1 Applying and Benefitting from Online Condition Monitoring Tony McGrail Doble Engineering Motivations? Justifications? Motivations: - ‘online’ systems can yield ‘real time’ information - Improve understanding of ‘true’ asset condition - Support asset related decisions – short and long term Expected benefits - Reliability improvement - can reduce the risk of an un-scheduled outage. - Failure avoidance costs: - Equipment replacement costs - Safety & Environmental penalties and fines - O & M Costs - Capital investment deferment - O&M cost reduction Value Destruction: Deepwater Horizon Over $2 B in cleanup costs Over $60 B in lost stock value 3 Success in Applying Condition Monitoring • Control the measurement being made • Understand Context and impacting parameters • Actionable Conclusions- timescales & SMART • Let’s take a simple example: single value DGA ©2012 Doble Engineering Company. All Rights Reserved Principal of Operation Normal transformer – this one has pumps and radiators Single Value DGA device- indicates levels of dissolved gases in transformer oil Set alarm levels at, say, 20% & 40% above ‘normal’ After an alarm – take a sample for lab DGA • Alarm? 5/7/2012 5/5/2012 5/3/2012 5/1/2012 4/29/2012 4/27/2012 4/25/2012 4/23/2012 4/21/2012 4/19/2012 4/17/2012 Dissolved Gas in ppm DGA Data • What do we expect to see? 90 Dissolved Gas in ppm for critical transformer 80 70 60 50 40 30 20 10 0 Recent dobleARMS notification Alert: Warning. Increase H2 115, SID: T1, Substation: Sub1 Perform lab test within 10 days Asset: CITY STATE\SITE\T1 Source: 2101 Alert Time: Jan xx 2014 xx:xxPM “That is a pretty significant increase in CO and hydrogen is really not a factor. .. there is an electrical condition affecting the condition of the paper. Continue to monitor, and when the composite reading gets to about 160 ppm the CO will be at 1000 ppm or thereabouts and they should make an effort to take the unit out of service and have a look.” Bushings: Graceful and Rapid Failures Asset Risk Management System IM Summary dobleARMS™ Drilling Down dobleARMS™ One Line Drill Down…. 14 Conclusions • Even simple devices need good analysis • Actionable information • Agree action plans in advance “Someone in the organisation needs to be responsible for online monitoring and learning all they can about their performance within their context. “ “ The capability of application engineers to support and interpret the full range of available data is often key to getting benefit from the monitoring application.” Look at Assets as interrelated Systems e.g. Transformers Create Failure Categories Focus on “Failure Methods/Modes” Apply Relevance Weighting at all levels Missing Data: Self Healing • Bushings • Insulating Materials • Thermal • Dielectric • Operational • OLTC • Mechanical • Transformers • Breakers • …. Assets/Apparatus Assessments Goal: Asset Health & Risk • Assessment sub groups • Interrelated sources • Complex rule engines • Statistical analysis • Configurable sources Methods Interventions/Modes Analytics • SCADA • IEDs • DGA/Oil/Furans • EAMs Sources • GIS • Other Doble’s ARMS Methodology 16 Areas for OLM Improvement • • • • • • Information not data Appropriate limits Analytics with context Integration for condition assessment Understanding of FMECA Relating condition to actions with timescales 17 Questions? [email protected]