cesc limited
DESCRIPTION
Cesc limitedTRANSCRIPT
P. MukherjeeDy. General Manager
IT - New Initiatives7th October, 2013
Distribution Related Engineering Asset Management System(DREAMS)
CESC – Electricity Generation & Distribution Company
Serving Calcutta & its adjoining areas since 1897.
The electrification of Calcutta took place 17 years after New York & 11 years after London.
The Calcutta Tramways switched to electricity from horse drawn carriages in 1902.
CESC now belongs to the youngest & one of the most vibrant industrial houses – RP - Sanjiv Goenka Group since 2011.
CESC – Electricity Generation & Distribution Company
Licensed Area of 567 sq. km.
Total Generating Capacity : 1225 MW
Peak Demand : 1900 MW
Average Demand : 1600-1700 MW
Total Low Tension Consumer Base : 27.20 Lacs
Total High Tension Consumer Base : 1726
CESC’s ExperienceEarlier Scenario :
Unstructured and non uniform practices followed in maintaining records of Asset and their up-keep.
CM & CBM were mostly not supported.
Leading to disproportionately more unplanned maintenance than planned maintenance .
Difficulty in estimating maintenance cost and analyzing maintenance performance.
Solution : CESC’s Asset Management Software.
Distribution Related Engineering Asset Management System
(DREAMS)
Features and Functionalities of DREAMS
Integrated Asset Register of major electrical plant and equipment in use including allied assets such as Substations building, premises and yards.
Maintenance Management functionalities encompassing Preventive Maintenance(PM) Status & Condition Monitoring (SM&CM) Condition Based Maintenance (CBM) Repair/Breakdown Maintenance (BM)Abnormal Observation (AO)
Carrying out all maintenance activities as per SM,CM,PM regimes stored in the system.
Analyze, interpret and maintain the transformers with the help of the Dissolve Gas Analysis (DGA) Dash-Board tool integrated with the system.
Handing Over Taking Over (HOTO) Module for managing assets during creation, installation and commissioning before handing over to Operations & Maintenance (O/M) group.
ASSETS CONSIDERED
Power Transformer 33/0.4 kV Earthing Transformer 33/0.4 kV Auxiliary Transformer Indoor Switchboard Outdoor Circuit Breaker Outdoor Isolator Outdoor CT Outdoor VT
Distribution Transformer Outdoor Lightning Arrester Ring Main Unit (RMU) Premises Neutral Earthing Switch Outdoor Cable Sealing End Battery Battery Charger Capacitor Bank
DREAMS
Total No. of Assets as on date : 24578
CODIFICATION OF ASSETS
DREAMS
An algorithm was formulated to assign an 8 character unique code to all assets
The left most character signifies the Super Category like Power Transformer etc. The next left most character denotes the Primary Voltage like 220KV etc. The next five digits from left is a unique serial number The right most character is used to differentiate amongst assets of same primary voltage but with different secondary voltage.
Super Category : Power Transformer
220/132/33 KV Power Transformer A7*****O
132/33 KV Power Transformer A6*****O
33/20 KV Power Transformer A5*****A
33/11 KV Power Transformer A5*****B
33/11-6 KV Power Transformer A5*****C
33/6 KV Power Transformer A5*****D
20/6 KV Power Transformer A4*****O
11/6 KV Power Transformer A3*****O
6/3.3 KV Power Transformer A2*****O
Super Category : Distribution Transformer
11/0.4 KV Distribution Transformer B3*****A
11/6-0.4 KV Distribution Transformer B3*****B
6/0.4 KV Distribution Transformer B2*****O
ASSET REGISTERDREAMS
Asset Searching Assets searched using different criteria such as
category/location/make/name/Asset No. All criteria appear on the upper part of left pane of the screen. General Tab The list of assets based on the selected searching criteria appears on the right
pane. All the attributes displayed alongside the asset no. with a scrolling facility.
ASSET REGISTERDREAMS
Asset Sorting & Filtering Sorting of Assets based on the values of any attribute in ascending/descending
order. Application of Filter on the values of any attribute of Assets.
ASSET REGISTERDREAMS
Health Tab Indication of health of any asset through color codes based on the last observations
from SM/CM/AO. ‘RED’ -> URGENT ’BLUE’ -> IMPORTANT
ASSET REGISTERDREAMS
Maintenance Tab Display of schedule for forthcoming maintenance activity (SM/CM/PM) as on date
through color codes based on the periodicity as mentioned in the maintenance Regime. ‘RED’ -> OVERDUE ’BLUE’ -> scheduled within one month.
MAINTENANCE FUNCTIONSDREAMS
Status Monitoring (SM) Monitoring of assets through visual inspection. Urgent/Important observations posted in the system. Job Allocation & Attending to the job by O&M engineers.
MAINTENANCE FUNCTIONSDREAMS
Condition Monitoring (CM) Monitoring of assets by measurements through Intrusive & Non-Intrusive activities. Non-Intrusive CM (e.g. Thermo-graphic Scanning etc.) measurements posted in the system. Job Allocation & Attending to the job by O&M engineers. Non-Intrusive CM Re-measurement done again. Intrusive CM measurements (e.g. IR & PI Values etc.) are taken & posted by O&M
departments. Non-Intrusive CM
MAINTENANCE FUNCTIONSDREAMS
Preventive Maintenance (PM) The Preventive Maintenance (PM) done by O&M departments as per the schedule
mentioned in the PM Regime.
MAINTENANCE FUNCTIONSDREAMS
Maintenance Regime The SM/CM/PM Regime for different categories of assets are stored in the system.
MAINTENANCE FUNCTIONSDREAMS
Queries & Reports There are a host of queries & reports which caters to the diverse requirements
across all user departments.
MAINTENANCE FUNCTIONSDREAMS
Dissolve Gas Analysis (DGA) Dash Board The results of gases (CH4,C2H2,C2H4 etc.) from oil samples of Power Transformer posted
inside the DGA Dash Board. Six different interpretation methods such as :- IEC Reference, ROGER’s Ratio, DORNENBERG’s
Ratio, Key Gas Method, Combustible Gas Method, Permissible Concentration Gas Method used to interpret the health of the transformer.
MAINTENANCE FUNCTIONSDREAMS
Dissolve Gas Analysis (DGA) Dash Board The results of gases CH4,C2H2,C2H4 can also be plotted on Duval Triangle . Trend Analysis of dissolved gases through Line & Bar Chart is also possible.
HARDWARE PLATFORM
DATA CENTRE
CENTRAL SERVER REGIONAL SERVICES
C
E
S
C
N
E
T
PCs at User End
ONLINE
ACCESS
SUNM4000 (App)
SUNM4000 (DB)
SUN StorageTek 6580 (16 TB)
CENTRALISED ARCHITECTURE
DREAMS
4 Ultra Sparc VII+128 GB
4 Ultra Sparc VII+
128 GB
SOFTWARE PLATFORM
State of the Art Technology
O/S : Sun Solaris 10
Database : Oracle 10g Enterprise Edition
Application tier : J2EE (Glassfish)
Front end : Web browser (Internet Explorer)
Architecture : 3-Tier Browser - Application Server - Database Server
DREAMS
ENGINEERING EXCELLENCE Pioneering effort in conceptualization, design, development and implementation of a state-of-the-art IT application for Engineering Asset Management, developed in-house.
Multi-faceted Asset Register.
Provides entire Asset database on finger tips.
An innovatively designed single window for viewing all asset information, health & maintenance schedules together.
DREAMS
Dissolve Gas Analysis (DGA) Dashboard :
A perfect analysis tool to identify failure prone Power Transformers and thereby taking proactive measures to avoid breakdown.
KEY IMPACTS Significant reduction in un-planned maintenance. Inculcating a new philosophy of planned maintenance through :
Status Monitoring (SM) Condition Monitoring (CM) & Condition Based Maintenance (CBM) Preventive Maintenance (PM)
DREAMS
24
112
136
18
63
81
0
20
40
60
80
100
120
140
160
11 KV DOWNSTREAM SWITCHGEAR
6 KV DOWNSTREAM SWITCHGEAR
TOTAL DOWNSTREAM SWITCHGEAR
2011-12 2012-13
Till Mar 2013
Resultant Fault Reduction in Switchgears
KEY IMPACTS DREAMS
Financial
Till Mar 2013Rupees in Lacs
Green Initiative Paper-less storage of asset information and maintenance records. Paper-less communication through system generated emails.
KEY IMPACTS
Tracking of assets throughout its lifecycle.
Planning and allocation of appropriate resources by O&M Departments well ahead of time.
A host of queries and reports available to monitor the timely completion of O&M activities, identify performing & non-
performing assets.
Analysis of commissioning and maintenance related data in order to provide insight into asset performance and planning for its
replacement.
DREAMS
FUTURE READINESSDREAMS
Having potential to make itself scalable at the enterprise level by including assets of Generation and Transmission.
Capable of Integration with Geographical Information Systems (GIS)
Capable of Integration with ERP for Finance and Purchase Divisions.
