MAS Health and Predict Overview Task Guide

This task guide is based on the MAS v8.11 early program environment. Please follow the steps in this task guide. Any deviation from the task guide and or changes you make to the system will also appear and may impact other users. Since this is a live system, some changes are inevitable, and you may find that some of the details of the task guide do not match the system.

For this overview, the following are required, and have been created by your instructor.

Capability	Data Required
Group (with scores)	EUORG1_EUDEMO_ST_A
Group (with scores)	ST_EFFICIENCY
Score Type	Substation Efficiency
Custom Matrix	Efficiency and Health
Investment Project	ST Investment Project
Plan Template	SUBSTATION_TRANSFORMER

If your instructor hasn't added the data, ask him to follow the steps in Build MAS Health and Predict Demonstration

Introduction

In this demonstration you will be a reliability engineer. Your role is to maintain the reliability of the grid. Your major responsibility is to ensure that the grid stays up and operational. You are also responsible for making short, medium and long term investment decisions that drive maintenance and replacement policies. You use asset condition and operational data to gain insights into Asset Health, Probability of Failure and Risk, both today and into the future.

Thankfully you have a Health and Predict solution from IBM with advanced analytics that help you work efficiently and confidently without relying on spreadsheets or point solutions that consider 1 or 2 data sources. Health and Predict incorporates multiple data sources such as Asset Master data from Manage, Work order data, historical failure data, GeoSpatial Data, Inspection and Test Logs, IoT and Sensor data. Health and Predict provides a flexible asset condition framework for mining the asset condition data. Health and Predict helps you identify assets that are at greatest risk of failure, across different circuits/feeders, substations and regions. The risk assessment helps you drive asset and work management activities in Maximo Manage or other EAM systems to keep the grid up, reduce operational expense, optimize and defend capital expenditures resulting in better outcomes.

Maximo Health and Predict are applications in Maximo Application Suite (MAS) that are targeted to the reliability engineer, and provide a view of the current state and future state of an enterprise's assets. IBM Maximo Models for Electrical Distribution is an accelerator that extends Health and Predict designed for understanding the condition of electrical distribution asset classes used by the utilities industry.

Identify

On the “Applications” tab, there are tiles for each of the applications that the admin has loaded from the Maximo Application Suite (MAS). On the “Industry Solution” tab, there is a tile for Health and Predict – Utilities.

1. From the main MAS page, select the Applications tab

2. Click the Launch link Health tile.

3. The Asset Table View is displayed with the default query of all assets.

Asset Table View

On the main screen, there is a table view of all managed assets in a familiar table view. From this page you can quickly choose the asset query that reflects the assets you are responsible for. You can filter those assets to quickly identify the assets that have poor scores by sorting the assets or by searching for assets using key words so that you can get the latest asset details on an individual asset.

This asset data is coming from Maximo Manage, but MAS can connect to other EAM systems with or App Connect, via API or using Monitor Connectors.

Different views of the data can be generated to make it easier to identify critical assets. On this grid, you can add and move columns, filter, search and sort.

1. Select the hamburger icon above to the magnifying glass to show the left navigation menus. This shows how you can navigate to other perspectives like locations to understand location health. There are other menu options to setup health scores, asset investment analysis or and prediction capabilities.

2. Click hamburger menu icon again to close the menu slider.

There’s an option to create private views, and public views which are available to everyone.

1. Click the selection box to show the saved views then click on the Substation Transformers view.

In the Table view, there are columns with calculated data. There are Health scores, which are created for groups of assets from the Scoring setting menu. These specify the group that scores are calculated on. The query the notebook to use and how frequently the score should be calculated.

1. You can display the data in the Table view that is most important to you. Use the selection box to choose which asset data columns to display in your table.
2. The Days to Failure column comes from a predictive model defined and scheduled in the Predict setting tab.

The IBM Maximo Models for Electrical Distribution includes the following model templates:

• Substation Transformers / Substation Power (IBM Transformers Tap Changers)

• Circuit Breaker

  • Air Blast Circuit Breaker (IBM Circuit Breakers Air Blast)

  • Air Magnetic Circuit Breaker

  • Circuit Breaker

  • Oil Circuit Breaker (IBM Circuit Breakers Oil)

  • SF6 Circuit Breaker

  • Vacuum Circuit Breaker

• Distribution Transformers (IBM Transformers Tap Changers)

  • Overheads (multiple)

  • Undergrounds (multiple)

• Instrument Transformers

  • Dry Current Transformer

  • Oil Filled Capacitive Voltage Transformer

  • Oil Filled Current Transformer (IBM Instrument Oil Filled CTs)

  • Oil Filled Voltage Transformer

  • SF6 Filled Current Transformer

• Switch gear / Gas Insulated Switch gear (IBM Gas Insulated Switchgear)

Map View

Another view to help identify assets in trouble is the map view. Using a map view focused to a container is a good way to understand the capabilities and benefits of the Map view. Containers enable to you reflect the geolocation of your assets and geo fencing of business areas. It could be a region, town, service subscriber area you are responsible for servicing.

We’ll look at a region that contains a mixture of transformers, circuit breakers, cables (OTWs), and switches. Select a group of assets, or a container, that contains a mixture of transformers, circuit breakers, cables (OTWs), and switches.

1. You filter the group of assets you want to focus on. Reset the View to show All shared assets. Reference the early instructions if you forgot how to do this.
2. Click the filter icon that looks like a funnel.
3. Select the pencil symbol for containers
4. Select NIXON9098
5. Click OK
6. Click Apply

You can see there are 261 assets in this container. When we sort by the health score from low to high, we find there are many assets with Health scores in poor health and many of them have a Criticality score of 0. This is concerning. Several column headers can be used to sort to help visualize the data in different ways. Sort by most critical assets and with the worst health.

1. On the Assets Table view, click Health column title to sort assets by the Health score.
   

2. Asset Criticality can be measured by understanding the importance an asset has to the grid performing it's job of providing electricity to customers. Asset End of Life is important to know so that assets can be planned to be replaced before they reach their end of life. On the Assets Table view, click Criticality column title to sort assets by the Criticality score.

You need to understand the relative position of the assets with the worst health and most critical in reference to the service are you are responsible for.

1. Click Map button. Selecting the pin icon in the upper right of the screen shows the selected assets on a map view. The different pin colors and icons represents the health of the assets, according to the legend at the bottom left of the screen. This is a quick way to understand which assets are in poor health.

1. Adjust the map using the controls and mouse. You can expand a two finger pinch press on the touch pad to zoom in.
   To move the map push one finger and move with the other finger on the touch pad

2. By turning on the Container selection, a polygon will appear around the assets in the container. The color of the container will reflect the overall health of the container.

3. Click the Container icon, and toggle on Containers

4. Zoom out to see the container color. You can decrease a two finger pinch press on the touch pad to zoom out.

5. Click the Scores icon and selecting another score will switch the view to a different score. The asset colors, and container color, will change accordingly.

6. Select another score like End of Life

7. You can return to the Health score view, and hovering over different assets, and the container, reveals the health scores. Click the Health button to return to the original view.

8. Zoom in or out until until you see the container outline color change from black to another color. You can two finger pinch press and squeeze your fingers together on the touch pad to zoom in and expand to zoom out. Or you can use the zoom plus and minus icons on the bottom right.

9. Hover over the Container outline to show the Health score of the Container.

10. Click the container NIXON9098 which is the dashed line surrounding the assets on the map to show the average scores of all the asset in that container on a single card.

You can zoom in to see each of asset pin locations. By clicking on the pins you can view the key asset KPIs for that asset. You can action assets in the map view, by creating plans, adding a flag for follow up, or submit a work order by clicking the Action button. Work Orders will be sent to Maximo Manage so that technicians can service or inspect the asset.

1. Zoom in. Click the pin for ST_1400518 to see the card. This is the substation transformer that likely needs attention.
2. Click on the Actions drop down selection box button to see the available options.

Note that you can click on the asset name to open the asset detail page which is explained later. However, there are other methods to identify assets in poor health. In the next section you will focus on substation transformers which you are responsible for.

Charts View

The Charts view page offers another way to identify assets that are not performing well relative to each other. There are four out of the box charts available that count the number of assets in a particular category or range of condition.

1. Navigate to the Charts view page. Click on the Charts Icon.
2. Choose a "View" for example select Pumps with status from the view drop down selection box.
3. Review the four charts that summarizes the currently selected views asset performance counts by range

The Charts view shows 3 charts:

• A health wheel chart categorizing all of the assets by health.
• Unplanned downtime chart view showing hours of downtime by month.
• A failure rate per manufacturer chart
• A Mean time between failure that shows the count of asset meeting a performance threshold for mean time to failure duration.

You will drill-down through each of these charts to see the assets details of each category.

Failure rate chart

1. On the Failure rate per manufacture click on the manufacturer PUMPSRUS to see the failures by that manufacturer. Clicking on the manufacturer Boggs shows a 100% failure rate. So all assets from Boggs have failed.
2. On the Failure rate per manufacture click on the manufacturer PUMPCO to see the failures by that manufacturer.
3. Return to the charts page by using the breadcrumb at the top of the page. Click on the Assets breadcrumb to return to the charts page.

Mean time between failure chart

1. Notice the Mean time between failure chart is not configured. Each time you navigate to the charts page you must select the thresholds to use on the current chart. Click the filter funnel icon to see thresholds option to create or select an existing threshold value. apm_9.0/img/mtbf_results.png
2. Click the threshold pencil icon.
3. Click the threshold radio box for 10k hours to indicate the asset must be running for more than 10k hours before it has an unscheduled maintenance.
4. Click the OK button. and Apply button.configure_chart_funnel
5. Notice the Mean time between failure chart displays a bar chart with the count of assets:
   • Meeting the threshold. Count and list of assets that went longer than 10k hours before having an unscheduled work order.
   • Not meeting threshold. Count and list of assets that were not able to achieve 10k hours before having an unscheduled work order.
   • Missing data. Count and list of assets that were missing data that prevented MTBF from being calculated.
   • Assets that don't have Asset Class Definition defined.
6. Hover on the red bar to see the count of assets not meeting the Mean time between threshold.
7. Click on the red bar to see the list of assets that did not not meet the Mean time between threshold. mtbf_results
8. Click on the asset name to see the asset details to see how many mean time betwee failure hours the asset went before having an unschedule maintenance. mtbf_assets_notmeeting_mtbf
9. Click on the bread crumb to return to the drilled in asset list. Or hit the next button to see the next asset that didn't achieve mean time between failure hours threshold before having an unschedule maintenance. mtbf_asset_details

Matrix View

Another view to help you identify the number of assets in different condition ranges is the Matrix view.

Now choose You want to focus on all substation transformers by changing the type filter, and select the Charts view to understand asset relative condition and performance.

1. Return to the Table view using the instructions below.
2. Reset the view to show ALL (shared assets) by clicking X on the Container filter
3. Click the funnel symbol
4. Select the pencil symbol for Query
5. Select ST_EUDEMO_A from the list
6. Click OK
7. Click Apply
8. You will now see the results for all substation transformers.
9. Select the 4th icon that looks like a Matrix in the upper right of the screen.
10. You can see the number of assets categorized on a Matrix view.
11. Set the Matrix Version to Criticality and End of life to see the X and Y axis change and score ranges change to the different score range categories. Note how many assets are for High Need For Action which means they need to be actioned.
12. Click Assets breadcrumb to navigate back to the Matrix view.
13. Set the Matrix Version to Criticality and End of life.
    
14. You can drill into the red cell with Criticality A and End of life High to see what assets are at close to the end of their life. Click the number of assets #.
15. You can also see the number of asset in the matrix in the future years if you have configured your forecast score notebooks.

Work Queues View

Using Work queues view is another way to identify assets in trouble or need your attention so that you can take an action to ensure KPIs are able to be calculated and to avoid asset unplanned downtime and be more proactive in maintenance planning.

There are a number of Work queues included with Health and Predict. Here are some example Work queues

• Predict assets with a High probability of failure
• Identify Assets in poor health
• Identify assets with Assets missing data

Work queues are preconfigured views designed to help find assets that meet specific conditions. They can be used by the reliability engineer to systematically address each asset on the list, in turn, and “work down” the list.

1. Hover over the left nav bar to expand it
2. Select the Work queues section on the left nav bar
3. Select Failing Before PM work queue

Investigate

The Failing before PM work queue shows all of the assets with scores in that work queue. As a reliability engineer at a Utilities plant, it is critical to avoid failures. Note that for this Work queues, there are several pumps and substation transformers that have a predicted failure before their next planned maintenance date. Two of the transformers are in the container that was viewed earlier. You will select ST_1400518 in the queue to start managing your work load for the day by investigating and addressing all of the assets in the work queue. You will use the Asset Details view to better understand the holistic asset condition of ST_1400518 so that you can better assess and pick a corrective action.

1. Select ST_1400518 which opens the asset details view. Details on this page will vary since this is a live demonstration environment system.

Assets Detail View

On the top of the Asset Details page there are the resulting scores from the predefined notebook for this substation transformer. These are health, criticality, risk, end of life and effective age score. Note that effective age is a calculation using the actual age and the health score. An asset in poor health will have an effective age greater than its actual age.

On the second line, there are custom scores, like the Substation Efficiency score.

The next Preventive Maintenance date and the MRR come directly from Maximo Manage.

• On the top of the page, there are details about the asset, and KPIs that give a snapshot of its current state.
• For this asset, there is a Health Score of 44, which is in the medium fair zone.
• This asset also has a high Criticality and low Risk Score.
• This asset has a low percentage of probability that there will be an imminent failure, based on the Installation Date and manufacturers recommended life.
• The asset is projected to fail in the next 0 days, but the next maintenance isn't planned for 30 days.

At the beginning of the investigation, you suspected the asset was going to fail before its planned maintenance. But, just by looking at the KPIs, additional evidence suggests that this asset may be in trouble, and that some action needs to be taken now. The Health history widget of this asset is below the Score widget. Using the historical health chart, you can see this assets health has been low for some time. This is another indication that this asset needs attention.

1. Scroll down the page to learn more about the health of the asset, go to the Score details widget.
2. Understand what is contributing to the poor health of the asset to see how you might address the problems.
3. Expand the view to see the contributors by clicking the chevrons to view the contributors to poor asset health.
4. See and sort on complete list of contributors to help understand what might be the root cause of the problem. Click Weight to understand what is contributing the most to the Score
5. From the Scoring drop down box you can also see other Custom score contributors that you have created using the custom score template.

The Health application supports asset-specific calculations and visualizations like Dissolved gas analysis for transformers. There a two types of visualization widgets available to understand the transformers gas conditions using inspection or sensor data readings.

1. Scroll down the Asset Details page until you reach the Dissolved gas analysis tile.
2. Click on each of the dots to get detailed information about the amount of those types of gases.
3. Click the switcher icon on the top right corner of the tile, to view the results in the table view.
4. The other widget is the history of combustible gas concentrations. It shows the combustible gas trend and rating over time. The rating represents the average acceptability of detected gas concentrations. The rating is determined by the overall factor.
5. Hover on each of the assessment dates to get the detailed asset condition information.

There are several predictive model templates that come with Predict. Your data scientist has trained and deployed these models built using Cloud Pack for Data and Watson Studio which is included with Maximo Application Suite. IBM Predict includes templates to:

• Predict days to failure
• Calculate probability of failure
• Detect anomalies
• Generate an asset life curve based on group asset deployment and decommission dates

These templates include a large number of algorithms and can automatically select the one that best fits the data for the optimal outcome. These models are built to detect specific problems for each asset problem and failure mode. They can detect problems and forecast the future condition of the asset using historical asset sensor data ingested by Maximo Asset Monitor or streamed into Health using the App Connect included with Maximo Application Suite.

1. Scroll down Asset Details page until you reach the Predictions tile.
2. Double click the " the Predictions tile tile to expand the tile and see the prediction cards.

Note that also included with MAS is Watson Studio and Watson Machine Learning, both of which a Data Scientist can use for building, training, and maintaining predictive models. In the case of this asset, the model tells us that it is projected to fail in 0 days plus or minus 1 day.

A Data Scientist can build predictive models for specific failure modes using the templates included with Predict if you have failure history data.

The reliability engineer can select those failure modes within the card to see the projection for each failure modes.

The failure training data is used to help calculate Failure probability. Different failure modes can be calculated and do impact predictions.

Failure probability is the chance that an asset may have a failure with a certain time period. For this asset there is a 20% probability of failure in the next 2 months due to overheating.

A Data Scientist must build specific models for time periods just like the failure modes. You can see the prediction results by making different selections within the card.

Failure probability history shows how the probability of failure for each mode and how it has changed over time.

The Factors that contribute to failure show which factors from the training data impacted failures the most, giving an indication of what may lead to future failures. The anomaly detection model creates a threshold based on history and shows when the asset exceeds that threshold in the card.

The End of life curve is built based on training data for assets that have been decommissioned. By applying the effective age calculation from the notebook, this curve can be used to estimate probability of an end of life failure.

The Effective age of the transformer is 27 years. The curve produces an end of life probability of 89%. This is one more indication that this asset needs to be attended to immediately.

1. Hover near the point where the Effective age crosses the curve.
2. How is this asset performing relative to others of a similar class and where it should be for it's age?

The Asset timeline card shows several pieces of key information about the asset in the same graph. For example, the timeline shows a predicted failure (on the top line of the graph), that will occur before the next preventive maintenance (on the second line of the graph).

1. Scroll down the page
2. Hover over a point on the timeline

There are several other sections on this page including:

• Operational status, showing recent meter readings, maintenance history, showing work orders for this asset.
• Replacement planning, showing any replacement or refurbishment plans created for this particular asset.

Take Action

There’s enough evidence from the investigation to take some action against this asset. Scroll to the top of the page and click the Actions dropdown selection box button to see the options.

1. Scroll to the top of the page.
2. Click the Actions button.

You could:

• Add flag which sets a replacement flag on this asset to make sure it is marked to be replaced in the next round of replacement planning.
• Create a plan to replace or repair this asset.
• Recalculate scores if there is new information or your scoring notebook has changed, you can request that the scores be re-calculated to reflect these changes.
• Edit source asset record to navigate to the asset record to make asset changes. In this case, possibly adjust the preventative maintenance schedule.
• Create a service requestso that a technician can do asset repairs, inspection or replacement.

However, this asset needs urgent maintenance. Create an emergency maintenance work order for this asset by selecting the Create work order option and completing the form.

1. Select the Create work order option
2. Show the form
3. Click Cancel to return to the asset detail page

Health and Predict gives many options to identify assets at risk with a table, map, chart and asset details views.

Additionally you can use and predefined Work Queues to help systematically address risky assets exhibiting the same problems or that are missing data in order to calculate their scores.

There’s a single page from which to conduct an investigation and take an action. In this case, submitting an emergency work order to prevent the imminent failure of a substation transformer.

In Health and Predict – Utilities, there’s also the ability to use a matrix (custom or OOTB) and do long-term replacement planning based on risk tolerance and available budget.

Identify / Investigate with Maps

Start building an investment project from the matrix view.

Identify / Investigate with a Matrix

Start building an investment project from the matrix view.

1. Hover over the left nav bar to expand it
2. Select the Assets section on the left nav bar
3. Make sure the asset view is for substation transformers by either using the filter symbol or a saved view. If necessary, clear the filters to start from the full set of assets under management
4. Click the “Matrix” icon to move to the matrix view

The default matrix view, in this case, is set to “Substation Efficiency and Health”. This is a custom matrix. The out-of-the-box matrices are… - Criticality and End of life - Criticality and Health - Criticality and Risk

This custom matrix is using the Health score generated by using the notebook for substation transformers. The Substation Efficiency score is a custom score. Together, on the matrix, they can represent a proxy for sustainability.

To get a different view of the assets, change the axes of the matrix by using the pull-down menu.

The color pattern can also be adjusted by clicking on the setting cog. By doing this, we are adjusting our risk tolerance.

1. Click on the pull-down menu to show the other matrix options
2. Click on the setting cog to briefly go into the setting page to show that the page is customizable
3. Click Close to return to the matrix view

This view shows that there are 35 assets in red or high category. Click through the summary boxes, or the boxes in the matrix, to see the details of the assets in a table view.

This table view provides a perfect example of how assets can be added to a new or existing investment project.

1. Click on the "High" box with 35 assets in it
2. From the table view, demonstrate how all of the assets can be selected by clicking on the selection box at the top
3. Show the options to add the assets to a new or existing investment project
4. Click Cancel
5. Click the Assets breadcrumb to return to the matrix

Take Action with AIO

In Health and Predict – Utilities, there’s a capability to build an Asset Investment Optimizer (AIO) project.

The AIO process starts with building a project of assets, assigning a length and starting date to the project, then running multiple strategies to determine which assets should be replaced over the life of the project, and when.

In this case, a project has already been built with the 35 assets in the “red” cell, and the 26 assets in the “yellow” cell next to it.

1. Hover over the left nav bar to expand it
2. Select the Asset investment optimizer section on the left nav bar
3. From the Projects tab, click on ST Investment Project

There are 3 strategies built out in the “ST Investment Project”.

The first strategy is to maintain the average risk of 8.2 for the 61 substation transformers in the 25-year project.

The second is to reduce the risk to 7.0.

The third is to stay within a $2.16M budget.

Each of the scenarios uses a plan template build for Substation Transformers specific replacement costs and cost of a failure.

1. Click the Maintain risk scenario
2. Review the scenario by using the 2 “details” buttons to toggle between the cost of the scenario, and the specific replacement plan
3. Repeat the process for “Stay within budget” and “Reduce risk” scenarios to review each scenario

Up to three strategies can be compared side-by-side and the details can be exported.

1. Click the Compare strategies button
2. From the pop-up, click all three scenarios
3. Click Compare
4. Review the output noting the results of each strategy

Summary

As the Reliability Engineer, maintaining the grid, I was able to use IBM Maximo Health and Predict to identify assets at risk, investigate those assets, and finally take an action to prevent a failure and unplanned downtown…saving thousands of dollars, and maintaining the integrity of the grid.

My actions will also help short, medium and long term investment decisions that drive maintenance and replacement policies.