This document describes CESC's Distribution Related Engineering Asset Management System (DREAMS) software. DREAMS allows CESC to digitally manage its large distribution network and various assets. It provides an integrated asset register, maintenance management functionality, and analysis tools. Some key benefits of DREAMS include significant reductions in unplanned maintenance, improved asset performance monitoring, and financial savings through more efficient maintenance. The system demonstrates engineering excellence and positions CESC for future readiness through its scalability and integration capabilities.
1. P. Mukherjee
Dy. General Manager
IT - New Initiatives
7th October, 2013
Distribution Related Engineering Asset Management System
(DREAMS)
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 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)
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. 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
7. 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
8. 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.
9. 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.
10. 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
11. 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.
12. 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.
13. MAINTENANCE FUNCTIONS
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&M
departments.
Non-Intrusive CM
16. MAINTENANCE FUNCTIONS
DREAMS
Queries & Reports
There are a host of queries & reports which caters to the diverse requirements across all
user departments.
17. MAINTENANCE FUNCTIONS
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 Method
used to interpret the health of the transformer.
18. MAINTENANCE FUNCTIONS
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.
19. HARDWARE PLATFORM
DATA CENTRE
CENTRAL SERVER REGIONAL SERVICES
C
E
S
C
N
E
T PCs at User End
ONLINE
ACCESS
SUN
M4000
(App)
SUN
M4000
(DB)
SUN Storage
Tek 6580 (16 TB)
CENTRALISED ARCHITECTURE
DREAMS
4 Ultra Sparc VII+
128 GB
4 Ultra
Sparc VII+
128 GB
20. 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
21. 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.
22. 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
23. 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.
24. 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
25. FUTURE READINESS
DREAMS
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.
