GROWING A TECHNICAL ASSET MANAGEMENT PROGRAM

Transcription

1 SOFTWARE GROWING A TECHNICAL ASSET MANAGEMENT PROGRAM Steps to Take and Advantages Along the Way SAFER, SMARTER, GREENER

2 Growing a Technical Asset Management Program WHITE PAPER ii Executive Summary Technical Asset Management (TAM): The proactive and strategic application of a comprehensive, integrated set of tools to optimize the performance of maintainable assets in order to maximize their value to the company. In simpler terms: When properly applied, a mature, predictive Technical Asset Management (TAM) strategy works to maximize the value of physical assets to the company s bottom line. To develop this type of program, a utility has to understand what TAM is and how to get the most out of it. The principles of TAM can be broken down into four main points: 1) TAM treats the company and all of its assets holistically. TAM is both a top-down and bottom-up endeavor. It is a top-down process because, for TAM to work, there has to be a philosophical shift and change leadership at the top levels. Departments and Divisions that used to focus solely on maintaining equipment in their territory will need to start looking at assets as parts in a company-wide system. It is also a bottom-up system, in so far as equipment data is of paramount importance. To implement an effective, evolving TAM program, a utility will need to identify and evaluate each maintainable asset and then develop a comprehensive maintenance strategy to increase the reliability and maximize the performance results of that asset. Field personnel must be engaged and involved. 2) TAM brings information from diverse sources (nameplate data, online monitoring information, conditional information including periodic diagnostic test results repair activities, etc.) into one locus of information. All analysis and decisions are derived from this Master Data Set. Having a current, normalized data source helps eliminate turf wars between departments and allows a utility to make financial decisions based on current, accurate data. 3) A mature TAM program monitors equipment Health (H) and determines a device s Criticality (C) to the overall performance of the company. By combining criticality and health, a utility can evaluate the Risk (R) to the organization s operation or corporate goals that are represented by a given piece of equipment. Using the CHR approach, a utility can effectively identify which devices should be temporarily but purposefully ignored, which should be maintained, and where and when replacements are required. This cuts down on unnecessary maintenance and directs capital expenditures to where they are necessary and are the most beneficial. 4) TAM provides flexibility, so categories of devices can be evaluated based on individual corporate situations and goals. A category might be as broad as all oil-filled reclosers or as specific as substation transformers made by the XYZ manufacturer in the 1960 s. A category can also include all devices on a critical transmission line. As more equipment data is collected, it will become easier to identify trends and therefore target equipment groups with similar characteristics and levels of importance.

3 iii WHITE PAPER Growing a Technical Asset Management Program It is important to keep in mind, TAM is a journey not a destination. Many utilities start with a basic Computerized Maintenance Monitoring System (CMMS) to perform Periodic Maintenance. Then, over time, they build on that system and add the features and capabilities that provide the greatest advantages. As the system evolves, companies move through various maintenance strategies to get to Predictive Maintenance (PdM), which enables a company to develop a Risk Centered Maintenance (RCM) program. TAM, in its best incarnation, is a proactive, strategic business process, whose purpose is to: Improve security of supply by reducing the risk of failure of critical assets Minimize unnecessary spending (lower maintenance costs) Eliminate or reduce low value maintenance Maximize design capabilities of existing equipment Effectively allocate capital expenditure Decrease asset and system down time A robust TAM program also allows utilities to create defensible Environmental reports Compliance reports Regulatory reports The remainder of this white paper will explain what an TAM program is and what it is not. It will provide a step-by-step description of how a utility can move from a nascent TAM system (Periodic Maintenance System) to a fully functioning, Risk based Maintenance (RbM) system capable of support larger organizational risk and security of supply goals. This paper will also explain what benefits can be gained along the way as utilities evolve their maintenance programs.

4 Growing a Technical Asset Management Program WHITE PAPER iv Contents Executive Summary Contents iii v Growing an Technical Asset Management Program 1 Periodic Maintenance 1 Condition-Based Maintenance 3 Risk-Based Maintenance 4 Maximizing the Value of a Next Generation TAM System 5 The Advantages of Technical Asset Management 8

5 Growing a Technical Asset Management Program WHITE PAPER 1 GROWING A TECHNICAL ASSET MANAGEMENT PROGRAM Steps to Take and the Advantages Along the Way Technical Asset Management (TAM) is sometimes confused with or likened to other methods of tracking equipment data and scheduling maintenance, but true TAM is much more than scheduling maintenance and requires a different approach. The following stages represent the typical path a company takes to a mature, robust TAM program as an energy utility. Periodic Maintenance Often, a company begins with a basic Computerized Maintenance Management Systems (CMMS) that might be nothing more than a database containing equipment nameplate information. This, in itself, is a valuable way to start because, unlike other large industries, an electric utility grid is typically spread out over a large territory. Equipment is often difficult to access, due to distance and/or terrain, and it is exposed to the worst weather nature has to offer. The importance of knowing where every maintainable device is located cannot be overstated. Once all equipment data is entered, the CMMS keeps track of what work has been done and schedules the next round of maintenance, base on fixed time frames. A CMMS enables a utility to do Periodic Maintenance. Today, the utility industry has reached a point where this approach is no longer sustainable for companies that compete in a modern de-regulated market. Periodic Maintenance focuses on maintenance procedures, not on objectives. Periodic Maintenance Focus is on performing scheduled time based maintenance Fixed schedules simplify maintenance planning Stage 1 Focus is on individual parts and devices, not on corporate goals Does not take equipment Health into account Does not take Criticality into consideration Does not provide insight to Risks affecting the utility The Advantages: Once the equipment data is entered, the system is easy to Most of the work done will be unnecessary run. Device categories can be set up and decisions can be or low value maintenance. made about when to do maintenance (every six months, every year, etc.) Periodic Maintenance makes it easy to predict how many man-hours of maintenance will be performed each year. Therefore, decisions about staffing levels (for maintenance work) are simple to make. There is no need for system-wide considerations, once standard schedules are set up. Therefore, each Division or Department can have their own CMMS or run their own part of a company-wide program.

6 2 WHITE PAPER Growing a Technical Asset Management Program The Disadvantages: A CMMS is not set up to maximize the advantages of monitoring or diagnostic testing results. Since time is not a true indication of the condition of the asset, periodic maintenance is not effective in preventing failures. There are multiple sources of equipment data. For example, nameplate data is kept in the CMMS, while Dissolved Gas Analysis (DGA) results or other test data might be stored in a file cabinet in a Division office. This approach does not take into consideration how critical a device is and therefore cannot be used to optimize overall system performance or its ability to meet corporate goals. If a company relies on a Periodic Maintenance system, most of the maintenance work completed will be unnecessary. This occurs for two reasons. First, all devices in a particular category receive the same level of maintenance, regardless of condition or usage. Second, Periodic Maintenance schedules are, by design, conservative. Therefore, the Periodic Maintenance schedule must be set to prevent failures of the oldest, weakest and most heavily loaded devices. All other devices get the same treatment meaning many assets are being overmaintained. Periodic maintenance does not consider condition so a device is maintained even if maintenance is not required. The result is higher Switching, Tagging and Travel costs to perform low value or unneeded maintenance. This takes away maintenance dollars from devices that are unhealthy due to operational stress events, and in addition may even introduce faults in healthy equipment. How To Move To The Next Level: Companies, sometimes reluctantly, naturally move from Periodic Maintenance to Predictive Maintenance due to scheduling and manpower uncertainties. Predictive maintenance programs benefit from information obtained about specific devices. This is typically diagnostic data, but can include loading operational stress events, repair and other information, as well.

7 Growing a Technical Asset Management Program WHITE PAPER 3 When discussing the evolution of TAM, Preventative Maintenance is often listed next, but the term Preventative Maintenance can be somewhat ambiguous. All companies want to prevent failures, so all TAM approaches can be considered preventative. Often, Preventative Maintenance is used to signify that a TAM system is in the nascent stage of Predictive Maintenance and that a company is starting to use operational stress and test data to identify which devices are likely to fail. In reality, this stage is best called Condition-based Maintenance. Condition-Based Maintenance The more sophisticated Condition-Based Maintenance approach begins to address the fact that not all devices (of the same type and age) are the same. Maintenance is performed based on the Health of a device and when necessary to prevent equipment failures. The focus is still on a device level with little or no recognition that some devices are more important than others (i.e. no criticality analysis). For example, a transformer serving 100 customers gets just as much attention as a transformer serving 1,000 customers or the region s hospital if the failure probability based on condition is the same. While most Condition-Based Maintenance programs are capable of collecting and manipulating test and usage data, they might not be able to handle data from diverse sources, like real-time SCADA and online condition monitoring information or other known sources from Oil Analysis and power factor and time testing. Condition-Based Maintenance Focus is on preventing failures Does not take the Criticality of assets into The Advantages: consideration. This approach can reduce the amount of maintenance work required, because unnecessary work is reduced. Since testing and monitoring results are considered and corrective action is focused on higher risk equipment, Condition-Based Maintenance does reduce the likelihood of equipment failures. The utility gets more value from its testing and diagnostic programs and improved resource utilization. Stage 2 The Disadvantages: Like Periodic Maintenance, this approach does not take into consideration how critical a device is and therefore cannot be used to optimize overall system performance or its ability to meet corporate goals. While some diagnostic and monitoring data is used, there is no comprehensive, centralized source of data. Without one single source of truth, decision making cannot be optimized at the highest (enterprise) level. Takes most data into account Maintenance schedules can vary, depending on equipment Health Focuses on individual parts and devices Does not concentrate on corporate or organizational goals How To Move To The Next Level: Utilities might be satisfied with the benefits of Condition-Based Maintenance, which does not require a profound change in philosophy. But, as the electric market becomes more competitive and when vast amounts of equipment health data become available, companies recognize that opportunities in efficiency are being missed.

8 4 WHITE PAPER Growing a Technical Asset Management Program A TAM system can only be truly considered a Predictive Maintenance program when Health and Criticality can be quantified and used to determine when to ignore, maintain or replace a device. Risk-Based Maintenance Risk based Maintenance (RbM) has many guises and comes in many forms. The bottom line is this: Maintenance programs move from being reactive to being proactive. The focus shifts from preventing failures to predicting what the optimal maintenance schedules are when maintenance work is most cost effective. This may seem like a minor difference, but it has powerful ramifications. To begin, Criticality is now included in the decision making process. Work can be prioritized based on the impact to the corporation upon a specific asset s failure. Through the monitoring of operational stress and measuring key electrical and mechanical parameters utilities can identify when a device crosses a performance threshold that would negatively impact grid operations. Risk based Maintenance, which is necessary to support organizational security of supply targets, is only enabled by a robust Predictive Maintenance system which enables utilities to identify those assets, which if they fail, have the highest impact to the enterprise. Predictive Maintenance uses all available equipment Health data. As a result, there has to be one comprehensive, trustworthy source of data. All decisions are made based on this common source of truth. Risk-Based Maintenance Stage 3 Focus is on overall organizational performance Pro-active, rather than reactive Uses all available equipment Health data Incorporates Criticality into maintenance plans Risk can Criticality and Health values are available Capable of supporting advanced risk management goals and reliability programs. The Advantages: Predictive Maintenance is the most efficient and effective way to schedule maintenance. It also maximizes the value of diagnostic and monitoring data which produce the most reliable results. This includes the high volume of data collected from diverse sources, like Smart Grid Technologies and Smart Meters.It allows a utility to view the company as a single entity, without separating goals by department. (e.g. Operations, IT, Budgeting, Financial, etc.) By using Predictive Maintenance, a utility can develop Risk-Based Maintenance plans. Maintenance triggers can be created and alerts sent to allow just-in-time maintenance. The Disadvantages: Moving from a Condition-Based to Predictive Maintenance approach requires a philosophical shift in the way everyone in the utility thinks about equipment and the purpose of maintenance. For example, line workers normally change out oil-filled reclosers every three years. Before Predictive Maintenance or RbM, they thought they were maintaining the lines. With Predictive Maintenance, they should be thinking, I TAM ensuring the revenue stream from the customers on this line, by maintaining or improving this line s reliability. Substation crews might find that the normally scheduled outage in the spring has been cancelled, because the risk of equipment failure is low and the loss of revenue does not justify shutting down the substation. Depending on what maintenance system was in use before, a Predictive Maintenance system may or may not require training. It may or may not require the integration of new monitoring systems to get data into a central data storehouse. If various Department and Divisions were used to working autonomously, there may be some resistance to sharing data and giving up decision making power. However, the cost savings, improved reliability, and increased organizational efficiency make overcoming these challenges worthwhile. How To Move To The Next Level: Once a Predictive Maintenance system is in place, a utility can develop an RCM system, adding more sources of data and fine-tuning work and capital expenditure plans, to meet corporate goals.

9 Growing a Technical Asset Management Program WHITE PAPER 5 Maximizing the Value of a Next Generation TAM System Below, is a discussion of some of the benefits of an advanced TAM system and some points to consider when choosing a vendor to supply and support such a system. Embrace Data Analytics Electric utilities are now in the data analytics business. This is the result of several global forces one being the proliferation of less expensive electronic monitoring technologies and the speed and availability of communications systems. Also, everyone wants to have the Smartest Grid possible. As a result, an unprecedented amount of raw data is being collected by utilities each day. Big Data, as it is referred to, is a double-edged sword. On one hand, all that data creates a real opportunity for utilities to better monitor and understand how a device or system is operating. On the other hand, converting that sea of data into actionable information can be a daunting task. Therefore, it is imperative to have an TAM system that can handle, integrate, and verify the data to maximize its value. Diversity of Utility Data Varying Times: from periodic diagnostic testing to real-time monitoring Diverse Equipment: power-class transformers through single-phase reclosers Different Data Types: from hand entered, visual inspection notes to high-tech partial discharge monitoring Multiple Sources: data from hundreds or thousands of different monitoring/test devices supplied by dozens of different vendors A major strength of a mature TAM system is the ability to bring all the data into one store house and develop algorithms that can analyze the data and predict which devices should be ignored, maintained, or replaced. The most effective TAM systems Can handle massive amounts of data and data diversity Put the Data to Use If a utility is collecting more data, it only makes sense to put that data to use in as many ways as possible to maximize ROI. The most obvious use is to evaluate the Criticality, Health and Risk of individual devices. Engineers can use standard industry evaluation criteria, like perform maintenance on breakers after X number of operations or when a single event had a fault current above Y. With the right TAM system, utilities can also create their own evaluation criteria, quite easily. In the example below, engineers at a large Investor Owned Utility (IOU) identified the most important risk factors associated with the failure of oil-filled breakers and created an algorithm to calculate the chance of failure. At the end of the evaluation, it was discovered that 4% of substation breakers (800 in total) needed replacement in order to maintain operational goals. The most effective TAM systems Let you develop your own algorithms

10 6 WHITE PAPER Growing a Technical Asset Management Program Case Study: Evaluating Oil-Filled Circuit Breakers Using CHR Criteria Each of approximately 20,000 oil-filled circuit breakers was rated in the following areas: Overstress (A) High Maintenance (B) Bushing Type (C) Manufacturer (D) In each category, every breaker was given a score of 0 through 3. The higher scores indicated greater concern. For example, certain bushing types had a history of failures, so any breaker with that type of bushing automatically received a score of three for Bushing Type. Historical data showed that overstressed breakers were at significantly greater risk of failure. This was addressed by creating the algorithm to weight the Overstress criterion by a factor of six. A final score (0 through 3) was calculated for each breaker and recommended action (ignore, monitor, replace) was based on that score. Evaluating Algorithm Resulting Action [6A + (B + C +D)] 0 or 1 No Action Necessary Monitor Closely 9 3 Replace Following this evaluation, the utility scheduled the replacement of 800 (4%) of its oil-filled breakers (over a ten year period). Roughly 1,400 breakers were monitored more closely. By using this approach, the utility identified where the greatest risk lay and took action to reduce that risk. This capability is one of the benefits of a robust TAM system. 4% 7% 89% Replace Monitor More Closely No Action Necessary Oil Circuit Breaker CHR Results

11 Growing a Technical Asset Management Program WHITE PAPER 7 Set Thresholds A PdM system can also be used to determine and set thresholds that trigger maintenance (or replacement) to reduce the risk of failure. For example, a transformer can be operated under heavy-load conditions for a long time without suffering and damage. But, if a transformer is over heated once, its life span can be reduced to essentially zero. The most effective TAM systems Allow you to set triggers and alerts Preventing a transformer from crossing the threshold (from hot to too hot ) can mean the difference between regular maintenance and potential replacement. The most effective TAM systems Allow you to generate regulatory reports Great Expectations One purpose of moving to a Predictive or Reliability-Centered Maintenance system is to use CHR to optimize non-operational aspects of the corporation. This can include required reports on reliability metrics (SAIDI, SAIFI, MAIDI, MAIFI) and on regulatory compliance. The Advantages of Asset Management Asset Management systems can provide a host of benefits to utilities wanting to capitalize on their data systems and maximize asset health. Asset management, when systematically applied: Collects and analyzes available data and uses it to make informed decisions about the conditions of equipment Identifies and schedules necessary maintenance on the most critical assets, while reducing or eliminating unnecessary work Determines the most cost effective capital replacement plan Provides regulatory compliance information and reporting capabilities Improves reliability and thereby improves customer satisfaction and increases revenue

12 SAFER, SMARTER, GREENER For more information: DNV GL - Software NO-1322 Hovik, Norway Tel: software.communications@dnvgl.com DNV GL NO-1322 Høvik, Norway Tel: DNV GL Driven by its purpose of safeguarding life, property, and the environment, DNV GL enables organisations to advance the safety and sustainability of their business. DNV GL provides classification and technical assurance along with software and independent expert advisory services to the maritime, oil & gas, and energy industries. It also provides certification services to customers across a wide range of industries. Combining leading technical and operational expertise, risk methodology, and in-depth industry knowledge, DNV GL empowers its customers decisions and actions with trust and confidence. The company continuously invests in research and collaborative innovation to provide customers and society with operational and technological foresight. DNV GL, whose origins go back to 1864, operates globally in more than 100 countries with its 16,000 professionals dedicated to helping their customers make the world safer, smarter and greener. The trademarks DNV GL and the Horizon Graphic are the property of DNV GL AS. All rights reserved. DNV GL 2014