Understanding Condition-Based Maintenance

© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC
Using the PI System for
Condition-Based Maintenance (CBM)
June 5th 2019
2

Your Speakers
jkorman@osisoft.com
kpierce@osisoft.com
3

© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC
 Intro to CBM
 A Real World Example
 4 Approaches to CBM
 Additional Resources
Agenda
7

An Introduction to CBM
8

What are our maintenance options?
Reactive
“Break-Fix”
Run to failure
Preventative
Calendar-based
Condition
Based
Repair based on insight
Predictive
Advanced Pattern
Recognition
9

The Problem With Calendar Based
Maintenance
10
Too Frequent
Wasted Time & Resources
Too Infrequent
Catastrophic Failure
“Most the time when we go
into an asset we see they
are pristine… They don’t
need any maintenance”
-Exelon Energy
Running a
transformer to failure
can cost $3 Million
dollars to replace
-Alectra Utilities

Long Gaps Between Measurement and Action
Handheld Data
Collection
Manual Analysis
Detect potential failure
Create Work Order
Perform Repair
Typical
Timeline:
Days, weeks or
months before
issue is
addressed
Schedule maintenance with
operations
11

Why Solve it?
Reduce Maintenance Costs
Improve OEE
Capture Knowledge
“Unplanned downtime is
10x more expensive
than scheduled maintenance.”
-ARC
12

Speaks to your data sources
No IT Expertise Needed
Built for Operations
Why PI is the Right Choice
13

A Real World Example
14

Are all of my pumps healthy today?
15

Before & After?
Pump #3 is down!
Hotshot a part out here!
Check your email…We’ll
need to schedule some
maintenance soon.
16

Connect
Collect & Store
Assign Context
Execute Condition
Logic
Alert and Notify Visualize
PI Interfaces
PI Connectors PI Data Archive
17

Building a Digital Model – Start Small
Connect
Collect & Store
Assign Context
Execute Condition
Logic
Flowrate HeadX
Horsepower
Time
Efficiency
18

Build a Template
Calculationswith AssetAnalytics
Efficiency
Element
Template
Pump
Attributes
Pump Status
Discharge Flow Rate
Horsepower
Total Head
Pump Runtime
19

75%
Pump
Efficiency <
Assign Context
Execute Condition
Logic
Connect
Collect & Store
Time
Efficiency PI Event Frames
20

Writing Logic is Simple
x
Elements
Pump01
Attributes
Pump Status
Flow Rate
Horsepower
Total Head Maintenance event
Expression
True for
10 min
Template: Pump maintenance
‘Pump Efficiency’ < ‘75’
Analytics
Run Hours
Pump Efficiency
21

Element
Template
Pump
PI Notification
Event Frame
Recipient(s)
Assign Context
Execute Condition
Logic
Connect
Collect & Store
22

Reuse Your Template
&
23

Beyond basics: Notifications to a CMMS
(Computerized Maintenance Management System)
Notifications IBM maximo
24

Assign Context
Execute Condition
Logic
Connect
Collect & Store
25

Assign Context
Execute Condition
Logic
Connect
Collect & Store
Speaks to your data sources
No IT Expertise Needed
Built for Operations
26

4 Ways to Approach CBM
27

CBM Prescriptive Guidance
28

Maintenance Budget & Types
29

• Usage-based PM's
• Run hours
• Start / Stop counts
• Tonnage processed
#1 Preventive Maintenance
30

San Francisco PUC
31

• May be any single or combination of
performance indicators
• Vibration (with operational data)
• Efficiency (and degradation over time)
• Temperature (compared to usage and
ambient conditions)
• May be simple or complex
• Incidence over time may be critical
#2 Condition Monitoring
32

Calculating Expected Heat Rate
33

#3 Condition Assessment
34

PSE&G
35

Asset Health Score
36

The P-F Curve
37

• When an asset is not
performing as it has
historically
• Use history to build a
model
• Compare current
operation to historical
model
#4 Advanced Pattern Recognition (APR)
38

AGL – Diagnostics Center
39

Monitoring Asset Conditions
40

Asset Overview
41

Event Analysis
42

Performance Monitoring
43

CMMS Integration
44

Resources to Help you Succeed
45

Partners Are Here to Help
Condition data
Context
KPIs
Alerts
Displays
Partner
Integration
Custom
solutions
Turn-key solutions and predictive
models
Start condition monitoring with out-
of-the-box capabilities
PI System foundation
Services - SI
Devices, Setup
47

• Corporate Site – General info and use case search, webinars,…
• CBM Guidebook – Reference material on CBM and Condition
Monitoring
• Technical Support – technical resources, downloads, questions,…
• PI Square and CBM – Lots of resources
• PI Community – Peer discussions and OSIsoft moderation, industry
groups, development resources, whitepapers, webinars,…
• YouTube – training and introduction videos
• PI Learning – online courses, course materials,….
• Incorporating machine condition monitoring data
PI System CBM Resources
48

GenOn Energy - power Proactive-Maintenance-Data-Gateway-Built-on-the-OSIsoft-PI-System-Infrastructure
Ameren - nuclear power generation A-new-paradigm-in-utility-condition-based-maintenance
Vistra Energy (Luminant) - power Cloud-Transformation-in-a-Nationwide-Power-Producer
Barrick Gold - metals & mining Mine-Haul-Truck-Health-Monitoring-System
Petronas - oil & gas PROTEAN---Rotating-Equipment-Analytics-in-PI-AF
EQT - natural gas pipeline Reliability-Centered-Maintenance-Program
King County - waste water treatment PI-as-a-Maintenance-Tool
PowerStream - electricity distribution Equipment-Failure-is-Not-an-Option
Uniper - power How-OSIsoft-PI-supports-Unipers-Maintenance-Strategy-Planning
PSE&G - electricity distribution - transformers Condition-Based-Maintenance-Case-Study
ADNOC - oil & gas Improving-Equipment-Reliability-and-Availability-through-Real-time-Data
MOL – oil refinery Supporting-Operational-Availability-by-Connecting-the-PI-System-and-SAP-PM
OSIsoft Introduction-to-Asset-Monitoring-and-Condition-based-Maintenance-with-the-PI-System
SNCF - railways Using-Operational-Data-for-the-Future-Maintenance-of-the-French-Rail-Infrastructure
Vattenfall – hydro power Deploying-a-Condition-Based-Maintenance-Strategy-in-the-Hydro-Power-Business
Alyeska Pipeline - oil & gas Achieving-Reliability-Centered-Maintenance-and-Diagnostics-with-the-PI-System
Portland General Electric - power generation Experience-using-the-PI-System-for-Full-Featured-Vibration-Monitoring
PSE&G - electricity distribution - circuits Extending-Condition-Based-Maintenance-Program-to-Underground-Networks/
Silicon Valley Power - power generation Optimizing-Predictive-Maintenance-by-Integrating-Vibration-Data-and-Process-Data
Chevron – oil exploration Condition-Based-Maintenance-and-Smart-Monitoring-in-Frade-FPSO-with-the-PI-System
ESB - power Using-the-PI-System-in-Power-Generation-Operation-and-Maintenance-to-Optimise-Commercial—Environment
Las Vegas Valley Water District - water treatment Evaluating-Efficiency-and-Predicting-Maintenance-with-Existing-Data-Using-PI-AF-and-Asset-Analytics
OSIsoft Getting-started-with-iiot-sensors (may need to register – free)
CBM Customer References
49

PI is Fundamental to CBM efforts
Get Started Now
Speak to your Account Manager (AM)
New to PI
Watch our next webinar on CBM
Webinar on PI Vision
Reply to the webinar invite to talk!
Takeaways
50

Questions?
51

THANK YOUTHANK YOU

Understanding Condition-Based Maintenance

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