Transcript Computerized Maintenance Management System

PSE&G
Condition-Based Maintenance
Angela Rothweiler
October 13, 2009
PI Seminar - Philadelphia
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Agenda
 Background
 Problem
 Solution
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Asset Registry
CMMS Functional Areas
Data Collection
Condition Assessment & Criticality
Inspection Process
Example
 Critical Success Factors
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Background
 Utility Overview
• New Jersey Based
• Total Assets ~ $14 Billion
• Total Revenue ~ $7 Billion
 Service Territory
• 70% of New Jersey’s
population
• 2.0 million Electric customers
• 1.6 million Gas customers
• 2,600 Square Miles
 Delivery Implementation
• 1999 – SAP
• 2000 - OMS, GIS & CAD
• 2002 - CMMS
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Problem
 No predictive maintenance program or strategy
 Significant liability risk and system outage potential from old
equipment vulnerable to failure
 Limited assessment
Asset Population by Division and Age Class Within
tools for determining
Equipment
asset condition
 Decreasing expertise in
both field maintenance
and engineering
 No formalized capital
spending program
 Asset Information in a
variety of disparate
systems
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Inside Plant Electric Asset Registry
 Equipment & Locations
• Class and Characteristics
• Nameplate
 Maintenance Plans
(56k Plans)
• Calendar-based
• Counter-based
• Condition-based
 Notifications
• Damage and Cause Codes
grouped by Equipment
 Equipment Visibility
• PM Plan Cost/Hours vs. Actual
• CM Cost
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Functional Areas
 Data Collection
• SAP Asset Information
• Time-Series Data Collection Application
• Diagnostic and Inspection Data
Data Collection
 Asset Analysis and Reporting
• Condition Assessment
• Work Prioritization
• Alerts / Notifications
Analysis & Reporting
Feedback
 Maintenance Management
• Measurement Points
• Maintenance Plan Modifications
• Notifications
2009 PI Seminar - Philadelphia
Raw data
PSEG T&D CBM
Measurement
points
Maintenance Management
Notification
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Data Collection & Consolidation
Distribution
SCADA
PI - OPC
Doble
Electrical
test results
Breaker
Tests
Transmission
SCADA
PI
ESOC PI
HDW
Diagnostic data
Transformer
loads
Delta-X
MV90
MDT
PI Manual Logger
Weekly substation inspection
2009 PI Seminar - Philadelphia
Hydran
Gas equipment results
PSEG T&D CBM
SAP-PM
Transformer oil
analysis
SAP order history and
technical object updates
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MDB Hierarchy Structure
MDB Properties & Aliases
Condition Assessment Overview
 Calculation Structure
• CA = F1(M1) + F2(M2) + F3(M3) + …
• Factors driven by data available
• Example Factors
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CM Cost & Count for Past 6 Months
Operation Count for Past 6/12 Months
Gas Analysis – Change over time
Average Load over Time
 Peer Groups
• Apply calculations by peer group
• Voltage, Class, Type
• Example Groups:
• 26KV – 69KV GCB
• 138KV+ Power Transformer
• LTC Vacuum Tanks
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Criticality
 Calculation Structure
• CA = F1(M1) + F2(M2) + F3(M3) + …
• SAP Static Factors
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Voltage
Location
Replacement Cost
Age
 Peer Groups
• Apply calculations by Equipment Class
• Example Groups:
• Gas Circuit Breaker
• Power Transformers
 Use as a tie breaker in CA evaluation
2009 PI Seminar - Philadelphia
Substation Inspection Process
Triggers
PI Manual Logger
database
Measurement
Document
Interface
PI-ML Tours
PI
Data
PM Orders
SAP PM
Measurement Points
Maintenance Plans
Equipment
Notifications
Order & Status
Updates
Tour
Tour and Values
CAD
Job and Status
PI Manual Logger
Data entry
CAD/PI
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SAP generates inspection order
CAD Auto-dispatch orders to operators groups
Operator collects inspection data via PI-ML and sends to PI
PI evaluates data and generates SAP notifications or transfers
measurement document to SAP via PI RLINK
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Alerts / Notifications
PI-ACE Algorithms monitor real-time &
weekly inspection data
Creates emails and SAP notification
Examples:
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Excessive LTC Operations
High GCB Temperatures
Low GCB Pressure
Low Transformer Oil Tank Levels
Low Nitrogen Cylinder Pressure
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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SAP BI Webinar 2009
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Algorithm Rules
Critical Success Factor
Right Vision (Business & Technical)
Organizational Changes to support
system
LOB Control
Change SME thought process
Tied success directly to SME and Asset
Engineers Goals
Constantly Measuring Inputs
2009 PI Seminar - Philadelphia
PSEG T&D CBM
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Q&A
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