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7/26/2019 Moving From Time Based Maintenance to Condition Based Maintenance (Webinar)
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Moving from Time Based Maintenance to
Condition Based Maintenance
Presented By: Thomas Linn Qualitrol LLCSeptember, 2013
Thomas Linn has a strong background of 20 years plus experience in high voltage equipmentsuch as gas insulated switchgear, high voltage bushings, cables, transformers, high voltagetesting, partial discharge measurement and monitoring and high voltage test equipment.
Thomas graduated from Technical University of Dresden with a degree in ElectricalEngineering, specialized in High Voltage Techniques. Afterwards he worked till today withhigh voltage equipment. 1998 he joint ABB in Switzerland and was responsible for HighVoltage Onsite Testing for GIS and cables, PD measurements onsite and PD monitoring ofGas Insulated Switchgear. 2003 he took over the responsibility for the High Voltage Test Labsfor routine and type testing mainly for high voltage transformer bushings.
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Agenda
Overview
1. Definitions around Maintenance
2. Traditional Methods and current state of Maintenance
3. Condition- based Maintenance (CBM) Basics
4. Challenges of Condition Monitoring Based Systems
5. Q & A
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Definitions around Maintenance
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Definitions around Maintenance
What is Maintenance?
Maintenance are actions necessary for retaining or restoring a piece of equipment,machine, or system to the specified operable condition to achieve its maximumuseful life.
Source: http://www.businessdictionary.com/definition/maintenance.html#ixzz2VFFiFfwd
Type of Maintenance?
Reactive maintenance (Run-to-failure maintenance)
Preventive maintenance (Time-based maintenance)
Predictive maintenance (Condition-based maintenance)
Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf
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Type of Maintenance Run-to-Failure Maintenance
Advantages
Low cost.
Less staff.
Disadvantages
Increased cost due to unplanned downtime of equipment.
Increased labor cost, especially if overtime is needed.
Cost involved with repair or replacement of equipment.
Possible secondary equipment or process damage from equipment failure.
Inefficient use of staff resources.
Definition:
Run-to-Failure maintenance (also known as corrective maintenance) involves all unscheduledactions performed as a result of system or product failure. Basically, it is an attempt to restorethe system/product to a specified condition.
Source: http://www.referenceforbusiness.com/management/Log-Mar/Maintenance.html#ixzz2VFbobDte
Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf
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Type of Maintenance Time- based Maintenance
Advantages
Cost effective in many capital-intensive processes.
Flexibility allows for the adjustment of maintenance periodicity.
Increased component life cycle.
Energy savings and Reduced equipment or process failure.
Estimated 12% to 18% cost savings over reactive maintenance program.
Disadvantages
Catastrophic failures still likely to occur.
Labor intensive. Includes performance of unneeded maintenance.
Potential for incidental damage to components in conducting unneeded maintenance.
Definition:
Time-based maintenance utilizes a previously developed maintenance schedule for eachasset/ equipment. This is much like an oil change on an automobile that takes place everythree months or 3,000 miles, whichever comes first.
Source: http://www.referenceforbusiness.com/management/Log-Mar/Maintenance.html#ixzz2VFbobDte
Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf
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Type of Maintenance Condition-based Maintenance
Advantages
Increased component operational life/availability.
Allows for preemptive corrective actions.
Decrease in equipment or process downtime.
Decrease in costs for parts and labor.
Better product quality.
Improved worker and environmental safety.
Improved worker morale.
Energy savings.
Estimated 8% to 12% cost savings over time-based maintenance program.
Disadvantages Increased investment in diagnostic equipment.
Increased investment in staff training.
Savings potential not readily seen by management.
Definition:
Condition-based maintenance involves all actions performed as a result of system or productcondition, detected by means of condition monitoring. Basically, it is eliminating causalstressors, with can lead to a degradation of the asset or equipment.
Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf
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Traditional Methods and current state
of Maintenance
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Traditional Methods and current state of Maintenance
A referenced study from US breaks down the average maintenance program asfollows:
>55% Reactive
31% Preventive
12% Predictive
2% Other
Note that more than 55% of maintenance resources and activities of an averagefacility are still reactive.
(Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf)
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Traditional Methods and current state of Maintenance
Commonly accepted practice is to follow Manufacturers advised schedule, likechanging your cars engine oil at every 3000 miles or three months
1) A Utility company cannot keep up with time based maintenance in a deregulated
business model, and highly regulated environment protection.
2) Experience and proven studies demonstrate greater asset risk and dependingrevenue loss when using time based maintenance
Traditional methods lack the needed sensors and associated measurements toanalyze, record and suggest preventive maintenance or control actions
Assets like Battery banks, cap banks, underground cables are relatively difficultand expensive to maintain, often underserved by Utilities
Diagnostics, Reporting and control measures are mostly a manual processprone to errors. Requires constant training and retaining large crews.
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Traditional Methods and current state of Maintenance
Full cost view includes secondary (invisible) costs:
Moral of employ Safety aspects
Reduced costs for parts and labor Secondary outage costs (penalties, branddamages etc.)
Inventory costs Indirect cost reduction due to longer lifetime
Full cost view includes secondary (invisible) costs:
Moral of employ Safety aspects
Reduced costs for parts and labor Secondary outage costs (penalties, branddamages etc.)
Inventory costs Indirect cost reduction due to longer lifetime
Traditional view includes primary (visible) costs:
Replacement parts costs Labor costs
Primary Costs for outages Storage costs
Traditional view includes primary (visible) costs:
Replacement parts costs Labor costs
Primary Costs for outages Storage costs
Cost calculation
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Traditional Methods and current state of Maintenance
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N
umberoftrouble
0~3 4~6 7~9 10~12 13~15 16~18 19~21 22~24 25~
Service years
OthersMaintenance DefectsEquipment Defects
In older Equipment maintenance is a big contr ibutor to failure!
(Source: CIGRE 1992)
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Traditional Methods and current state of Maintenance
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Condition- based Maintenance (CBM)
Basics
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Condition- based Maintenance (CBM) Basics
Condition-based maintenance is a set of activities that detect changes in the physicalcondition of equipment (signs of failure) in order to carry out the appropriate maintenancework for maximizing the service life of equipment without increasing the risk of failure.
Condition-based maintenance
depends on continuous or periodic condition monitoring equipment to detect the signs offailure.
Defining maintenance decisions
Assessing Condit ion of equipment
Intelligent data analyzing/ processing
Collecting the data
Defining valuable data to measure
Condition-based Maintenance
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What is needed to do Condition-based Maintenance?
Condition- based Maintenance (CBM) Basics
Commitment of Management
Suitable Sensors
CBM Concept
Reliable System Knowledge
Data processing
CBM relevant quality data analyses by expertsystems
Maintenance decision based on data and Knowledge (automatic/ manuallysupported)
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Condition- based Maintenance (CBM) Basics
CBM Concept
For a suitable CBM Concept the level o actions needs to be defined and represented in themonitoring system (different level of access etc.). The responsibilities, the included actionsand the expected decisions for each level needs to be clearly defined.
First Level: qualified data/ warning/ alarms will be provided (System)
Second Level: Information will be received, reviewed and acknowledged; decision about furtheractions will be drawn (e.g. by operator with system support)
Third Level: Received data will be further analyzed; decision about further investigation will be
drawn (e.g. by maintenance crew with system support)
Forth Level: Further investigations on the equipment itself (e.g. time- of- flight, oil sampling);decision about necessary maintenance actions will be drawn (e.g. external or internalspecialist with system support and/or additional diagnostic methods)
Fifth Level: applying maintenance (e.g. repair or replacement by external or internal stuff); the
decision about clearance for further operation will be drawn (e.g. maintenancemanager).
The above mentioned concept shows an basic example and might varies according to CBM strategy of theequipment owner, level of experience, level of competences etc.
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Condition- based Maintenance (CBM) Basics
Suitable Sensors
The used sensors should be able to collect the measured parameter with a minimumdemanded sensitivity, which should be proven by means of state of the art methods anddocumented.
The sensors should not incorporate unnecessary risk to the monitored equipment, to OHSand environment.
Fixing and connection to equipment and the buildup of the sensor itself and all connectedparts should be resistant to the same environment as the monitored equipment itself at least.
The expected lifetime should be as long as the monitored equipment itself or, if not possible,
at the high end of state of the art of same kind of sensors.In case of a defect of a sensor, it should not result in a fault of the monitored equipment.
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Condition- based Maintenance (CBM) Basics
Reliable Monitoring System
The connected monitoring system should provide different level of access according to thelevels in the CBM concept (e.g. red and green light for first level, some data analysesfeatures for the second level etc.).
It should be suitable to withstand the environment where it will be installed.All system failures should create a signalization to first level.
The system should be meant for long life operation, equipped with proven reliablecomponents/ parts.
The user interface needs to be so designed, that it is easy to use and all information provided
must be easy to find according to the level of access.The recorded data have to be stored in a save and reliable way.
The system should be able to be integrated to station networks, equipment owner privatenetworks and phone lines.
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Scalable System Architecture:
1) Scalable from single asset to a complete substation, or to include complete Utilityinfrastructure
2) Choice of integration in existing SCADA or an independent CMBS3) Optional use of Cloud computing, web interface, apps for smart phones
Mature information management and rule packs for data interpretations
1) Minimize nuisance alarms
2) Accurate interpretation with specific recommendation for maintenance action3) Custom reporting capabilities for different levels of organization
4) Long term archival (1 to 10 years), trending and projected asset availability
Condition- based Maintenance (CBM) Basics
Reliable Monitoring System further properties
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Condition- based Maintenance (CBM) Basics
Integrated solution - Example of data integration
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Condition- based Maintenance (CBM) Basics
Integrated solution - Example SmartSUB
SF6 monitor DGA monitor (8 gases)
PD moni tor
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Condition- based Maintenance (CBM) Basics
Data processing and CBM relevant quality data analyses by expert systems
Condition monitoring is a joint effort between
manufacturers (OEM and 3rd parties, utilities
(equipment, P&C, communications) and software
developers
The data analyses system should be a
development with Utilities, OEMs and University
researchers to provide best in class modelling and
simulation module accuracy to ultimately provideautomated link to CBM planning tools.
The messages to the user should be clear and
should provide the necessary information to
assess the cause of the degradation of physicalcondition (e.g. type of defect, area of source etc.)
Raw DataFrom Sensors
Signal Processing
Qualify DataBased on CM Attributes
Boolean / Fuzzy LogicBased Expert System
Artificial Neural Network
Expert Systems (Diagnostics & Modelling)
AutomatedCBM Planning
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Example: Transformer Dissolved Gas Analysis Diagnostic
First new DGA diagnostic tool in decades
Correct fault condition identification in 96% of cases surpassing existing
tools Provides fault identification AND severity levels
Enables Exception-Based analysis on Big Data DGA databases
Condition- based Maintenance (CBM) Basics - Example
Utilizes Artificial Neural Network (ANN) Programming and an Expert System
ANN trained on data sets that marry pre-failure DGA data with post-failureinspection results
Additional analytic elements include: Harmonic Regression to remove harmonic components in the data, clearly
revealing the underlying trends
Piecewise Linear Approximation to accurately assess gassing rate of change
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Four fault categories are identified High Energy Discharge (HEDA)
Low Energy Discharge (LED)
Over Heated Oil (OHO)
Cellulose Decomposition (CD)
Severity of the fault category is assigned and ratedwithin a 6 level scale
Notifications can be customized by fault category andseverity to enable exception-based analysis.
Diagnostics:
Condition- based Maintenance (CBM) Basics - Example
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DGA Visualization example (8 gases)
Condition- based Maintenance (CBM) Basics - Example
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Condition- based Maintenance (CBM) Basics
Knowledge Management
Or
What to do with my Information?
Knowledge Management!
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Condition- based Maintenance (CBM) Basics
Knowledge Management (KM) comprises a range of strategies andpractices used in an organization to identify, create, represent, distribute,and enable adoption of insights and experiences.
Such insights and experiences comprise knowledge, either embodied inindividuals or embedded in organizational processes or practice.(company know-how)
KM efforts focus on organizational objectives such as improvedperformance, competitive advantage, innovation, the sharing of lessonslearned, integration and continuous improvement of the organization.
Data and Information are useful, but nowhere as valuable as Knowledge and Wisdom!Condition Monitoring will only be useful if you know what to do with the Data and
Information to give you Knowledge!
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Condition- based Maintenance (CBM) Basics
Moving from Data to Wisdom
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Condition- based Maintenance (CBM) Basics
Integration of knowledge from past events into expert system
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Asset Manager1) Avoid Early Life Failures
2) Capture Design and Manufacturing
flaws in Warranty period3) Benchmark OEMs
4) Extend Operational Life of Asset
Maintenance Manager1) Adopt condition based maintenance
processes
2) Eradicate non value add servicecycles
3) Reduce maintenance budget
4) Improve safety for on-site personnel
Operations Manager1) Maintain high system reliability
2) Overload assets when needed withconfidence and dynamically definedlimits
3) Minimize asset time out of servicedue to impact on above
EHS Manager 1) Improve safety for on-site personnel
2) Limit impact of issues on generalpublic
3) Eliminate all risks that could lead tofatalities (No need for business case)
4) Improve compliance to EnvironmentLegislation
Condition- based Maintenance (CBM) Basics
Why condition-based Maintenance?
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Challenges of Condition Monitoring
Based Systems
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Challenges of Condit ion Monitoring Based Systems
1) Availability (or lack) of communications infrastructure
2) Incremental spending in front end Capital Expense, varying rate of return
3) Slow adoption of new standards
4) Lean engineering organizations at Utilities, slow process to change currentpractices
5) Training the workforce, education for the industry
6) Few vendors offering integrated CMB systems at Global scale
7) Early stages in real-time analytics and dynamic modeling for power systems
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Condition Monitoring is like insurance.
Everybody agrees its prudent to have it, but nobodywants to pay for it.Anybody could see the benefits, and
Somebody always asks why it was not fitted when its all
gone wrong
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References
1) WD IEC 61850-90-3
2) Application of Condition Monitoring and Technology within National Grid(UK), CarlJohnstone, National Grid, UK. CIGR-089 2012 CIGR Canada Conference
3) http://www.businessdictionary.com/definition/maintenance.html#ixzz2VFFiFfwd
4) http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf
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Q & A
Thank you for your time
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