital Rep
Corrective
Maintenance
Note:
Illustration depicts overall changes in maintenance investment strategy
Failures
Corrective
Maintenance
Preventive
Maintenance
Condition Based
Preventive
Maintenance
Calendar-Based
Preventive
Maintenance
Historical
Today
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

12. PSE&G’s Estimated Savings with PI-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 & 2006 > $2M
$264,600
9 LTC’s and 2 GCB’s
$800,000
5 Transformers
2005 & 2006 > $1M
Public Service of Electric and Gas in New Jersey, shared its PI-based CMMS (Computerized Maintenance Management System) success story with us at last year’s PI T&D users group meeting in Rhode Island. Their project is very interesting. They classified each equipment, assigned different weight or factor, calculated the algorithm, when it hit certain threads hold, it triggered their SAP system, to generate the work order automatically.
On the left hand side, they shared with us the money saved on assessment.
On right hand side, it shows the money saved on early notification to prevent the problems from happening.
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
That is very beautiful.
But if we have more real-time data, we can do even better.
With real-time data, we can do even better!
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

13. (San Diego Gas & Electric)
SDG&E
(San Diego Gas & Electric)
RtCBM Program
Now I’m going to show you San Diego Gas & Electric Company’s Real-time Condition-Based Maintenance program. I used to work for SDG&E. In January, 2006, I left SDG&E and joined OSIsoft. I was in charge of SDG&E Grid Operations real-time control system and PI system. So I’m very familiar with this pilot project and SDG&E’s operations.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

14. SDG&E – System Statistics
2 Generation Facilities (590 MW)
1,805 Electric Transmission Miles
18,000 Transmission Structures
130 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
FERC
CAISO
CPUC
Look at the investment and assets one utility has? A lot. Some of the equipments were designed for 40-year lifespan. They are old. How do you extend the longevity of the equipments, bring the value now and over time.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

15. SDG&E RtCBM Objectives
Minimize personnel dependency (resources & training needed for asset data analysis)
Provide equipment monitoring and analysis platform to access 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
SDG&E has a 150K-tag PI server and they have lots and lots of data in PI.
So you have lots and lots of people monitor lots and lots of data. Different people interpret the data differently, so you want to minimize the dependency or discrepancy. You want to use computers to monitor, not human to monitor. You want to transfer the human experience, knowledge, intelligence and skills into computer as much as possible. Then you can provide the standard analysis, calculation and automatic alarming/alerting and reporting.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

16. RtCBM Process Enhancement and More
Equipment benchmarks (with normalized data)
Refining equipment specifications design validation and new equipment procurement practice
Provide insights into substation design & configuration
Standardization of analysis
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
Even more benefits…
With more real-time equipment data, you can also compare the equipment benchmarks, manufacturer-advertised vs. real-time benchmark. What are the equipments under-performing? What are the equipments always more efficient? It helps the fine-tuning. Maybe if we design or configure it differently, it will behave differently?
We can also utilize flexible applications that take advantage of different factors, like asset age, environmental or customer impact, into consideration.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

17. RtCBM – Data Integration
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
System & Engineering
Simulation
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
Data Integration is very important. In SDG&E, they get all the data needed into PI (directly or indirectly), to help them make better decision. For the users, it’s one-stop shop.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

18. SDG&E RtCBM Architecture
Microsoft SharePoint Server
RtWebParts
User Interface
and
Analysis Tools
Maintenance PI Server
Algorithms
Alerts
Relational Databases
Operations
PI Server
Maintenance
System
Dissolved
Gas Analysis
Others
SCADA
This is SDG&E’s Real-time Condition-Base Maintenance architecture. The most important part is on the lower-right corner, what we called non-scada data (non-operations data from Intelligent Engineering Devices). We use gateways to bypass SCADA to collect all the data directly into PI.
Again, we use automatic calculations and alerts, use RtWeb parts to provide the user interface and analysis tools.
Not all the data needs to be in PI. Some relational and transactional databases are all over the corporate or headquarter, but PI can access it as needed. As long as our users can see everything in front of them, they don’t care how PI gets it for them. And that’s the beauty of PI.
WiMax/ Wired LAN
Connection
Non-Scada Data
On-line Monitors / IEDs
RTU
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)
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

19. 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
Planned
Approach
Maintenance Intervals
Yr.
Now I’ll give you two practical examples.
The first one is related to “circuit breakers”.
On the left hand side, we’re getting all the data available associated with circuit breakers, including the operating conditions, operations counter, and wear-and-tear, etc.
Normally every three years, we would perform a major overhaul equipment replacement. Hopefully with more real-time information available, by doing some frequent inspections, minor checkups, we can extend the overhaul from three to every six years, possibly even eliminate the overhaul in the future. It’s a more proactive, predictive and preventive vs. reactive approach.
Yr.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

20. Circuit Breaker Operations
Substation Relays with
Circuit Breaker Monitor
Concerns
Proper fault clearing
Fault testing
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 good decision
16 Ports Ethernet Gateway (DNP3)
For operations, to do the proper fault clearing is not easy.
Say, if you had a breaker tripped open (there is an outage out there), normally the first thing you tried to do is to close it right away. Then it opened again, without knowing what’s going on, you closed it again. You tried that a few times and it didn’t work, finally you had to send someone out to the substation and check the problem. This open-close/open-close is called “fault testing”, is very stressful for a circuit breaker.
But with more data available with this breaker, by looking at its operating history, you know this breaker is healthy or it is problematic.
So we say, more data -> better decision. You have more data, it can help you make a quick and better decision.
On-line
Monitors
Ops. & Maintenance PI Server
Algorithms
Alerts
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

21. 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
Another example is related to Transformer.
Utilities consider transformers as very valuable assets, due to the cost. Normally they don’t have 100% redundancy because it’s very expensive. So if you lose one, either you let it out (which is an outage), or the other one has to pick up the load. But what happens if it’s running at the peak, say, 85% loading, when you lose one, that means the other one that picks up the load from the malfunctioning transformer, has to run 170% load over its normal rating. Can you take that risk? Is the transformer healthy enough, strong enough? How long can I run it with overload condition? How confident am I? What decision should I make? Let it out for a few hours until the crew repair it? Or I can take the risk to reduce or avoid the outage, at the same time, to maintain the safety and reliability?
New Insulation Paper: < DPv < 1300
Middle Aged Insulation Paper: DPv = 500
Old Age Insulation Paper: DPv < 251
Severely Degraded Insulation Paper: DPv < 151
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

22. Transformer at Emergency Rating
This is a real example from SDG&E, happened in May, last year.
They lost one transformer. With more information available, like top oil temperature, hot spot temperature, Loss of Life, plus temperature profile and load profile, they were able to make the decision to avoid the outage based on real-time data. In this case, the operators were more confident to run the operations and make better decision. Without the 4-6 hours of outage, it maintained the system reliability, increased the company revenue (because meters still running), and improved the customer satisfaction. This is a great benefit to the company.
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
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

23. 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.
Summary.
Operations: reliability, availability, automatic alarming.
Maintenance: proactive, reduce outages
Improve short-term and long-term planning
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

24. OSIsoft Enabling Technology
Now you’re going to say, “Show Me” how do we do it?
So we’re going to show you how OSIsoft RtPM PI can help you with all we were just talking about.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

25. Real-time CBM Process Integrated Asset Information (RtWeb Parts)
Alert Notification
(RtAlerts)
Work Order Generation
(RLINK)
Asset Reliability
(PI OLEDB and
RtReports)
Asset Information
Structure
(PI and RDB)
Real-time Rule
Assessment
(PI ACE)
First, classify and define asset information by using module database to create structure and hierarchy.
Then, using ACE (Advanced Computing Engine) to define the rules and algorithms.
Set automatic alarms/alerts and trigger the work order.
Use RtWebPart to get all the asset information/data, integrate together and present it to the users.
Generate the reports.
But that’s not the end of it.
The whole process is a continuous process, no beginning point and no ending point. After the report, we evaluate it and refine the rules/algorithm and we make more improvement to go on.
Next, we’re going through each process to show you all the details.
Improve Reliability
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

26. Asset Information Structure
Division Level
District Level
Site
Individual Asset
Asset Class
Define the asset information structure, attributes and hierarchy using module database, and AF (Analysis Framework). Later the new “Foundation” will combine module database and analysis framework, and provide more features.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

27. Asset Information Integration Hierarchy
Level 1
Level 2
Level 3
The 4-level hierarchy, from maintenance overview, site detail, asset detail and rule detail, I’ll go through each level in details.
Level 4
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

28. Maintenance Overview – Level 1
The first level, maintenance overview.
You have the region and substation hierarchy using RtTreeview WebPart, point-and-click each regional district, it will give you the maintenance status of the substations within the region. Green is okay, yellow is to pay attention, and red is warning.
Then you have RtTable WebPart to show the repair information, and history.
The bottom is the recent work orders.
These are all using our standard RtWebParts.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

29. Site Detail – Level 2 Site Detail:
You define the hierarchy for each site, with substation diagram to show real-time data.
Then you can see the Contact information. We can also use the new RtMessenger to check who’s online, and send the Instant Message to whoever is on duty.
Some of the field inspections being done in the old days, are all in paper format. But that’s okay. We scanned it to PDF format and stored it into the computer. So when we want to look at it, it brings up the electronic format. So there is no paper or no manual work anymore.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

30. Asset Detail – Level 3 Level 3 is Asset Detail.
This shows the asset current operations. We define for each asset, analysis algorithm and calculation rules to set the alert triggers. The example also shows the equipment health and recent work orders.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

31. Rule Detail (PI) – Level 4
We provide the analytical information and define rule detail. Algorithm, time range, alert level and notification list,
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

32. Rule Detail (RDB) – Level 4
Not all the information needed is stored in PI (like analysis history in the lab). But we can use OLEDB to access any relational database and present it in PI to the users.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

33. Maintenance Alert Notification
This is using RtAlert (our standard tool) to configure and set up alert. No programming is needed. It’s all user-configurable.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

34. Asset Reliability Report
The last one is report.
This is using the standard RtReport. Since all the dataset (to define the rule criteria or algorithm) being created in RtBaseline Services. When you generate the report, you can re-use those existing datasets without re-creating a new one. That’s very easy and very convenient to do.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

35. Summary
Leveraging your investment and resources by utilizing the PI System…
Servers
Analytics
Visuals
Expand the value from Operations, Engineering, Protection, Maintenance, and Planning, to…
Enterprise
The message we are trying to convey is…
You already have PI, you already invested in PI, and your staff are already familiar with PI tools. We can build any more applications or projects based on the existing same platform.
Value now, value over time.
The PI-based platform is scalable and we can grow and expand it into a true enterprise system, and it’s an enterprise solution for your entire organization.
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.

36. THANK YOU!!
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.