Post on 28-Mar-2015
Using PI for Back Testing Usage-Based and Condition-Based Maintenance Strategies Prior to Deployment in Asset Management
Gopal GopalKrishnan, P.E. OSIsoft, Inc.
Larry Hruby Basin Electric
Mark Blaszkiewicz Sebastien Cournoyer, CMRP DTE Energy
Agenda
• About Basin Electric, About DTE Energy• History of PI System at Basin Electric and DTE Energy• History of maintenance systems:
– Basin has Ventyx AssetSuite (aka Indus Passport)– DTE has IBM Maximo
• Case studies for back-testing:– Usage-based strategies– Condition-based strategies
• Q & ASebastien Cournoyer, CMRP DTE Energy
What You Can Expect
• Talk is not product specific – use several tools available in the PI Infrastructure
• Start with maintenance tasks and work backward to see if data exists in operations history that can be used– Collect additional equipment inspection data for proactive
maintenance
• Use PI tools and in-house resources in small increments without new capital outlay
Coal-fired Power Plant
http://en.wikipedia.org/wiki/Fossil_fuel_power_plant
Basin Electric Power Cooperative
• HQ – Bismarck, North Dakota, wholesale provider (generation and transmission) of power to 126 Rural Electric Systems covering portions of 9 states
• Operate coal, wind, gas, oil based power generating facilities and a synthetic natural gas production facility
• Capacity– 3623 MW (Base load)– 405 MW (Peaking – CTs)– 136 MW (Wind)
Basin - Leland Olds Station (LOS)Fuel: Lignite with PRB (Powder River Basin) blending
Unit 1: 220 MW - 1966 Pulverized Coal Boiler (Babcock & Wilcox) Turbine, GE DCS, Emerson Ovation 2007 upgrade
Unit 2: 440 MW - 1975 Cyclone boiler (Babcock & Wilcox) Turbine, Alstom DCS, Emerson Ovation 2006 upgrade
Under Construction: Limestone Scrubbers for SO2 capture ($410MM capital project)
Leland Olds, Stanton, North Dakota
Leland Olds Station (LOS)– Software Infrastructure
OSIsoft PI (piloted in 2005)• 20,000 tags• Emerson Ovation DCS, Rockwell PLCs, GE relays
Ventyx Asset Suite (previously Indus Passport)• Started using in 1998 as Passport, has evolved into Asset
Suite in 2008 • Used for Work Management, PM’s, Inventory,
Equipment spec’s & history, Purchasing, Contracts
Leland Olds – Maintenance Initiatives
• Working toward condition based maintenance (CBM) for years– Vibration, oil analysis, thermography etc.
• Investigated Rockwell and OSI PI as platform to feed CBM and operational data to AssetSuite
• PI data reviewed:– Standard PM work orders usage based– Machine status work order management– Sensor drift and calibration– Control Loop Health– Condition-based notification
DTE Energy – Detroit Edison
Detroit Edison
• Michigan’s largest electric utility with 2.2 million customers
• Over 11,000 MW of power generation from 7 plants - mostly coal fired
• 54,000 GWh in electric sales
• $4.7 billion in revenue
DTE Energy - Detroit Edison
DTE - Plants and Performance Center
Greenwood – 785 mwRiver Rouge - 527 mw Fermi – 1,100 mw
Monroe – 3,135 mw
Trenton Channel - 730 mw
Belle River – 1,260 mw
St Clair – 1,417 mw
Harbor Beach – 103 mw
Performance Center – 11,588 mw
DTE – History of PI and Maximo
• PI is a key infrastructure and technology enabler for real-time operations data as part of the “Enterprise Business System” at DTE
Additional details from a Nov. 2008 presentation at:
www.osisoft.com/osisoft/downloads/Regional_Seminars/Detroit/DTE%20Energy%20(John%20Kapron).pps
• IBM-Maximo is a key application for work management as part of the “Enterprise Business System” at DTE
Additional details at:
http://www-03.ibm.com/press/us/en/pressrelease/21649.wss
Success!
DTE – Details of PI usage
• In use since 1998 – started with a pilot at Monroe in 1998
• Enterprise Agreement for corporate wide use
• PI is an infrastructure product – magnitude of use and functionality is expanding
DTE - Total Fleet Management
Real-timeProcess Applications
Distributed Control Systems (DCS) Distributed PI Historians
WEB Portal
SME Status Displays
Applications
Expert Systems
FinancialsWork Management
SAP Maximo
Market
MISO, Fuel Coat Framework
Unit Capacity Framework
Drives Performance Excellence Process CostsAsset Health
Operational Performance Market Value
Fleet Optimization
Discrete data Limited value
ActionableInformation – KPI’s
Distributed Control Systems (DCS) Distributed OSIsoft PI Historians
Large Population of Data
Post Event Analysis DCS, PLC & PI
90%
Business IntelligenceOutage & De-rate (UCF)Maintenance & Market
Relate all Data SourcesProcessNet Framework
(PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View ..)25%
% CompleteABB
System DashboardsFleet Status Assessment
Fleet Drill downSubject Matter Experts90%
WEB VisualizingPlant Alarm, DCS Real-time WEB Graphics
Easy Access to Information
Standard User InterfaceWEB Visualization
100%
Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework
Process Discrete Data
Process Discrete Data Engineering ApplicationsRFID, PMAX, DFTS, eNote,
Fuel Cost Framework,Alarm Management 90%
Expert SystemsPredictive Monitoring, Optimization
MBO/PdM/Risk Assessment
Advanced Analysis & Process OptimizationReliability Academy
Equipment, Process, Performance, Reliability ModelsClosed Loop Process Optimization60%
DTE - Control & Technology FrameworkDTE - Control & Technology Framework
Fossil Generation Business Unit Strategy
People Making right decisions when it matters!
Fleet Optimization
Process CostsAsset Health,Market Value
Drives Performance Excellence Fleet Optimization
Process Costs, Asset Health,Reliability
Operational Performance, Market Value
15%
Link Operations and Maintenance
• Business goals– Usage based maintenance (UBM) strategies
• Mostly, data is already in PI– Condition-based maintenance (CBM) strategies
• When relevant data not in PI, collect equipment inspection specifically designed to drive maintenance benefits
• Business justification– Calendar-based maintenance strategy := Amount of
maintenance will be same as last year – UBM and CBM:= Opportunities for savings– Use PI history and Maintenance history to:
• Back-test calendar based PM for conversion to UBM • Back-test corrective work order (CM) events for conversion
to CBM
Usage-based Criteria
• Run-hours - – Coal feed conveyor – Pulverizer– High pressure service water pumps
• Run-modes - number of starts, number of trips – Peaker CT blades
• Run-weight - tonnage processed (mining industry), flow-rate (time-integral) converted to volume
• PI totalizer • PI time-filtered conditional expressions (time-weighted and event-weighted)
Service Water Pump – Usage BasedPumps were off for extended period, however the PM WO still went out - 28 PM hours
Fuel Conditioner – Usage BasedEquipment runs about 80% of total year; usage based maintenance can save 152 PM hours
Coal Conveyor - Usage BasedMaintenance: 60 PM hours per conveyor per year; 22 conveyors per site, 6 sites
Actual runhours: 25% based on PI data, implies a 75% savings
Projected savings: 900+ PM hours (approx. $45,000 at $50/hr) per year per site
Pulverizer - Usage BasedMaintenance: 160 PM hours per pulverizer per year; 16 pulverizers per site, 6 sites
Actual runhours: 80% based on PI data, implies a 20% savings
Projected savings: 480+ PM hours (approx. $25,000 at $50/hr) per year per site
Condition-based Criteria
• Equipment failure is known to be correlated to a slowly degrading metric that can be monitored– Temperature (Motor windings, Bearing) – Pressure or DeltaP (heat-exchanger plugging, filters)– Vibration – Amplitude, FFT etc. ; Also interpret along
with operations data in PI
• Instrument and transmitter calibration• Control loop health
Secondary Air Heater PluggingAir heater tube plugging causes DeltaP (green line) to increase over several months and is a trigger for maintenance
Boiler (convection section) Tubes - PluggingRapid rate of change of Delta P over several days is a trigger for maintenance
Steam Condenser FoulingSteam condenser fouling causes condenser pressure to rise (blue line), note the rapid rise in a matter of few days. Threshold is 4 inHg.
Green line shows the inlet water temperature which is relatively constant
Vibration – Conveyor Motor - Note the rapid rise in vibration amplitude in Jan. and Feb.; also shown in the trend.
- Resolved by a shaft re-alignment – see next slide
Vibration – Conveyor Motor Shaft realignment resolves the vibration issue
Instrument Drift – O2 Analyzer – U2-EBased on redundant dual sensors
Transmitter Drift
Good
Not Good
Boiler feedwater pump discharge pressure
Based on redundant triple transmitters (PressA, PressB and PressC)
XY Plot, PressA (X) vs. PressB (Y1), PressC(Y2)
Transmitter Drift – U1 – Spray FlowGreen – Delta between the transmitters Blue – Unit 1 is at about 220 MW
Firing Rate Control Loop – Boiler Exit O2O2 set point: Approx. 3.2%
Actual process value (green line): Varies from 1% to 5.5%
Firing Rate Control Loop – See NotesAt purple crosshair, air (red) peaks when coal (yellow) dips causing O2 (green) to peak after 30-40 secs.
At white crosshair, air (red) dips when coal (yellow) peaks causing O2 (green) to fall below 1% after a lag of 30-40secs, and so on….
Manual Inputs – Operator Rounds in PI
Source: www.aeec.com/conveyor/Belt_Cleaners/Vplow.aspx (retrieved Jan 2009)
Operator Rounds: V-PLOW status on a coal conveyor belt
Equipment inspection data collection specifically designed to help maintenance tasks (data not already in PI)
Benefits: Proactive maintenance for increased MTBF (mean-time-between-failure)
Breaker Inspection SheetEquipment inspection data specifically designed to help with maintenance tasks (data not already in PI)
Data collection includes numeric values such as resistance, clearance etc.
• Breaker inspection – 80 attributes per breaker, 1000 breakers – annual inspection or after a trip• Dust Collector• Screw conveyor• Electric motor • Reducer • Bearings• Transfer point / chute liner condition• Limit-torque actuator• Hydraulic cylinder, Pneumatic cylinder• Pumps• Mechanical seals• Conveyor skirting• Conveyor scraper, primary and secondary• Idler, roll assembly• Pulley• Lube system• Coupling• Torque coupling• Valve• Piping
Manual Inputs – Operator Rounds in PIEquipment inspection data specifically designed to help with maintenance tasks (data not already in PI)
Everything we visually inspect, measure or observe can be recorded in PI to track, trend and monitor
Findings• Operations history and maintenance history can validate and
quantify benefits for usage-based criteria prior to deployment
• Use manual input data (Manual Logger) to supplement condition-based strategies
• Review control loops, including the instruments, transmitters and calibrations
• Vibration data – combine with equipment operating conditions for better diagnostics
Enterprise GatewaySOA (service oriented architecture) to exchange information between the PI System and any external system via web services.
Questions?
Thank you
www.osisoft.com