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Asset-intensive companies demand predictable production at the lowest sustainable cost, starting with a clear picture of an enterprise’s overall asset health.   Using intelligent asset strategies, Meridium’s Asset Performance Management (APM) software and solutions can help your organization reduce operating risk and improve reliability by predicting and preventing asset failures. 

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Basin Electric Updates Calibration Management, Cuts Failures 10%

Merges seven databases into one, covers 4,000 assets, saves $20K annually in productivity

Challenge & Opportunity

Basin Electric Power Cooperative (Basin Electric) is one of the largest electric generation and transmission (G&T) cooperatives in the United States. Basin Electric:

  • Is consumer owned by 137 member cooperative systems, with members’ service territories comprising 540,000 square miles in nine states
  • Will operate 4,913 megawatts (MW) of wholesale electric generating capacity and have 5,478 MW of generation capacity by end of year 2014
  • Owns 2,168 miles and maintains 2,253 miles of high- voltage transmission maintains equipment in 70 switchyards and 149 telecommunication sites
  • Serves 2.8 million electric consumers

Recently, the utility decided to implement a new calibration management system at its Leland Olds generating station. The Leland Olds station had an existing calibration management program in place, but Basin Electric LOS managers felt they weren’t able to keep up with growing regulatory requirements, and that the existing program didn’t adequately reflect management’s vision for a world-class maintenance strategy. 

The existing maintenance program had multiple databases that each stored data for different groups of instruments. The current system was also found to frequently contain duplicate entries, for example, for a single transmitter or pressure switch. All calibration management was centered in the computerized maintenance management system (CMMS) system, which left users searching for additional information. Also, when work orders were received, technicians had no easy way to store “As Found” and “As Left” information. Recording calibration results, as well, was a manual process.

Solution

Basin Electric decided to implement Meridium Enterprise APM as the foundation of their new calibration management strategy, and created a single instrument database in Meridium. Next, Basin Electric LOS cleaned the data in the seven existing databases, and exported it for uploading into Meridium. Finally, their technicians simplified the user interface and created data sheets to simplify the process of adding or correcting data or user-defined fields to capture the specific data needed to monitor each type of device.

The calibration management system was designed so that Basin Electric LOS technicians:

  • Can review complete certification history at a glance for any device
  • Can view all certification documents via a link
  • Save time and costs and improve productivity by having a single database to maintain
  • Require less training and actual time to complete a calibration
  • Have a universal point of access for all involved to locate and update instrument calibration information

Conclusion

As a result of implementing a new calibration management strategy, Basin Electric LOS:

  • Cut the number of asset failures by 10% through early detection of potential problems
  • Estimates more than $20,000 savings annually just in technician productivity
  • Merged seven separate instrument databases into one, covering more than 4000 instruments, so technicians can access all needed device information in one place
  • Can quickly access a list of calibrations due, and at-a-glance know what has been completed and the route that a specific instrument is assigned to
  • Simplified the process of maintaining its instrument inventory

Meridium solutions used:

  • APM Failure Elimination
  • APM Strategy
  • APM Mechanical Integrity
  • APM Safety
  • APM Health
  • Asset Answers