Using PI for Back Testing Usage-Based and Condition-Based Maintenance Strategies Prior to Deployment in Asset Management

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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
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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 A

Sebastien Cournoyer, CMRP
DTE Energy
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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

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Coal-fired Power Plant
http//en.wikipedia.org/wiki/Fossil_fuel_power_pla
nt
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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)

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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
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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, PMs, Inventory,
  Equipment specs history, Purchasing, Contracts

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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

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DTE Energy Detroit Edison
Detroit Edison

• Michigans 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
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DTE - Plants and Performance Center
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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_Seminar
  s/Detroit/DTE20Energy20(John20Kapron).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/216
  49.wss

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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

Success!
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DTE - Total Fleet Management
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DTE - Control Technology Framework
People Making right decisions when it matters!
Fossil Generation Business Unit Strategy
ABB
Complete
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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

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Usage-based Criteria

• PI totalizer
• PI time-filtered conditional expressions
  (time-weighted and event-weighted)

• 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

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Service Water Pump Usage Based
Pumps were off for extended period, however the
PM WO still went out - 28 PM hours
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Fuel Conditioner Usage Based
Equipment runs about 80 of total year usage
based maintenance can save 152 PM hours
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Coal Conveyor - Usage Based
Maintenance 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
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Pulverizer - Usage Based
Maintenance 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
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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

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Secondary Air Heater Plugging
Air heater tube plugging causes DeltaP (green
line) to increase over several months and is a
trigger for maintenance
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Boiler (convection section) Tubes - Plugging
Rapid rate of change of Delta P over several days
is a trigger for maintenance
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Steam Condenser Fouling
Steam 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
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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
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Vibration Conveyor Motor
Shaft realignment resolves the vibration issue
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Instrument Drift O2 Analyzer U2-E
Based on redundant dual sensors
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Transmitter Drift
Boiler feedwater pump discharge pressure Based on
redundant triple transmitters (PressA, PressB and
PressC) XY Plot, PressA (X) vs. PressB (Y1),
PressC(Y2)
Good
Not Good
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Transmitter Drift U1 Spray Flow
Green Delta between the transmitters Blue
Unit 1 is at about 220 MW
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Firing Rate Control Loop Boiler Exit O2
O2 set point Approx. 3.2 Actual process value
(green line) Varies from 1 to 5.5
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Firing Rate Control Loop See Notes
At 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.
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Manual Inputs Operator Rounds in PI
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)
Source www.aeec.com/conveyor/Belt_Cleaners/Vplow.
aspx (retrieved Jan 2009)
Operator Rounds V-PLOW status on a coal
conveyor belt
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Breaker Inspection Sheet
Equipment inspection data specifically designed
to help with maintenance tasks (data not already
in PI) Data collection includes numeric values
such as resistance, clearance etc.
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Manual Inputs Operator Rounds in PI
Equipment 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

• 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

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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

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Enterprise Gateway
SOA (service oriented architecture) to exchange
information between the PI System and any
external system via web services.
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Questions?

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Thank you
www.osisoft.com