Cesc limited

1. Distribution Related Engineering Asset Management System
(DREAMS)
P. Mukherjee
Dy. General Manager
IT - New Initiatives
7th October, 2013

2. 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.

3. 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

4. CESC’s Experience
Earlier 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
maintenance than planned maintenance .
unplanned
Difficulty in estimating maintenance cost and analyzing
maintenance performance.
Solution : CESC’s Asset Management Software.
Distribution Related Engineering Asset Management System
(DREAMS)

5.  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.

6. DREAMS
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
Total No. of Assets as on date : 24578

7. DREAMS
 CODIFICATION OF ASSETS
 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
 Super Category : Distribution Transformer
220/132/33 KV Power Transformer
A7*****O
11/0.4 KV Distribution Transformer
B3*****A
132/33 KV Power Transformer
A6*****O
11/6-0.4 KV Distribution Transformer
B3*****B
33/20 KV Power Transformer
A5*****A
6/0.4 KV Distribution Transformer
B2*****O
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

8. DREAMS
 Asset Searching


 ASSET REGISTER
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.

9. DREAMS
 Asset Sorting & Filtering
 ASSET REGISTER

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.

10. DREAMS
 Health Tab

 ASSET REGISTER
Indication of health of any asset through color codes based on the last observations from
SM/CM/AO.
‘RED’ -> URGENT
’BLUE’ -> IMPORTANT

11. DREAMS
 ASSET REGISTER
 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.

12. DREAMS
 MAINTENANCE FUNCTIONS
 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.

13. DREAMS
 MAINTENANCE FUNCTIONS
 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.


Non-Intrusive CM Re-measurement done again.
Intrusive CM measurements (e.g. IR & PI Values etc.) are taken & posted by O&M
departments.
Job Allocation & Attending to the job by O&M engineers.
 Non-Intrusive CM

14. DREAMS
 MAINTENANCE FUNCTIONS
 Preventive Maintenance (PM)

The Preventive Maintenance (PM) done by O&M departments as per the schedule
mentioned in the PM Regime.

15. DREAMS
 MAINTENANCE FUNCTIONS
 Maintenance Regime

The SM/CM/PM Regime for different categories of assets are stored in the system.

16. DREAMS
 MAINTENANCE FUNCTIONS
 Queries & Reports

There are a host of queries & reports which caters to the diverse requirements across all
user departments.

17. DREAMS
 MAINTENANCE FUNCTIONS
 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.

18. DREAMS
 MAINTENANCE FUNCTIONS
 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.

19. DREAMS
 HARDWARE PLATFORM
CENTRALISED ARCHITECTURE
SUN
M4000
(App)
SUN
M4000
(DB)
4 Ultra
Sparc VII+
E
4 Ultra Sparc VII+
128 GB
C
128 GB
S
C
ONLINE
ACCESS
SUN Storage
Tek 6580 (16 TB)
DATA CENTRE
CENTRAL SERVER REGIONAL SERVICES
N
E
T
PCs at User End

20. DREAMS
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

21. 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.
 Dissolve Gas Analysis (DGA) Dashboard :
 A perfect analysis tool to identify failure prone Power Transformers
and thereby taking proactive measures to avoid breakdown.

22. DREAMS
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)
 Resultant Fault Reduction in Switchgears
Till Mar 2013
160
140
2011-12
120
2012-13
136
112
100
81
80
63
60
40
24
20
18
0
11 KV DOWNSTREAM
SWITCHGEAR
6 KV DOWNSTREAM
SWITCHGEAR
TOTAL DOWNSTREAM
SWITCHGEAR

23. DREAMS
 Financial
KEY IMPACTS
Rupees in Lacs
Till Mar 2013
 Green Initiative
 Paper-less storage of asset information and maintenance records.
 Paper-less communication through system generated emails.

24. DREAMS
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.

25. DREAMS
FUTURE READINESS

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.

26. DREAMS
e-mail : partha.mukherjee@rp-sg.in