Moving from Time Based Maintenance to

Condition Based Maintenance

Presented By: Thomas Linn Qualitrol LLC
September, 2013
Thomas Linn has a strong background of 20 years plus experience in high voltage equipment
such as gas insulated switchgear, high voltage bushings, cables, transformers, high voltage
testing, partial discharge measurement and monitoring and high voltage test equipment.
Thomas graduated from Technical University of Dresden with a degree in Electrical
Engineering, specialized in High Voltage Techniques. Afterwards he worked till today with
high voltage equipment. 1998 he joint ABB in Switzerland and was responsible for High
Voltage Onsite Testing for GIS and cables, PD measurements onsite and PD monitoring of
Gas Insulated Switchgear. 2003 he took over the responsibility for the High Voltage Test Labs
for routine and type testing mainly for high voltage transformer bushings.

Agenda
Overview
1. Definitions around Maintenance
2. Traditional Methods and current state of Maintenance
3. Condition- based Maintenance (CBM) Basics
4. Challenges of Condition Monitoring Based Systems
5. Q & A

Definitions around Maintenance

Definitions around Maintenance

What is Maintenance?
Maintenance are actions necessary for retaining or restoring a piece of equipment,
machine, or system to the specified operable condition to achieve its maximum
useful life.
Source: http://www.businessdictionary.com/definition/maintenance.html#ixzz2VFFiFfwd

Type of Maintenance?

Reactive maintenance (Run-to-failure maintenance)

Preventive maintenance (Time-based maintenance)

Predictive maintenance (Condition-based maintenance)

Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf

Type of Maintenance Run-to-Failure Maintenance

Definition:
Run-to-Failure maintenance (also known as corrective maintenance) involves all unscheduled
actions performed as a result of system or product failure. Basically, it is an attempt to restore
the system/product to a specified condition.
Source: http://www.referenceforbusiness.com/management/Log-Mar/Maintenance.html#ixzz2VFbobDte

Advantages

Low cost.

Less staff.

Disadvantages

Increased cost due to unplanned downtime of equipment.

Increased labor cost, especially if overtime is needed.

Cost involved with repair or replacement of equipment.

Possible secondary equipment or process damage from equipment failure.

Inefficient use of staff resources.

Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf

Type of Maintenance Time- based Maintenance

Definition:
Time-based maintenance utilizes a previously developed maintenance schedule for each
asset/ equipment. This is much like an oil change on an automobile that takes place every
three months or 3,000 miles, whichever comes first.
Source: http://www.referenceforbusiness.com/management/Log-Mar/Maintenance.html#ixzz2VFbobDte

Advantages

Cost effective in many capital-intensive processes.

Flexibility allows for the adjustment of maintenance periodicity.

Increased component life cycle.

Energy savings and Reduced equipment or process failure.

Estimated 12% to 18% cost savings over reactive maintenance program.

Disadvantages

Catastrophic failures still likely to occur.

Labor intensive.

Includes performance of unneeded maintenance.

Potential for incidental damage to components in conducting unneeded maintenance.

Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf

Type of Maintenance Condition-based Maintenance

Definition:
Condition-based maintenance involves all actions performed as a result of system or product
condition, detected by means of condition monitoring. Basically, it is eliminating causal
stressors, with can lead to a degradation of the asset or equipment.
Advantages
Increased component operational life/availability.
Allows for preemptive corrective actions.
Decrease in equipment or process downtime.
Decrease in costs for parts and labor.
Better product quality.
Improved worker and environmental safety.
Improved worker morale.
Energy savings.
Estimated 8% to 12% cost savings over time-based maintenance program.
Disadvantages
Increased investment in diagnostic equipment.
Increased investment in staff training.
Savings potential not readily seen by management.
Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf

Traditional Methods and current state

of Maintenance

Traditional Methods and current state of Maintenance

A referenced study from US breaks down the average maintenance program as
follows:
>55% Reactive
31% Preventive
12% Predictive
2% Other
Note that more than 55% of maintenance resources and activities of an average
facility are still reactive.
(Source: http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf)

Traditional Methods and current state of Maintenance

Commonly accepted practice is to follow Manufacturers advised schedule, like
changing your cars engine oil at every 3000 miles or three months
1) A Utility company cannot keep up with time based maintenance in a deregulated
business model, and highly regulated environment protection.
2) Experience and proven studies demonstrate greater asset risk and depending
revenue loss when using time based maintenance

Traditional methods lack the needed sensors and associated measurements to

analyze, record and suggest preventive maintenance or control actions
Assets like Battery banks, cap banks, underground cables are relatively difficult
and expensive to maintain, often underserved by Utilities
Diagnostics, Reporting and control measures are mostly a manual process
prone to errors. Requires constant training and retaining large crews.

Traditional Methods and current state of Maintenance

Cost calculation
Full cost view includes secondary (invisible) costs:

Traditional view includes primary (visible) costs:

Replacement parts costs

Labor costs
Primary Costs for outages
Storage costs

Moral of employ
Safety aspects
Reduced costs for parts and labor
Secondary outage costs (penalties, brand
damages etc.)
Inventory costs
Indirect cost reduction due to longer lifetime

Traditional Methods and current state of Maintenance

1400

Others
Maintenance Defects
Equipment Defects

Number of troubles

1200
1000
800

118
153

600
400
200
0

157

173

174

172

121

70

117

166

227

246

227

215

189

0~3

4~6

7~9

139

342

386

196

194

107

822

477
398

207

190

10~12 13~15 16~18 19~21 22~24

261

25~

Service years
(Source: CIGRE 1992)

In older Equipment maintenance is a big contributor to failure!

Traditional Methods and current state of Maintenance

Condition- based Maintenance (CBM)

Basics

Condition- based Maintenance (CBM) Basics

Condition-based maintenance is a set of activities that detect changes in the physical
condition of equipment (signs of failure) in order to carry out the appropriate maintenance
work for maximizing the service life of equipment without increasing the risk of failure.
Condition-based maintenance

depends on continuous or periodic condition monitoring equipment to detect the signs of

failure.
Condition-based Maintenance

Defining valuable data to measure

Collecting the data

Intelligent data analyzing/ processing

Assessing Condition of equipment

Defining maintenance decisions

Condition- based Maintenance (CBM) Basics

What is needed to do Condition-based Maintenance?
Commitment of Management

CBM Concept

Suitable Sensors

Reliable System

Knowledge

Data processing

CBM relevant quality data analyses by expert

systems
Maintenance decision based on data and Knowledge (automatic/ manually
supported)

Condition- based Maintenance (CBM) Basics

CBM Concept
For a suitable CBM Concept the level o actions needs to be defined and represented in the
monitoring system (different level of access etc.). The responsibilities, the included actions
and the expected decisions for each level needs to be clearly defined.
First Level:

qualified data/ warning/ alarms will be provided (System)

Second Level:

Information will be received, reviewed and acknowledged; decision about further

actions will be drawn (e.g. by operator with system support)

Third Level:

Received data will be further analyzed; decision about further investigation will be
drawn (e.g. by maintenance crew with system support)

Forth Level:

Further investigations on the equipment itself (e.g. time- of- flight, oil sampling);
decision about necessary maintenance actions will be drawn (e.g. external or internal
specialist with system support and/or additional diagnostic methods)

Fifth Level:

applying maintenance (e.g. repair or replacement by external or internal stuff); the

decision about clearance for further operation will be drawn (e.g. maintenance
manager).

The above mentioned concept shows an basic example and might varies according to CBM strategy of the
equipment owner, level of experience, level of competences etc.

Condition- based Maintenance (CBM) Basics

Suitable Sensors
The used sensors should be able to collect the measured parameter with a minimum
demanded sensitivity, which should be proven by means of state of the art methods and
documented.
The sensors should not incorporate unnecessary risk to the monitored equipment, to OHS
and environment.
Fixing and connection to equipment and the buildup of the sensor itself and all connected
parts should be resistant to the same environment as the monitored equipment itself at least.
The expected lifetime should be as long as the monitored equipment itself or, if not possible,
at the high end of state of the art of same kind of sensors.
In case of a defect of a sensor, it should not result in a fault of the monitored equipment.

Condition- based Maintenance (CBM) Basics

Reliable Monitoring System
The connected monitoring system should provide different level of access according to the
levels in the CBM concept (e.g. red and green light for first level, some data analyses
features for the second level etc.).
It should be suitable to withstand the environment where it will be installed.
All system failures should create a signalization to first level.
The system should be meant for long life operation, equipped with proven reliable
components/ parts.
The user interface needs to be so designed, that it is easy to use and all information provided
must be easy to find according to the level of access.
The recorded data have to be stored in a save and reliable way.
The system should be able to be integrated to station networks, equipment owner private
networks and phone lines.

Condition- based Maintenance (CBM) Basics

Reliable Monitoring System further properties
Scalable System Architecture:
1) Scalable from single asset to a complete substation, or to include complete Utility
infrastructure
2) Choice of integration in existing SCADA or an independent CMBS
3) Optional use of Cloud computing, web interface, apps for smart phones

Mature information management and rule packs for data interpretations

1) Minimize nuisance alarms
2) Accurate interpretation with specific recommendation for maintenance action
3) Custom reporting capabilities for different levels of organization
4) Long term archival (1 to 10 years), trending and projected asset availability

Condition- based Maintenance (CBM) Basics

Integrated solution - Example of data integration

Condition- based Maintenance (CBM) Basics

Integrated solution - Example SmartSUB

SF6 monitor

DGA monitor (8 gases)

PD monitor

Condition- based Maintenance (CBM) Basics

Data processing and CBM relevant quality data analyses by expert systems
Condition monitoring is a joint effort between
manufacturers (OEM and 3rd parties, utilities
(equipment, P&C, communications) and software
developers
The data analyses system should be a
development with Utilities, OEMs and University
researchers to provide best in class modelling and
simulation module accuracy to ultimately provide
automated link to CBM planning tools.
The messages to the user should be clear and
should provide the necessary information to
assess the cause of the degradation of physical
condition (e.g. type of defect, area of source etc.)

Raw Data
From Sensors

Signal Processing

Qualify Data
Based on CM Attributes

Boolean / Fuzzy Logic

Based Expert System

Artificial Neural Network

Expert Systems (Diagnostics & Modelling)

Automated
CBM Planning

Condition- based Maintenance (CBM) Basics - Example

Example: Transformer Dissolved Gas Analysis Diagnostic

First new DGA diagnostic tool in decades

Correct fault condition identification in 96% of cases surpassing existing
tools
Provides fault identification AND severity levels
Enables Exception-Based analysis on Big Data DGA databases
Utilizes Artificial Neural Network (ANN) Programming and an Expert System
ANN trained on data sets that marry pre-failure DGA data with post-failure
inspection results
Additional analytic elements include:
Harmonic Regression to remove harmonic components in the data, clearly
revealing the underlying trends
Piecewise Linear Approximation to accurately assess gassing rate of change

Condition- based Maintenance (CBM) Basics - Example

Diagnostics:
Four fault categories are identified

High Energy Discharge (HEDA)

Low Energy Discharge (LED)
Over Heated Oil (OHO)
Cellulose Decomposition (CD)

Severity of the fault category is assigned and rated

within a 6 level scale
Notifications can be customized by fault category and
severity to enable exception-based analysis.

Condition- based Maintenance (CBM) Basics - Example

DGA Visualization example (8 gases)

Condition- based Maintenance (CBM) Basics

Knowledge Management
Or
What to do with my Information?

Knowledge Management!

Condition- based Maintenance (CBM) Basics

Knowledge Management (KM) comprises a range of strategies and
practices used in an organization to identify, create, represent, distribute,
and enable adoption of insights and experiences.
Such insights and experiences comprise knowledge, either embodied in
individuals or embedded in organizational processes or practice.
(company know-how)
KM efforts focus on organizational objectives such as improved
performance, competitive advantage, innovation, the sharing of lessons
learned, integration and continuous improvement of the organization.
Data and Information are useful, but nowhere as valuable as Knowledge and Wisdom!
Condition Monitoring will only be useful if you know what to do with the Data and
Information to give you Knowledge!

Condition- based Maintenance (CBM) Basics

Moving from Data to Wisdom

Condition- based Maintenance (CBM) Basics

Integration of knowledge from past events into expert system

Condition- based Maintenance (CBM) Basics

Why condition-based Maintenance?

Asset Manager
1)
2)
3)
4)

Avoid Early Life Failures

Capture Design and Manufacturing
flaws in Warranty period
Benchmark OEMs
Extend Operational Life of Asset

Operations Manager
1)
2)

3)

Maintain high system reliability

Overload assets when needed with
confidence and dynamically defined
limits
Minimize asset time out of service
due to impact on above

Maintenance Manager
1)
2)
3)
4)

Adopt condition based maintenance

processes
Eradicate non value add service
cycles
Reduce maintenance budget
Improve safety for on-site personnel

EHS Manager
1)
2)
3)
4)

Improve safety for on-site personnel

Limit impact of issues on general
public
Eliminate all risks that could lead to
fatalities (No need for business case)
Improve compliance to Environment
Legislation

Challenges of Condition Monitoring

Based Systems

Challenges of Condition Monitoring Based Systems

1) Availability (or lack) of communications infrastructure
2) Incremental spending in front end Capital Expense, varying rate of return
3) Slow adoption of new standards
4) Lean engineering organizations at Utilities, slow process to change current
practices
5) Training the workforce, education for the industry
6) Few vendors offering integrated CMB systems at Global scale
7) Early stages in real-time analytics and dynamic modeling for power systems

Condition Monitoring is like insurance.

Everybody agrees its prudent to have it, but nobody
wants to pay for it. Anybody could see the benefits, and
Somebody always asks why it was not fitted when its all
gone wrong

References
1) WD IEC 61850-90-3
2) Application of Condition Monitoring and Technology within National Grid(UK), Carl
Johnstone, National Grid, UK. CIGR-089 2012 CIGR Canada Conference
3) http://www.businessdictionary.com/definition/maintenance.html#ixzz2VFFiFfwd
4) http://performancealliance.org/Portals/4/Documents/Committees/NonResQM/OM_5.pdf

Q&A
Thank you for your time