24/7 systems mission integrate, communicate, and analyze plant reliability information from multiple...
TRANSCRIPT
24/7 Systems’ Mission
Integrate, communicate, and analyze
PLANT RELIABILITY INFORMATION
From multiple plant condition, repair, overhaul, installation, and inspection data sources
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
E-mail File Transfer
Plant LAN
Repair Shop 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
Problems - Condition Gate keeping work orders at
planning meeting
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
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
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
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
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
Test and Inspection Task Management Task which require a managed
document Subcontractor management
Data Mining Analyze Historical data for Patterns Reliability Measurement Plant Performance
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
Integrated Condition Report Contd.
Browser based, easy to view, & tailored to user’s 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
Data vs. InformationPlants 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 Tango’s ability to provide Management
focus on condition problems is a major advantage.
Tango | Condition Manager Program
Integrate, Organize, and Communicate Predictive Maintenance Results
ElectricalVibrationThermography
ProcessOilUltrasonics
Tango | Integrated Condition Report
Pie chart quickly shows how many assets in a user’s 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
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 Analyst’s Technical Report
Tango Equipment Life Cycle Functions
IsEquipment
RepairPractical?
Scrap
NO
YES
EquipmentFailure
EquipmentRemoved From
Service
EquipmentSent ForRepair
ShopShips
Equipment
ShopRepairs
Equipment
YES
NO
Plant Receives
Equipment
Repair QuoteApproved?
EquipmentPurchased
Calculate MTBF
Cost of Failure
Failure Root Cause
Failure Progression Copyright 24/7 Systems, Inc. 2002
Stores
Inspections & Data Logging
Task Sheet
ManagementCondition Assessment
EquipmentInstallation
In Place
Maintenance
Tango Equipment Management
Tango EquipmentInventory
CMMS
•Cost of Repair
•New Purchase Equipment
•In place Maintenance
OLAP Database
Data Mining
INSTALLED SPAREOUT FOR REPAIR
PURCHASE SCRAP
•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
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
Tango | Location History Report
Click to unfold equipment design information
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
Inspection Task1. 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
Rounds Logging of Parameters & Observations
•Measurements
•Gauge Readings
•Observations
•Barcode Point ID
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.
Data Mining Using Tango
Tango has several predefined data mining reports, which allow you to determine what equipment or locations are the least reliable.
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
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.
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.
You Can Look at Premature Failures
According to the data, 65 motors were installed less than 2 weeks –that’s over 6% of installed motors
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.