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PSE&G CMMS
(Computerized Maintenance Management System)
Foundation for Smart Grid
Modernization
Presented by:
Richard Wernsing – Manager, Asset Strategy
© Copyr i g h t 2013 OS Iso f t , LLC .
Agenda
• About PSE&G
• Problem
• Functional Areas
• Substation (CBM) Conditioned Based
Maintenance
• Benefits of CBM
• Engineering Desktop
• Expanding CBM to Underground Network
© Copyr i g h t 2013 OS Iso f t , LLC .
PSE&G Background
• Utility Overview
– New Jersey Based
– Total Assets ~ $14 Billion
– Total Revenue ~ $7 Billion
• Service Territory
– 323 Municipalities
– 70% of New Jersey’s population
– 2.2 million Electric customers
– 1.7 million Gas customers
– 2,600 Square Miles
© Copyr i g h t 2013 OS Iso f t , LLC .
Problem
• No predictive maintenance program or strategy
• Significant liability risk and system outage potential from
old equipment vulnerable to failure
Limited assessment tools for determining asset condition
Decreasing expertise in both field maintenance and engineering
No formalized capital spending program
Asset Information in a variety of disparate systems
© Copyr i g h t 2013 OS Iso f t , LLC .
Benefits Breakdown
These annual expenditures protect $1.7 B of inside plant assets and
full benefits after approximately five years.
Note:
Illustration depicts overall
changes in maintenance
investment strategy.Preventive
Maintenance
Corrective
Maintenance
Capital Rep.
Calendar Based
Preventive
Maintenance
Corrective
Maintenance
Failures
Condition Based
Preventive
Maintenance
Historical Today
Failures
Capital Rep
10%-20% Overall Reduction
© Copyr i g h t 2013 OS Iso f t , LLC .
Functional Areas of CMMS
• Data Collection and Consolidation– Diagnostic and Inspection Data – Time-series Data– Relational Data– Maintenance Data
Data Collection
Analysis & Reporting
Maintenance Management
Raw data
Measurement points
Notification
Feedback
Asset Analysis and Reporting– Condition & Criticality Assessment– Equipment Ranking– Work Prioritization
Maintenance Management– Measurement Points– Work Order Generations– Maintenance Planning
© Copyr i g h t 2013 OS Iso f t , LLC .
Condition Based Maintenance (CBM)
• Provides better insight into condition of assets
based on available data
– Operational
– Diagnostic
– Maintenance
– Nameplate/Characteristic
• Support system that assists in making repair,
maintain and replace decisions.
– It is NOT a “crystal ball” that predicts failures
– It does NOT put the process on “cruise control”
– It is NOT a “budget slashing” tool
© Copyr i g h t 2013 OS Iso f t , LLC .
Consolidate Data
PI PI
MV90
Hydran
Doble
SAP-PM
Diagnostic data
Delta-X
MDT
Transmission SCADA
Distribution SCADA
Transformer loads
PI Manual Logger
Substation Inspections
SAP maintenance and
equipment & locations
Gas & Oil
analysis
Gas Results
Breaker Tests
Electrical test results
GIS
Ratings, Solar &
Circuit Lengths
OMS
POR and
PPC
© Copyr i g h t 2013 OS Iso f t , LLC .
Build Asset Model and Correlate Data in PI AF
© Copyr i g h t 2013 OS Iso f t , LLC .
Build Algorithms in PI AF
© Copyr i g h t 2013 OS Iso f t , LLC .
Calculation Framework• Calculation Structure
– CA = F1(M1) + F2(M2) + F3(M3) + …
– Factors driven by data available
– Example Factors
• CM Cost & Count for Past 6 Months
• Count of Operations 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
© Copyr i g h t 2013 OS Iso f t , LLC .
Run Algorithms
© Copyr i g h t 2013 OS Iso f t , LLC .
CMMS Save helped avert an in service failure
Excessive gassing and over heating found on 3/1//2011
History of
CBM Score
© Copyr i g h t 2013 OS Iso f t , LLC .
Action and Results
T20 LTC excessive gassing and overheating problem identified by CMMS on 3/1/2011
Inspection showed coking contacts
Assembly cleaned and new contacts installed
Great find because T20 contacts would have failed when additional load was added during replacement of T10 transformer
Conservative Failure Avoidance Cost Saving = $1.5M– LTC = $150k cost & labor
– Transformer = $1.5M cost & labor
Final CBM score after refurbishment
© Copyr i g h t 2013 OS Iso f t , LLC .
CBM Benefits
• Extremely valuable system when you have
– You have $1.6B of installed assets with a
replacement value of $5.7B
– Average age of the assets exceeds 40 years
– All equipment is expected to be used and useful all
the time
– Maintenance expenditures erode earnings and
capital replacement provides for no new revenue?
• Justify millions of dollars in saving over past 7
years in equipment failure avoidance
© Copyr i g h t 2013 OS Iso f t , LLC .
Engineering Desktop Demo
© Copyr i g h t 2013 OS Iso f t , LLC .
Summary of Worst Performing LTCs
© Copyr i g h t 2013 OS Iso f t , LLC .
SME Knowledge of Asset
© Copyr i g h t 2013 OS Iso f t , LLC .
Algorithm Details
© Copyr i g h t 2013 OS Iso f t , LLC .
History
© Copyr i g h t 2013 OS Iso f t , LLC .
Assessing Asset Condition
Assessing Asset Condition
CircuitsSAIFI
UndergroundNetwork
Reliability
SubstationReliability
PoorestPerforming
Devices (PPD)
Advanced Loop
Scheme (ALS)
VisibilityMonitoring
Dynamic Transformer Monitoring
TransformersBreakers/Relays
© Copyr i g h t 2013 OS Iso f t , LLC .
Asset Health Score
© Copyr i g h t 2013 OS Iso f t , LLC .
Asset Health Score – Drill down
© Copyr i g h t 2013 OS Iso f t , LLC .
Assessing Asset Condition
Assessing Asset Condition
CircuitsSAIFI
UndergroundNetwork
Reliability
SubstationReliability
PoorestPerforming
Devices (PPD)
Advanced Loop
Scheme (ALS)
VisibilityMonitoring
Dynamic Transformer Monitoring
TransformersBreakers/Relays
© Copyr i g h t 2013 OS Iso f t , LLC .
SAIFI
Industry vs. PSE&G
0
0.2
0.4
0.6
0.8
1
1.2
2007 2008 2009 2010 2011 2012
PSE&G
Industry
© Copyr i g h t 2013 OS Iso f t , LLC .
Traditional 13 kV Recloser Loop Scheme
Self-Healing Loops
TieFdr #1 Fdr #1
Station #1 Station #2
Existing Configuration
© Copyr i g h t 2013 OS Iso f t , LLC .
Advance Loop Scheme (ALS)
451S
451S
651R 651R 651R 651R 651R
651R
651R651R651R651R
Station #1
Station #2
R FR
1
R
tie
FR
2
FR
3
FR
4
FR
5
FR
1
FR
2
FR
3
FR
4
Fiber
Optic
Cable
High Speed
Communications
© Copyr i g h t 2013 OS Iso f t , LLC .
Summary of Reliability BenefitsInnovations Current System Smart Grid
Customer
Segmentation
(SAIFI)System Average Interruption
Frequency Index
Average 1500
customers Impacted per
outage
Average 500 Customers
Impacted per outage
Single Phase
Tripping
(SAIFI) < 5 Minutes
System Average Interruption
Frequency Index
Not Implemented
Average 1500
customers Impacted per
outage
Average 167 single
phase customers
impacted per outage
Make Before Break
(MAIFI) >5 Minutes
Momentary Average Interruption
Frequency Index
Momentary Interruption
30-60 seconds
No Momentary
Interruptions
© Copyr i g h t 2013 OS Iso f t , LLC .
Comparing – SAIFI Improvements
Options Cost
Traditional Approach
Trim tree’s, replace equipment $6 - 12 M per loop
Smart Grid Technology
Limit risk, add communications (fiber), and
leverage technology$2 - 4 M per loop
Both options produce similar SAIFI results for the first year
© Copyr i g h t 2013 OS Iso f t , LLC .
Enhancements to SAIFI assessment
and asset management programs…
OpportunityRising SAIFI Trends are not adequately
being addressed with current
Asset Management Programs
SolutionLeverage
opportunitiesto improve toolsfor investment prioritization
BarriersCulture Change
System upgradesDedicated personnel
Securing funding
OutcomeA device based
program that has optimized
SAIFI reduction and spend
…will mitigate rising electric distribution SAIFI trends.
© Copyr i g h t 2013 OS Iso f t , LLC .
Poorest Performing Device (PPD) Program
Targeting extended customers interrupted, a two part
asset evaluation algorithm was developed, modeled after
our current inside plant CMMS system structure.
Frequency
•Number of occurrences
30%
CustomersInterrupted
•Number of customer interruptions
60%
Remediation Complexity
•Variance of cause codes
10%
I. Incident Evaluator Algorithm:
Device Health Score provides the basis for an initial prioritization of potential projects, subject to further field inspections and cost estimates as described below.
SAIFI Yieldon Investment(Yield Score)
Remediation Cost Estimate
SAIFI Benefit Validation
•Scope of work assessment by field
engineering / asset management
–SAIFI benefit validation
–Remediation cost estimates
II. Field Inspection, SAIFI validation and Cost Estimates:
Scope of work assessment in field provides basis for cost estimate and validation of SAIFI benefit.
Benefits and costs form basis for SAIFI Investment Yield calculation and final prioritization of projects.
© Copyr i g h t 2013 OS Iso f t , LLC .
Incremental SAIFI Benefit vs. Cumulative Cost
0.00
0.05
0.10
0.15
0.20
0.25
0.30
$- $20.0 $40.0 $60.0 $80.0 $100.0 $120.0 $140.0
Cost in $Millions
Inc
rem
en
tal
SA
IFI
Be
ne
fit
Reliability Base Spend plus Incremental Device Approach Spend ($M)
SAIFI Benefit
attained from Incremental Spend
© Copyr i g h t 2013 OS Iso f t , LLC .
Remediation Options Prioritized by SAIFI Yield
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101 106 111 116 121 126
Prioritized Remediation Projects
Yie
ld (
SA
IFI/$
Millio
n In
ve
ste
d
= Metro
= Central = Palisades
= Southern
SAIFI Yield (SAIFI Benefit/ $ Invested)
© Copyr i g h t 2013 OS Iso f t , LLC .
SAIFI Trending
Non-Weather Day (Blue Sky) vs Weather Day
0.63 0.64
0.69 0.69
0.76
0.70
0.84
0.78
0.66
0.43
0.470.45
0.500.47
0.510.48
0.54
0.210.18
0.24 0.250.23
0.19
0.35
0.24
0.70
0.420.42
0.24
0.27
48 49
95
7067
68
65 62 6253
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
SA
IFI
0
50
100
150
200
250
300
350
400
450
500
Da
ys
Overall SAIFI Non-Weather Day SAIFI (Blue Sky) Weather Day SAIFIWeather Days Log. (Weather Days) Log. (Overall SAIFI)Log. (Non-Weather Day SAIFI (Blue Sky)) Log. (Weather Day SAIFI)
* Weather Day Definition -
Temp >=90
OR any two of the following:
- 1" Liquid Precip
- Thunderstorms
- Sustained Wind >= 30 mph
- Wind Gusts >= 35 mph
Note: 2012 data is pro-rated based on 5 Year AverageData through 9/30/2012
0.49
0.30
0.19
59
© Copyr i g h t 2013 OS Iso f t , LLC .
Assessing Asset Condition
Assessing Asset Condition
CircuitsSAIFI
UndergroundNetwork
Reliability
SubstationReliability
PoorestPerforming
Devices (PPD)
Advanced Loop
Scheme (ALS)
VisibilityMonitoring
Dynamic Transformer Monitoring
TransformersBreakers/Relays
© Copyr i g h t 2013 OS Iso f t , LLC .
Networking Monitoring System
(NMS)
• Reduce restoration time for underground cables.
• Pattern recognition to determine type of fault.
• Visibility to all key underground network assets
• Consolidated asset inspection, test and maintenance data
• Consistent information base for comparative analysis
© Copyr i g h t 2013 OS Iso f t , LLC .
System Visualization
© Copyr i g h t 2013 OS Iso f t , LLC .
Vault Summary KVA, Amps and Status
© Copyr i g h t 2013 OS Iso f t , LLC .
Protector Backfeed
© Copyr i g h t 2013 OS Iso f t , LLC .
Networking Monitoring System
(NMS) Benefits
• Provides control and indication• Provides Condition Assessment for transformers
and network protector• Remote access to network relays for settings and
validation.• O&M savings
– OT savings (5% reduction in CM)– “Day priors” can be done via system rather than
by field crew– Improved response & turnaround during faults
© Copyr i g h t 2013 OS Iso f t , LLC .
26KV Underground Network Display
© Copyr i g h t 2013 OS Iso f t , LLC .
UG Transmission Action & Lifecycle
Strategy
Lifecycle
Analysis
Pipes
Average Circuit Score By
Asset
Condition Assessment at Asset Level to identify
troubled assets
Replacement Strategy at
Circuit Level
SplicesPumping
PlantsTerminators
Gas/Physical
Analysis
Age/DesignFluid/X-Ray
AnalysisFluid
Analysis
© Copyr i g h t 2013 OS Iso f t , LLC .
OH Transmission Action & Lifecycle
Strategy
Lifecycle
Analysis
Average Circuit Score By
Asset
Condition Assessment at Asset Level to identify
troubled assets
Replacement Strategy at
Circuit Level
TowersConductors
Age
Hardware Condition
Insulator Condition
Age
Structure Design
Hardware/Foundation
Condition
Paint Condition
© Copyr i g h t 2013 OS Iso f t , LLC .
Future Vision
• Cyber Security
• Asset Reliability Management System
• Outage Management
• Graphic Information System
• Mobile Data
• Risk Management
© Copyr i g h t 2013 OS Iso f t , LLC .
Asset Reliability Management
SystemTo Be Virtual Dispatch Center
CMMS PI SystemHDW
Metro
CentralPalisades
Southern
ESOC
OMS
GIS Asset Mgr’sEngineers/Planners DERC
Advanced
Applications
The overall initiative focuses on utilizing, improving and augmenting the overall capabilities of the Transmission Operation System while incorporating new technology, methodology, recognizing and capitalizing on business drivers and opportunities along the way.
© Copyr i g h t 2013 OS Iso f t , LLC .
The Future of GIS and OMS
Desktop Server Mobile Online
Promoting easy flow of information for better business
decisions
Asset
Management
Planning &
Analysis
Field
Mobility
Operational
Awareness
Collect, organize
& exchange data
Transform data
Into actionable
information
Get the
information
where it is most
needed
Foster a culture
That disseminates
knowledge
Thank you
© Copyright 2013 OSIsoft, LLC.
777 Davis St., San Leandro, CA 94577
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