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24/7 Systems Mission Integrate, communicate, and analyze PLANT RELIABILITY INFORMATION From multiple plant condition, repair, overhaul, installation, and.

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Presentation on theme: "24/7 Systems Mission Integrate, communicate, and analyze PLANT RELIABILITY INFORMATION From multiple plant condition, repair, overhaul, installation, and."— Presentation transcript:

1 24/7 Systems Mission Integrate, communicate, and analyze PLANT RELIABILITY INFORMATION From multiple plant condition, repair, overhaul, installation, and inspection data sources

2 Desktop & Web Software Architecture Tango DB on Web Server Tango Web Services Plant Intranet Reports Via Web Browser Desktop Tango Administrative Users Desktop Software Repair Shop 1 Repair Shop 2 File Transfer Plant LAN Repair Shop 3

3 Problems with Managing Condition Information Measurement of Success Cost Avoidance/Basic Reliability Improvement Communications Many sources of information need single point for results Focus Selecting correct technologies for criticality Reporting

4 Problems - Condition Gate keeping work orders at planning meeting

5 Problems – With Managing Equipment Information How to calculate MTBF, MTBR, MTTR Data not put in system Data on paper in file cabinets Many Documents to find and maintain Root Cause difficult to get Cost of failure

6 Principles of Equipment Life Cycle Management Elimination of Failures in Service in Assets which disrupt production and cause high maintenance cost Increase operating life period between failures by the systematic elimination of Root Causes of Failure

7 Tango Equipment Lifecycle Management Functions Manage Equipment Condition Information and Action to Prevent Failures in Service Manage Equipment Life Cycle Information, Reliability Measurement and Improvement metrix Data Mining

8 Manage Equipment Condition Information and Action to Prevent Failures in Service Condition Entry Integrated Condition Report Condition Assessment Task Management and Subcontractor Management Manage Criticality, Aliases, Documents Rounds logging

9 Manage Equipment Life Cycle Information, Reliability Measurement and Improvement metrics Vendor Input Repair information Equipment Design Search Rotating Spares Equipment Vs Location Reliability Reliability Metrics

10 Test and Inspection Task Management Task which require a managed document Subcontractor management

11 Data Mining Analyze Historical data for Patterns Reliability Measurement Plant Performance

12 Integrated Condition Report Provides focus & communication Allows Managers to address upcoming reliability problems & measure performance Emphasis on: Which component has problems What is the problem (faults) How severe is problem What should be done (recommendations) Data is secondary & used to help visualize problem

13 Integrated Condition Report Contd. Browser based, easy to view, & tailored to users area Ability to view by severity or criticality Provides feedback to originator for work performed & requires validation of repair Creates Work Order in CMMS & receives Work Order closure information

14 Data vs. Information Plants have multiple condition monitoring & analysis systems, each is specialized for a technology. Each technology usually has one or more trained Analyst. Tango is used to gather what an Analyst knows about a problem. Integrate that with what other Analyst from other technologies know about the problem. Tango allows Management & Planners to focus on the problem & make good reliability improvement decisions. Our Customers report that Tangos ability to provide Management focus on condition problems is a major advantage.

15 ElectricalVibration Thermography Process Oil Ultrasonics

16 Tango | Integrated Condition Report Pie chart quickly shows how many assets in a users area are in states of problem severity Color coded list shows most severe problems at top of the list Findings from multiple condition monitoring technologies are shown for each asset component Work Order Status shows if work has been initiated by each Condition Entry Case Closure shows that work has been completed and is ready for condition confirmation

17 Navigate the Integrated Condition Report Double Clicking on Component opens the Tree for fast access to Location, Equipment, and Condition History Reports Double Clicking on Severity opens the Technology Status Reports Clicking on Paper Clip opens Linked Documents such as Analysts Technical Report

18 Tango Equipment Life Cycle Functions Is Equipment Repair Practical? Scrap NO YES Equipment Failure Equipment Removed From Service Equipment Sent For Repair Shop Ships Equipment Shop Repairs Equipment YES NO Plant Receives Equipment Repair Quote Approved? Equipment Purchased Calculate MTBF Cost of Failure Failure Root Cause Failure Progression Copyright 24/7 Systems, Inc Stores Inspections & Data Logging Task Sheet Management Condition Assessment Equipment Installation In Place Maintenance

19 Tango Equipment Management Tango Equipment Inventory CMMS Cost of Repair New Purchase Equipment In place Maintenance OLAP Database Data Mining INSTALLEDSPARE OUT FOR REPAIR PURCHASESCRAP In Place Maintenance Test & Inspection Scheduled Replacement Condition Findings/History Trend Data & Observed History Location Documents Store Room Stores Reliability Task Repair Shops Failure Causes & Root Causes Cost Design Information Repaired Documents New Equipment Vendors Design Information Cost

20 Tango | Equipment History Report Click on the line to unfold equipment design data. Click to provide purchase and design warranty details. Click to view repair shop report. Click on the line to unfold location and cause of failure information. Click paper clip icon to view design attachments. · Drawings · Service bulletins · Manuals

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22 Linked Documents Location Procedures Checklist Photos RCM Analysis Test Reports Inspection Documents Equipment Manuals Service Bulletins Drawings Condition Entry Trends Thermography Images Oil Reports Repairs Shop Repair Reports Shop Test Photographs of Damage Condition Comments Letters To/From Vendors Internal Discussions

23 Inspection Task 1. Condition Assessment Task Management -Vibration -PdMA Testing-Thermography -Ultrasonics-Oil Analysis-Visual Inspection 2. Rounds Logging Task -Trendable Parameters-Observations 3. Test & Inspection Task Management *Requires management of the document* -Breaker Load Test-Transmitter Calibration -Crane Inspection 3. Maintenance Task - based on time -Roll Replacement-Safety Relief Valve Change & Test -Equipment Removal for Cleaning & Refurbishment

24 Rounds Logging of Parameters & Observations Measurements Gauge Readings Observations Barcode Point ID

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26 Test & Inspection Task Management Many plant tasks require the completion of an inspection or test document to record results and preserve a record of the inspection. Breaker Testing Crane Inspection Transmitter calibration Thickness testing The Plant CMMS typically will not handle the management of these task documents. Often the plant tracks these items in home grown systems. Tango allows the definition of a Test / Inspection task, its interval, Next / Last Performance date and an Excel spreadsheet to be completed for the task.

27 Data Mining Using Tango Tango has several predefined data mining reports, which allow you to determine what equipment or locations are the least reliable.

28 Data Mining Report Listing You can use standard mining reports You can add your own custom mining report You can serve the reports via the web

29 How do the Equipment Measures Look? Data mining reports are drill down reports. You start at the top of a hierarchy and drill down to the levels which seem interesting.

30 Pick Out the Interesting Items From this level its easy to see that AC Induction motors have an MTBF of less than 3 years based on a population of over 1000 installations – much less than what is considered the industry standard.

31 You Can Look at Premature Failures According to the data, 65 motors were installed less than 2 weeks –thats over 6% of installed motors

32 Do We Have a Lemon? We can see that the piece of equipment with Plant Tag 55 was installed twice for just a single day. At this point we would want to look at the equipment history report for this motor to understand why this motor failed twice so quickly.


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