Asset Optimization and Condition Based Maintenance Ann Moore

Asset Optimization and Condition Based Maintenance Ann Moore Business Development Executive OSIsoft

Agenda • Objective & Evolution of Asset Optimization • CBM Drivers • Why use real-time data • PSE&G implementation & deployment results • SDG&E Rt. CBM Program • OSIsoft Enabling Technology – Business Process – Sample Capabilities Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 2

Objectives for Asset Optimization Maximize asset performance at lowest life-cycle cost 1. Reduce maintenance and corresponding O&M expense – Dispatch skillful technicians for specific problems – Manage trouble response to minimize cost 2. Maximize equipment performance - utilization - reliability 3. Optimize asset replacement strategy and 4. Eliminate or reduce catastrophic equipment failures Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 3

Evolution of Asset Management 1. Traditional asset management approaches - issues limitations 2. Evolution of maintenance practices Future Present Past • Interval based – Time based – Counter based • • • Condition based Real-time Condition based Future Asset Management Practice Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 4

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 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 5

Typical Implementation Overview PI Manual Data Logger Workstations Rt. Portal Thick (Smart) Clients Rt. Portal Webbased Clients ERP / MMS Measurement Points Asset Definitions OSIsoft Technology PI - Time Series Database Analytics Contextual Database Tools RLink Bi -directional Gateway Rt. Portal Web. Server Tasks Standard Interfaces PI to PI - OLEDB – OPC-API - COM connectors - Batch Delta. X Hydran Doble Dist SCADA Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. MV 90 Mntc Plans Trans SCADA Substation Gateway Substation Server Gateway Server Order History Maintenance Orders 6

PSE&G (Public Service Electric & Gas) CMMS (Computerized Maintenance Management System) Copyright © 2007

WHY? Inside Plant (Transformers, Breakers and Relays) What do you do when… ØYou have $1. 1 B of installed plant with a replacement value of $4. 4 B ØAverage of the assets exceeds 40 years ØAll equipment is expected to be used and useful all the time, and ØMaintenance expenditures erode earnings and capital replacement provides for no new revenue? Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 8

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

Benefits Breakdown 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 Preventive Maintenance Historical Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. Failures Corrective Maintenance Condition Based Preventive Maintenance Calendar-Based Preventive Maintenance Note: Illustration depicts overall changes in maintenance investment strategy Today 11

PSE&G’s Estimated Savings with PI-based CBM Deployment Assessment • 2003 - $300, 000 – Oil Diagnostics targeted 16 LTC’s, 5 had contact problems • 2004 - $1. 2 M – 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. Notification • 2003 - $264, 600 – 9 LTC’s and 2 GCB’s • 2004 - $800, 000 – 5 Transformers • 2005 & 2006 > $1 M • 2005 & 2006 > $2 M With real-time data, we can do even better! Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 12

SDG&E (San Diego Gas & Electric) Rt. CBM Program Copyright © 2007 OSIsoft, Inc.

SDG&E – System Statistics F E R C C AI S O n 2 Generation Facilities (590 MW) n 1, 805 Electric Transmission Miles n 18, 000 Transmission Structures n 130 Substations C P U C n 906 Distribution Circuits n 7, 941 Underground Circuit Miles n 6, 875 Overhead Circuit Miles n 220, 362 Distribution Poles n 145, 764 Distribution Transformers n 1, 315, 134 Electric Meters Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 14

SDG&E Rt. CBM 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, Email & Investigating Work Orders – Reporting capabilities Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 15

Rt. CBM 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 tradeoffs Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 16

Rt. CBM – Data Integration • Weekly general inspections • Specific equipment – 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 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. – – – – 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 17

SDG&E Rt. CBM Architecture Microsoft Share. Point Server Rt. Web. Parts User Interface and Analysis Tools Maintenance PI Server Algorithms Email Alerts Relational Databases Operations PI Server Maintenance System SCADA Wi. Max/ Wired LAN Connection RTU Dissolved Gas Analysis Others Non-Scada Data On-line Monitors / IEDs Real-time Equipment Data 16 Port Ethernet Gateway (DNP 3) Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. Temperature -Winding, -Top Oil, -LTC Bushing Hydrogen/ Monitors Water in Oil Phase A, B & C Monitor LTC Tap Position Indicator 18

Time-based to Rt. CBM – 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 – I 2 T and Contact Wear – Operations Counter Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. Maintenance Intervals Planned Approach 3 6 9 Yr. 19

Circuit Breaker Operations Concerns Substation Relays with Circuit Breaker Monitor • 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 (I 2 T) to make a good decision Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 16 Ports Ethernet Gateway (DNP 3) On-line Monitors Ops. & Maintenance PI Server Algorithms Email Alerts 20

Transformer at Emergency Rating TRANSFORMER Health Indices • Insulation Power Factor • LTC Application & Design • Oil Conditions POWER TRANSFORMER • Bushing & Accessories • Operating History & Conditions Paper Insulation Health Location of Paper Sample Degree of Polymerization (DP) NLTC – Phase A 586 NLTC – Phase B 737 69 k. V Bushing C 688 New Insulation Paper: Middle Aged Insulation Paper: Old Age Insulation Paper: Severely Degraded Insulation Paper: Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 1000 < DPv < 1300 DPv = 500 DPv < 251 DPv < 151 21

Transformer at Emergency Rating Comparison of hot spot rise over top oil simulated versus actual Top Oil Hot Spot LOL IEEE 105 176. 149 Decision: Based on Transformer Unit Health Ptload 105 145. 039 and Real Time Conditions Actual HS rise 106 131. 014 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 22

Summary of Rt. CBM 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. Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 23

OSIsoft Enabling Technology Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 24

Real-time CBM Process Integrated Asset Information (Rt. Web Parts) Alert Notification (Rt. Alerts) Work Order Generation (RLINK) Asset Information Structure (PI and RDB) Real-time Rule Assessment (PI ACE) Improve Reliability Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. Asset Reliability (PI OLEDB and Rt. Reports) 25

Asset Information Structure Division Level District Level Site Asset Class Individual Asset Copyright ©

Asset Information Integration Hierarchy Level 1 Maintenance Overview Level 2 Site Detail Level 3 Asset Detail Site Detail Asset Detail Level 4 Rule Detail Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. Rule Detail 27

Maintenance Overview – Level 1 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights

Site Detail – Level 2 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights

Asset Detail – Level 3 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights

Rule Detail (PI) – Level 4 Copyright © 2007 OSIsoft, Inc. Company Confidential. All

Rule Detail (RDB) – Level 4 Copyright © 2007 OSIsoft, Inc. Company Confidential. All

Maintenance Alert Notification Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 33

Asset Reliability Report Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 34

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 Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved. 35