Asset Condition Assessment and Analyticsemmos.org/prevconf/2014/Asset Condition Assessment...Data Analytics o Real-time monitoring, simple trending, and calculations Reactive Plus:

© Structure Consulting Group, LLC. Confidential and proprietary .

Asset Condition Assessment and

AnalyticsEMMOS Training

1

September 10, 2014


Introductions

2

Bob Knox

(302) 545-4656

[email protected]

mailto:[email protected]


Agenda

• Focus

•PI Technology Review

•Maintenance Maturity Model

•Conclusion

•Q&A

3


Focus

4

• Introduce a Maintenance Maturity Model through an evolution of asset monitoring, data analysis, and organizational value

• Learn how utilities are leveraging their PI system for asset monitoring, condition assessment, and condition based maintenance

• Identify ways in which a utility can better utilize their own data for improved maintenance processes


Industry Dynamics

5

Massive Transmission Investment driven by Renewables

Aging Utility Infrastructure and Workforce

Higher Regulatory Scrutiny of Outages

Demand Response to Climate Changes

“Our existing energy technologies and policies were designed for a 20th

century climate. To weather the extremes of a 21st century climate, we need to a 21st energy system…”

Forbes Magazine, July 2013


Information and Operation Technology Enablers

6

Evolution and Expansion of IED, Monitoring, and Sensing Technologies

Big Data Infrastructure and Analysis

Improved Asset Health Visualization and Decision Support

Faster and Wider Communication Infrastructure

“Information is the oil of the 21st century, and analytics is the combustion engine.”

Peter SondergaardGartner Group


Utility Analytics and Maintenance Trends

7

Evolving Maintenance Strategies

Maintenance Activities for Distribution Assets and Underground Networks

Enhanced Data Infrastructure and Analytic Platforms and Applications

Progressive Utility Stewardship of Performance Based Mechanisms

“The utility industry is now at the precipice of a new era of asset management.”

Utility Analytics Institute, July 2013


Agenda

• Focus



•Conclusion

•Q&A

8


PI System Infrastructure

9


Agenda

• Focus



•Conclusion

•Q&A

10


Maintenance Maturity Model

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Optimized Maintenance

Long-Range Planned Asset History AnalysisCapital Planning and

Budgeting

Proactive Maintenance

Predictive Multi-Factor AnalysisLower O&M and Capital

Deferrals

Reactive Maintenance

Calendar and/or Corrective Single Factor Monitoring High O&M Expenses


Reactive Maintenance Objectives

•Detect and take action on Incipient failures

• Implement a combined approach of both preventative and corrective maintenance

–Preventative is calendar based (3 Months / 3k Miles)

–Corrective is condition based (Top Oil Temp is over limit)

• Leverage real-time monitoring, manual inspection, and lab data to drive corrective maintenance

•Do not allow assets to Run-To-Failure

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Maintenance Maturity - Reactive

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Maintenance Maturity Reactive Maintenance



Maintenance Strategy o Corrective and Calendar based maintenance

Measurements and Data o Manual Inspectiono Limited transformer or

other monitoring datao Lab data – oil and gasses

Data Analytics o Real-time monitoring, simple trending, and calculations

PI System Integration o Manual data logging to PIo SCADA and/or non-

operational data integration to PI (DNP, Modbus)

Work and Asset Management o Nameplate and financialdata recorded in Asset Mgt.

o Limited or no Work Mgt.

Value to Utility

??


Reactive Maintenance Workflow

14

Substation Monitoring

PlantOperations

Top OilTemp is High

RTUInterface

To PI

Inspection Data to PI

PI-AF and Data Archive

PlantMaintenance

PI Notifications

Health Display

CorrectiveAction !!

Top OilTemp is Normal


Maintenance Driven Asset Model using PI-AF

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• Asset model is a hierarchical relationship of region, substation, equipment type, and asset data

• Assets in the model is created from AF templates to simplify the creation of new assets in PI AF

• Model is leveraged in the PI client tools

• Measurement data is included for each element (asset) in the model

• Nameplate data such as asset identifier, installed capacities, and work history are linked to EAM and WM system


Transformer Health Display in PI ProcessBook

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• Asset Health Dashboard for Transformer• Leverages PI AF for Element relative display – selectable by each

transformer from PI AF• Includes all sources of data including EAM, monitoring, maintenance

management, condition assessment results, and lab data


Maintenance Maturity - Reactive

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Value to UtilityCorrective action is taken when needed and equipment is not run-to-failure.


Proactive Maintenance Objectives

•Utilize condition assessments and scoring to better identify equipment requiring service or maintenance

•Better manage and prioritize O&M spending by prioritizing work according to scoring results and criticality

• Implement a condition assessment program where maintenance is compared and scored across asset classes or individual asset

•Do the Right Work at the Right Time!

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Maintenance Maturity - Proactive

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o Condition Assessment, Scoring, and Condition Based Maintenance



Reactive Plus:o Electrical and diagnostic

testingo Additional Monitored Assets


Reactive Plus:o Health assessments and

scoringo Power flow optimization



Reactive Plus:o Condition Based

Maintenance using PI



Reactive Plus:o Work Order Integration


??


Approaches to Condition Assessment

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Assessment by Specific Asset:

• Dependent on availability of data sources and monitoring devices

• Dedicated data interfaces to each device type

• Known conditions to monitor for each asset type

• Higher concentration of data points and data resolution from IEDs

• Utilization of SEL devices per substation (i.e. SEL 3354)

Assessment by Asset Class:• Utilization of existing and available

data sources• Limited or no visibility to IEDs • Peer group comparisons within the

asset class• Limited number of data points and

data resolution• Manual inspection data often required

to satisfy assessment rules and calculations

Condition assessment is typically a combined approach of the two assessment types.

Availability of Data Points for Each Asset

Deployment of Monitoring Devices and IEDs

Data Concentration of Points for Assessment


Condition Assessment and Scoring

•Not all rules are equal in the final scoring of condition assessment for each asset type

•Many factors (rules) are weighted based on the criticality of that rule

–For example, transformer top oil temperature might be weighted higher than dissolved gas analysis

–Weighting of the rules should be based on organizational and industry best practices

•Analysis of the scoring results is often required before work prioritization occurs

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Example Scoring Method

• Calculation Structure–Health Index = f1(M1) + f2 (M2) + f3 (M3) + …–Factors (fx) driven by available data–Example Factors

• CM Cost & Count for Past 6 Months• Operation Count for Past 6/12 Months• Gas and Oil Analysis – Change over time• Average Load over Time

• Asset Classes–Apply calculations by asset class–Voltage, Class, Type–Example Groups:

• 26KV – 69KV GCB• 138KV+ Power Transformer• LTC Vacuum Tanks

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Aggregated Condition Trending

• Time series of measurements can be used to estimate “aggregated” condition trends such as rate of loss of life.

• Many approaches to aggregating measurements.

• “Aggregated” trends are useful in prioritizing maintenance

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Tem

pera

ture

Time

Cond

ition

Time

Rate

of L

oss o

f Life

Time


Condition Assessment Example

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IED / Substation Monitoring

ManualInspection


Lab Data: Oil and Dissolved Gas

Asset Classes:

Transformers…

Breakers…

LTCs…

Line / Bus…

Relays…

Batteries…

Electrical Testing

Wave FormAnalysis

ConditionAssessment:

EAM & Work Mgt.

f1 x (M1) +

f2 x (M2) +

f3 x (M3) +

f4 x (M4) +

f5 x (M5)

=HealthIndex

f1

f2

f3

f4

f5


Condition Assessment Scoring in PI-AF

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• Asset model is extended to include Condition Assessment analytics

• AF templates are created to support Factor (fx) level analytics

• Weights, Thresholds, and Case results are configured as Attributes to support analytics

• A final Factor (fx) level score attribute is calculated


Condition Assessment Scoring in PI-AF (cont’d)

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• Analysis templates are used to perform each Factor (fx) analysis

• Outputs of the function analysis are stored to the Case Value

• The final Factor (fx) level score is calculated by weighting the Case value


Condition Assessment Scoring in PI-AF (cont’d)

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• An additional analysis template is configured to support Factor (fx) aggregation

• The score from each Factor (fx) analysis is “rolled-up” to an overall Health Index score


Condition Assessment Scoring

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Condition Assessment Workflow

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Operations

Work Planning and Prioritization !!Poor Health

Index

ConditionAssessment:

F1 x (M1) +

F2 x (M2) +

F3 x (M3) +

F4 x (M4) +

F5 x (M5)

=

SubjectMatter

Experts (SMEs)

ConditionAssessment

Reports

Engineering

Planning


CBM Objectives

•Utilize EAM and work management systems to automate maintenance and work activities

• Increase the reliability of work management business processes through automation

•Create appropriate CBM conditions using your Asset Monitoring data and Condition Assessment results

•Transition from manual to automated processes carefully

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Condition Based Maintenance Basics

•Define quantitative and qualitative rules

–Quantitative – usage or event based

–Qualitative – trigger based on status or limit data

•Define Maintenance plans in the Work Management application

• PI System integration to asset and work management applications

–PI AF integration using Data Access tools and drivers

–EAM and Work Mgt. integration using vendor APIs

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Condition Based Maintenance Workflow

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Operations & Maintenance

High Limit Exceeded

Engineering & SMEs

Qualitative

Number of Operations

Quantitative

Oil Dielectric Strength

Accumulated Loading

EAM/WM API

Notifications and Work

Orders

Work Order History

Health Index

EAM/WM Software

EAM/WM Software


Maintenance Maturity - Proactive

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Condition assessment and CBM provides a higher operational efficiency and lowers O&M costs.


Optimized Maintenance Objectives

• Leverage data history, assessments, and aggregates for long-range business intelligence

• Implement business improvements for operationaland maintenance performance issues

•Provide critical data for budgeting and planning of infrastructure upgrades and capital expenditures

•Provide data mining capabilities for identifying historical vendor performance, asset health analysis, and other operational indices

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Maintenance Maturity - Optimized

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o Predictive and Condition Based Maintenance

o Long-range planning for capex spending





o Condition assessment history and trending

o Rich history of correlated data factors




o Performance analysiso Vendor analysiso Operational efficiency





o Business Intelligence tools and applications such as MS PowerPivot, IBM Cognos, etc.




o Work history integrationo Asset budgeting and

planning


Health assessments and predictive analyticsprovide a higher operational efficiency and lower O&M costs.

??


Optimized Maintenance Analysis

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Long-Term ScoringAnd Trending

Engineering & Planning

Assessment History…

Maintenance History…

Vendor Type…

Weather Info…

Load and Congestion…

Criticality…

Time Periods…

Vendor Assessment

Maintenance & Operations

Performance

Load Demographics and Criticality

Budgeting and Capital Planning

IndustryExpansion

Analysis Dimensions:


PI System Business Intelligence

37


Business Intelligence for Asset Data

38



39


























planning


Condition assessment and CBM provides a higher operational efficiency and lower O&M costs.

Robust asset historyanalysis, targeted capital planning and budgeting, and overall performance improvements.


Agenda

• Focus



•Conclusion

•Q&A

40


Conclusions

• Business value is increasingly captured along the maintenance maturity model

• Your existing PI system and asset data can be leveraged today for maintenance automation

• System implementation of the required technologies and processes requires a knowledgeable and experienced project team across multiple disciplines

–Asset management, PI integration, engineering analysis and rule development, operational support, etc.

• Implement automation according to the criticality and reliability of the equipment

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42


























planning


Condition assessment and CBM provides a higher operational efficiency and lower O&M costs.

Robust asset historyanalysis, targeted capital planning and budgeting, and overall performance improvements.

Lower ValueHigh Reliability

Higher ValueLower Reliability

Aging Assets

Highest ValueAssets Exceeding End of Life

Poor Performing AssetsRepair vs. Replace


Agenda

• Focus

• Industry Dynamics, Trends, and Enablers



•Conclusion

•Q&A

43


Q & A

44

Please use the chat feature to submit questions to ALL PRESENTERS.

QUESTIONS?

• For copies of this presentation, please send email request to [email protected]


© Structure Consulting Group, LLC. Confidential and proprietary .45

QUESTIONS?Bob Knox

(302) 545-4656

[email protected]

Q & A


Documents

Asset Condition Assessment and Analyticsemmos.org/prevconf/2014/Asset Condition Assessment...Data Analytics o Real-time monitoring, simple trending, and calculations Reactive Plus: