PSE&G Condition-Based Maintenance Angela Rothweiler October 13, 2009 PI Seminar - Philadelphia 2009 PI Seminar - Philadelphia PSEG T&D CBM

Agenda Background Problem Solution Critical Success Factors Asset Registry CMMS Functional Areas Data Collection Condition Assessment & Criticality Inspection Process Example Critical Success Factors 2009 PI Seminar - Philadelphia PSEG T&D CBM

Background Utility Overview Service Territory Delivery Implementation 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

Asset Population by Division and Age Class Within Equipment 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 Asset Population by Division and Age Class Within Equipment 2009 PI Seminar - Philadelphia PSEG T&D CBM

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

Maintenance Management Functional Areas Data Collection SAP Asset Information Time-Series Data Collection Application Diagnostic and Inspection Data Asset Analysis and Reporting Condition Assessment Work Prioritization Alerts / Notifications Maintenance Management Measurement Points Maintenance Plan Modifications Notifications Data Collection Analysis & Reporting Maintenance Management Raw data Measurement points Notification Feedback 2009 PI Seminar - Philadelphia PSEG T&D CBM

Data Collection & Consolidation PI - OPC Doble Distribution SCADA Electrical test results Transmission SCADA Breaker Tests PI HDW Diagnostic data ESOC PI Transformer loads Delta-X MV90 Transformer oil analysis SAP-PM MDT Hydran PI Manual Logger SAP order history and technical object updates Weekly substation inspection Gas equipment results 2009 PI Seminar - Philadelphia PSEG T&D CBM

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 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

Criticality Calculation Structure Peer Groups CA = F1(M1) + F2(M2) + F3(M3) + … SAP Static Factors 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 Notifications PM Orders Measurement Document Interface Triggers Order & Status Updates Data Tour CAD/PI Tour and Values Job and Status PI Manual Logger database PI Manual Logger Data entry 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

Alerts / Notifications PI-ACE Algorithms monitor real-time & weekly inspection data Creates emails and SAP notification Examples: 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

SAP BI Webinar 2009 PSEG T&D CBM

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

Q&A 2009 PI Seminar - Philadelphia PSEG T&D CBM