Lessons from the Real World Webinar Series

Transcription

1 Lessons from the Real World Webinar Series

2 End-to-End Asset Health September 11, 2013

3 End-to-End Asset Health 1. The challenge and the opportunity 2. The end-to-end process 3. Asset health center concept (with examples) 4. AEP s real-world experiences

4 Today s Presenters Jesse Berst Host & Moderator SmartGridNews.com Chris Lemay Product Manager Ventyx Gary Rackliffe VP Smart Grids NA ABB, Inc Carey Schneider Engineer, Asset Health Center American Electric Power

5 Chris Lemay, Ventyx Name Background Chris Lemay Product Manager - Ventyx 12+ years in development and delivery of software solutions for asset intensive business. Involved with solutions for asset health monitoring and assessment, mobile workforce management, and enterprise asset management Member of the IEC working group responsible for the Common Information Model (CIM) standards used in the electric power distribution industry (TC57/WG14)

6 Asset Health Management How to turn complex data into clear and actionable intelligence

7 Challenge & Opportunity Aging Infrastructure Aging workforce Expectations for higher reliability Reliability standards/documentation Increasing assets/flat O&M budgets Information challenges

8 Utility Analytics IT and OT Convergence Information Technology Synthesizes big data into critical insights and automated actions Large volumes of data for visibility into condition and status 1 2 Insights drive justin-time work to optimize enterprise Benefits of the IT/OT Convergence Enterprise Respond faster to real time conditions Gain insight for business process improvement Operational Technology Monitors and controls critical assets 3 Prioritize work to reduce the risk of outages

9 Asset Health Management End-to-End Process Operations Technology (OT) Information Technology (IT) Performance models based on embedded T&D equipment intelligence Apparatus & Service Sensors & Monitoring Substation Gateway Asset Database Analytics & Performance Models Work & Asset Management Transformers Transformer monitors Substation Automation Equipment spec Decision Support: Work Management Breakers Circuit Breaker monitors Data Concentration Failure data 1. Operations Impact Inventory Batteries HVDC & FACTS Switches Reclosers Switchgear Battery monitors Relays (IED s) Instrumentation/sensors Communications Test results Service records 2. Optimized Maintenance 3. Lifecycle Management 4. Recommended Work Execution Crew Deployment

10 Asset Health Solution Mincom 1 Data Acquisition 2 3 Decision Support Data from a variety of sources ranging from Data Aggregation and Analytics Leveraging Subject Matter Experts, Statistics, and Condition Assessments KPIs and workflows to prioritize Investment and Maintenance Work 4 Results and Communications Actionable; Integrated into Work and Asset Management Real time data (condition, EMS-SCADA, monitors and sensors) Analytics, Algorithms and Engineering best practices determine total risk KPIs That Matter Digital Dashboards Near real time data (GIS, mobility, Historian, EAM) Mechanical risk Thermal risk KPI Dashboards Packaged Analytics Field Inspections/ Communications & Work Notifications Dielectric Risk Enterprise Data (EAM data warehouse, market databases, ERP etc) Accessory risk Miscellaneous risk Notifications & Reports Adhoc capabilities Work and Asset Management Work Orders

11 From Equipment Data Data Sources

12 From Equipment Data Data Sources SMEs

13 From Equipment Data to Actionable Intelligence Advanced BI Solution Data Sources SMEs Actionable Intelligence Continuous Feedback Enterprise Asset & Work Management

14 Gary Rackliffe, ABB, Inc Name Background Gary Rackliffe VP Smart Grids North America ABB, Inc Over 30 years of T&D working for ABB Leading ABB s business development, establishing alliances and partnerships, product strategies, and sales and marketing. Chair of the GridWise Alliance Smart Grid Implementation Workgroup, a member of the DistribuTECH Advisory Committee, the chair of the NEMA Smart Grid Council, and a member of the Research Triangle Cleantech Cluster Advisory Committee Co-authored a T&D planning book, and has written numerous technical papers. Holds a BS and ME degrees in Power Engineering from Rensselaer Polytechnic Institute, a MBA from Carnegie Mellon. He is a Registered Professional Engineer and an IEEE Senior Member

15 Asset Health Center Power Transformers InfraRed scans or monitoring Partial Discharge detection 3D Acoustic Emission defect location LTC Gas-in-oil and contact wear Solid-state Gas-in-oil sensors UHF Partial Discharge (Future Research) Wireless Mesh sensors Frequency Response Analysis Monitoring and evaluating 68 different inputs

16 Static Analysis Expertise Dynamic data/information Static data or information Ongoing development ONLINE SENSORS DATA: Gas sensor H20 sensor Bushing LTC PD FRA/Transients SCADA DATA: ENTERPRISE HQ Trff fingerprint Events, alarms Load Top oil T. amb Tap pos. Expertise Equations Statistics Computation MTMP Risk of Failure OFFLINE DATABASES DATA: Offline DGA Offline SOT, Furans Routine tests FRA, DFR, Z, etc Maintenance actions

17 Dynamic Analysis and Results Dynamic data/information Static data or information Ongoing development ONLINE SENSOR DATA: Gas sensor H20 sensor Bushing LTC PD FRA/Transients SCADA DATA: Trff fingerprint Events, alarms Load Top oil T. amb Tap pos. Expertise ENTERPRISE HQ Equations Computation Statistics DTMP Trxf. 1 Trxf. 2 Trxf. 3 Trxf. n OFFLINE DATABASES DATA: Offline DGA Offline SOT, Furans Routine tests FRA, DFR, Z, etc Maintenance actions Dashboards Recommended Actions Updated Risk of Failure

18 Asset Details Levels of Detail Drilldown Summary Trending Messages & Notifications Duval Triangle Health Index

19 Circuit Breaker Monitoring Breaker Health Parameters SF6 gas system Interrupter wear Mechanical System Electrical Controls & Aux. CBS CBS-Lite Benefits Data acquisition and analysis occurs automatically Increases reliability and identifies potential problems early Eliminates need for time-based or operation based maintenance CBS-F 6

20 Asset Health Center HV Breakers SF6 Gas System Tank/Gas Temp. ( o C) Comp. SF6 Pres. (psi) Leak Rate (1) (psi/s) Leak Rate (2) (psi/min) Leak Rate (3) (psi/h) Leak Rate (4) (psi/day) Leak Rate (5) (psi/month) Circuit Breaker Sentinel 0 SF6 M Electrical Controls & Auxiliaries Close Coil Monitor Primary Trip Coil Monitor Secondary Trip Coil Monitor Close Coil Energization Time Primary Coil Energization Time Secondary Coil Energization Time Mech/Cabinet Temperature Thermostat / Energized Heaters Motor Starts (total) Motor Starts w/o Operation Motor Run Time Trip Count Interupter Wear Contact Wear (%) Aux Noz. Wear (%) Main Nozzle Wear (%) RMS Current(1) ka RMS Current(2) ka RMS Current(3) ka Mechanical System Total Travel (mm) Reaction Time (ms) Mechanism Time (ms) Contact Velocity (m/s)

21 Total Travel Close (Open) Operation Analysis Contact Travel Make/Break Distance Speed Calc. Zone Contact Velocity Reaction Time Mechanism Time Coil Time Close Coil Energization

22 Managing Risk Risk = Probability x Consequence

23 Predicting Future Problems Source: analytics value curve from the Utility Analytics Institute Analytics uses past data to forecast, predict, and optimize Anticipating future problems improves decision-making

24 Predictive Maintenance Pays ARC estimates corrective can cost 10x as much as predictive Traditional preventive approach often results in no action 35% 30% 35% 28% 25% 20% 20% 15% 10% 5% 6% 6% 4% 0% Routine check No Problem Calibration shift Zero Off Plugged lines Failed Source: Shell Global Solutions

25 Questions?

26 Carey Schneider, AEP Name Background Carey Schneider Engineer, Asset Health Center AEP Data & IT Lead for AHC team at AEP 10+ years leadership positions focused on process improvement and information technology in the healthcare product distribution and telecommunication industry 20+ years in manufacturing and business process improvement technology project implementations, and project/engineering management. BS in Mechanical Engineering- Ohio State, BS in Management Information Science Franklin U, and MBA Ohio Dominican University

27 AEP Asset Health Center Program Asset Health Center Diagnostic Monitoring and Analysis Program Driving Performance for the Modern Electric Grid September 11,

28 AEP Transmission Technology Overview Align with Business Strategy Expanded Transmission Investment Advanced Operational Performance Technology Focus Areas System Awareness Competitive Design Operational Excellence Public Policy Execution Speed System Awareness Competitive Design Operational Excellence Initiatives (in Awareness Focus Area) Wide area measurement and control Asset Health Center Automated inspection technologies Execution Speed Public Policy 28

29 Asset Health Management - Vision We are masters of our system and its assets. (Finally!... and in a time and galaxy not so far, far away) We know the condition of all our assets, what to do about it, and when to do it. 29

30 Problem Statement Aging asset population combined with pressure to reduce operations and maintenance costs AEP system wide populations: 33% of transformers in service more than 50 years old 34% of circuit breakers in service more than 30 years old Current policies dictate that all equipment gets maintained evenly on time based schedules Health of equipment is not factored into the prioritization of maintenance spend Standard practice is to run equipment to failure which increases the chances of unexpected outages and decreases reliability Maintenance and failure documentation exists across multiple platforms Analysis of existing data requires custom time-consuming queries Failure prediction and root cause analysis is not automated and requires manual data analysis by equipment experts Reliance on manual inspections and manual data entry exposes AEP to possible compliance based fines

31 Asset Health Center General Overview Purpose of the Asset Health Center (AHC) Prevent failures Optimize maintenance Prioritize asset renewal Transformational technology Convergence of operational & information technology Automates condition analysis, recommends actions Determines health index and remaining life Maintain on condition rather than time interval Leverages existing infrastructure & data Implementation Development of platform under way Monitoring included on new equipment Retrofit monitoring in stages to existing equipment 31

32 Asset Health Business Case Near Term Benefits Capital saving benefits based upon avoidance of unexpected failure costs and failure prevention Improved awareness and decision support for asset renewal (Capital) spending Avoid/redeploy maintenance (O&M) cost via condition awareness Standardization of maintenance tracking, data processing, and failure reporting Increased knowledge of our fleet and the availability of real time health assessments (event analysis, highlight outliers, and trends of interest) Reduce compliance risks Long term vision New installations of transformers, breakers, batteries are currently being standardized with monitoring packages A monitor retrofit program will be proposed in 2013 goal is to equip all existing EHV equipment with monitors over 10 years. Continue to adapt the solution with new monitoring sensors, data sources, policy modifications, etc. As technology matures sensing & decision tools benefits rise x n

33 Asset Health Center - Principles Do no Harm Commit to solving the problem Leverage what already exists on system Automate inspection/test procedures in real time Build standard sensors into all new devices Refit existing assets with sensing in progressive stages Develop platform focusing intelligence centrally Deploy relevant, practical sensing locally Relevant - Target top failure modes per equipment class Practical - Simple, resilient, low cost, low/no maintenance Note: These apply to AEP, US largest Transmission owner, spread over 11 states, 3 RTOs, with 3500 substations, 5500 transformers, over 11,000 breakers and whose service area is largely rural. 33

34 Asset Health Center Solution Asset Health Center Diagnostic Monitoring and Analysis Program AEP/ABB Technology Alliance A 4-phase 2 year project that will produce a collaborative developmental solution that leverages AEP s and ABB s subject matter expertise and allows AEP to substantially define use cases for the industry Program will analyze transformers, breakers, and batteries across the transmission system Solution involves web-based tool that Transmission personnel can access via AEP Intranet Trending of data from several sources Solution provides unique visualization tools that can be tailored to variety of audiences: asset renewal, maintenance planning, failure reporting, Transmission Leadership

35 Asset Health Center Technology Overview Asset Health Center Algorithms

36 Asset Health Center Algorithms Co-developed by AEP and ABB Based on industry standards, historical information, and failure studies Can analyze different sets of data with unique sampling rates Can assess the current health of an individual asset or measure against an asset family

37 Available Data Sources Nameplate, inspection, maintenance, and failure data available in ISIS, test files, Doble DTA Web. Will allow trending of historical data. Real time SCADA data such as loading, temperature, and operations will aid in the long term health assessment of equipment Real time sensors can automate maintenance and inspection functions and provide evidence for equipment failure prediction.

38 AHC Solution User Interfaces Web-based interface available to all Transmission personnel Can view asset condition for various levels of organization Real time alarming capability for field personnel Asset health prioritization for maintenance planning users Identify remaining useful life for asset renewal planning Can view trends for business management functions

39 Monitor What Matters Most Transformers EHV: leading failure cause is dielectric partial discharge is critical (PD) Dissolved gasses in oil Oil quality/leak detection: dielectric qualities, moisture, level, leaks Core & Coil: oil and winding temperatures, SFRA, thermal image profile Accessories: Bushings (C, PF/tand, PD); pumps, fans Gas Circuit Breakers Mechanism timing, motion, motor/pump starts, current draw (force) Contacts arcing time, wear/condition metrics Insulating medium gas pressure, density, moisture, quality, leak detection Controls operating coil current draw signatures Batteries Battery string V(float) and I, connection to load, connection to charger Individual cell temperature, electrolyte level, conductance Monitor Parameters Relevant to Trouble Causes and Practical to Maintain 39

40 Reflections Past Monitoring Experience FOCUS Targeted what s easy not what matters most INSTALLED COST Not scalable across enterprise O&M EFFORT Excessive attention required PERFORMANCE Unsustainable and ineffective SOFTWARE/FIRMWARE Weak organization, automation & use of existing assets Prior Asset Health/Real Time Monitoring Techniques Miss the Mark 40

41 Questions?

42 Thank You! You will receive a link to download a copy of the slides to the you used to register. Jesse Berst Host & Moderator Smart Grid News [email protected] Chris Lemay Product Manager Ventyx [email protected] Gary Rackliffe VP Smart Grids NA ABB, Inc [email protected] Carey Schneider Engineer, Asset Health Center American Electric Power [email protected]