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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.
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• 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)
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• 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
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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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© Copyright 2015 OSIsoft, LLC
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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Questions
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