CESC Limited

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 mostvibrant industrial houses – RP - Sanjiv GoenkaGroup 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 useincluding allied assets such as Substations building, premises and yards.

Maintenance Management functionalities encompassingPreventive 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 regimesstored in the system.

Analyze, interpret and maintain the transformers with the help of theDissolve Gas Analysis (DGA) Dash-Board tool integrated with the system.

Handing Over Taking Over (HOTO) Module for managing assets duringcreation, installation and commissioning before handing over toOperations & 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



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 REGISTER

DREAMS

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 REGISTER

DREAMS

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 REGISTER

DREAMS

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 REGISTER

DREAMS

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 FUNCTIONS

DREAMS

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.


DREAMS

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&Mdepartments.

Non-Intrusive CM


DREAMS

Preventive Maintenance (PM) The Preventive Maintenance (PM) done by O&M departments as per the schedule

mentioned in the PM Regime.


DREAMS

Maintenance Regime The SM/CM/PM Regime for different categories of assets are stored in the system.


DREAMS

Queries & Reports There are a host of queries & reports which caters to the diverse requirements across all

user departments.


DREAMS

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 Methodused to interpret the health of the transformer.


DREAMS

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-TierBrowser - Application Server - Database Server

DREAMS

ENGINEERING EXCELLENCE Pioneering effort in conceptualization, design, development and

implementation of a state-of-the-art IT application for EngineeringAsset Management, developed in-house.

Multi-faceted Asset Register.

Provides entire Asset database on finger tips.

An innovatively designed single window for viewing all assetinformation, health & maintenance schedules together.

DREAMS

Dissolve Gas Analysis (DGA) Dashboard :

A perfect analysis tool to identify failure prone Power Transformersand 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-performingassets.

Analysis of commissioning and maintenance related data in order to

provide insight into asset performance and planning for itsreplacement.

DREAMS

FUTURE READINESS

DREAMS

Having potential to make itself scalable at theenterprise level by including assets of Generation andTransmission.

Capable of Integration with Geographical InformationSystems (GIS)

Capable of Integration with ERP for Finance andPurchase Divisions.

e-mail : [email protected]

DREAMS

CESC Limited

Technology

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