leveraging the pi system's analytics and visualization...

© Copyright 2015 OSIsoft, LLC

Presented by

Leveraging the PI System's Analytics and Visualization Capabilities to Enable Condition-Based Maintenance Manila Electric Company

Mr. Rommel Rivera – Project Manager for Substation Automation, NTSE Mr. Raymond Herrera – Associate, Middleware and Integration, CIT Mr. Isamu Shinozaki – Chief Architect, Calibr8 Systems Inc.

© Copyright 2015 OSIsoft, LLC 2

• Largest electric distribution utility in the Philippines.

• Celebrated 112th year in service last March.

• Powers 5,367,720 customers in Metro Manila and adjacent provinces.

• Footprint covers 9,377 square kilometers.

• Home to approximately 25% of the Philippine population.

• About 50% of the Philippine Gross Domestic Product (GDP) is generated within the Meralco franchise

• 60% of Philippine manufacturing output produced within the franchise

• Accounts for nearly 75% of Luzon’s and 55% of Philippine energy sales

• 2013 sales revenue was equivalent to US$ 7.0 billion.

• Market capitalization at year-end 2013 was equivalent to US$ 6.4B.

Company Profile – Manila Electric Co. (MERALCO)


• Proactive approach to equipment maintenance

• Automatic notifications • Automated reporting • Proactive response to incipient

equipment failure • Prolong transformer life • Defer capital investment

Solution Benefits Challenges

Collect Transformer DGA test results & data from online DGA sensors

To provide better analytics in order to predict potential transformer problems

Integration of various systems and diverse data sources

PI System as the real-time Data Infrastructure Diagnostics detect potential problems

before they occur Optimizing equipment loading based on

equipment condition Reference Data and actions are

available to concerned users Different Views for Different Users on

any Device

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Leveraging PI System’s Analytics and Visualization to enable CBM


Web Service Delivery Channel and Condition Based Maintenance

PI Notifications

(PI AF)

Web Service

Maintenance System

Enterprise Asset

Management System

(EAM)

Networks Requirements for Historian • Repository for power transformer test data with

Analytics. December 2015 was the end of support for mainframe that runs MWMS/mainframe

• Real-time Data from Calisto and Hydran DGA, Circuit Breakers, etc.

• Integration with EAM for Conditions Based Maintenance.

• Operational Efficiency with loss of field visits on equipment

• Archive critical equipment

High Level Requirements of Meralco

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Chemical Testing Substation Operations Management

Implemented User Interfaces in Pilot Project

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Operation

Real-Time Notification and can send automatic work orders

Analyze

Data Warehouse

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Benefit • Collect and Store Data • Software Flexibility and

display data in various visualization types in Near Real-Time through PC, Tablet and Mobile

• Consolidation, Aggregation, Correlation and Consistency of Data

• End-to-End Connectivity • Analysis Accuracy

Pilot Set-Up

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High Level Roadmap Phase 1 - DGA

2015

Phase 2

2016-2017

• DGA Real time monitoring on all Transformers – 200+ units

• Implementation of 5 Key Gas Ratios

• Key Gases Ratio

• Roger’s Ratio

• Doernenburg’s Ratio

• IEC Basic Gas Ratio

• Duval’s Triangle

• Notifications via Email

• Automated reporting

• Different Views for Different Users on any Device

• Integration to:

• EAM

• ADMS / OMS

• GIS

• Other Potential Data Sources

Real – Time Data Platform and Historian

High Level Roadmap

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• Average Transformer Age: 25yrs. Life expectancy = 30 to 35 years.

Conclusion:

Almost $222,000 savings over 45 years per Transformer $4,900 savings Annually per Transformer $490,000 savings Annually for selected 100 Transformers ROI: 3 years

Yr 5 Yr 10 Yr 15 Yr 20 Yr 25 Yr 30 Yr 35

Yr 5 Yr 10 Yr 15 Yr 20 Yr 25 Yr 30 Yr 35

New Transformer Acquisition

$4.6 Million Investment

Yr 5 Yr 10 Yr 15 Yr 20 Yr 25 Yr 30 Yr 35 Yr 40 Yr 45

Yr 5 Yr 10 Yr 15 Yr 20 Yr 25 Yr 30 Yr 35 Yr 40 Yr 45

New Transformer Acquisition

$ 444,000 Investment

Existing Transformer Lifecycle

High Risk Average Life of Meralco Transformer

Average Life of Meralco Transformer High Risk Extending Life

Transformer Lifecycle with Real Time Monitoring

Sample Benefit Computation

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Pi Historian

Meralco Datacenter

• PI Server with Asset Framework • Meralco hierarchy based on divisions,

substations and equipment • Asset Analytics

• DGA business rules • PI Notifications

• E-mail alerts for condition based maintenance • Visual KPI visualization suite

• User customizable executive dashboards • Rapid response platform for maintenance

engineers • Viewable on most devices

• PI Manual Logger • Manual data entry to PI Data Archive

• PI UFL interface • Automated data collection from gas

chromatographer • Upload historical data from MWMS

• PI ProcessBook • Customizable Human Machine Interface (HMI)

for engineers • PI DataLink

• DGA reports • Visual KPI for Any Device Access • Calibr8 Systems for - System Integration and Services

(Deployment, Customization and App Development)

OSIsoft Products and Third Party Services Applied

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Rommel Rivera

[email protected]

Project Manager for Substation Automation

Network Technology Strategy and Execution

Manila Electric Company

Raymond Herrera

[email protected]

Associate

Middleware and Integration

Corporate Information Technology

Manila Electric Company

Isamu Shinozaki

[email protected]

Chief Architect

Calibr8 Systems, Inc.

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mailto:[email protected]





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