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

2. 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

3. 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
OMS, GIS & CAD
CMMS
2009 PI Seminar - Philadelphia
PSEG T&D CBM

4. 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

5. 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

6. 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

7. 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

8. MDB Hierarchy Structure

9. MDB Properties & Aliases

10. 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

11. 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

12. 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

13. Alerts / Notifications
PI-ACE Algorithms monitor real-time & weekly inspection data
Creates s 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

14. SAP BI Webinar 2009
PSEG T&D CBM

23. Algorithm Rules

24. 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

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