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Tango Motor Management Implementation

Tango Motor Management Implementation. Forrest Pardue Jan 2006. © 24/7 Systems, Inc. - 2006. Current State of Motor Management. Many separate pieces of motor information in reports, databases, computer folders, spreadsheets No Standardization No Integration Poor Communication

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Tango Motor Management Implementation

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  1. Tango Motor ManagementImplementation Forrest Pardue Jan 2006 © 24/7 Systems, Inc. - 2006

  2. Current State of Motor Management • Many separate pieces of motor information in reports, databases, computer folders, spreadsheets • No Standardization • No Integration • Poor Communication • No warranty tracking • No Ability to Analyze Performance © 24/7 Systems, Inc. - 2006

  3. RELIABILITY ADVANTAGES ARE WELL KNOWN World ClassAverage • Average life of electric motors > 15 yrs < 10 yrs • Mean time between repairs for pumps > 6 yrs < 3 yrs • Average vibration levels < 0.1 in/sec > 0.3 • Overtime, percent of total hours worked < 3 % > 10 % • Emergency work < 5% > 15 % • Total maintenance cost as percent of RAV < 2% > 3% “Reliability impacts safety,environmental,quality,service,cost,and CTO” Source: Bob Taylor SMRP 2003

  4. Why do Motor Management? • Prevent Failures in Service • Extend Motor Life • Manage Stores and Surplus Inventory • Manage Warranty Claims • Understand and Measure Reliability • Mine population for patterns • Manage repair vendors © 24/7 Systems, Inc. - 2006

  5. Payback of Motor Management • More production – Elimination of Failures in service • Less Maintenance – Longer MTBF • Inventory Control/ Reduction • Warranty Management – 3% motor cost? • Repair Vendor Mgt – Quality/ MTBF © 24/7 Systems, Inc. - 2006

  6. Motor Management isInformation Management • Identification and Design data • Design documentation • Purchase • Stores • Install and location • Condition Test and Results • Failure, Repair, and Warranty • Collective analysis © 24/7 Systems, Inc. - 2006

  7. Motor Management Outline • Get Started – Goals and Success metrics • Build a Motor database - Import any existing motor design data • Failure/Repair Tracking - Set up repair tracker for all repair vendors • Identify and enter stores inventory: Train stores person to keep current • Import Motor functional locations from CMMS © 24/7 Systems, Inc. - 2006

  8. Motor Management Outline 6. Functional location tracking by Production Area 7. Condition Tracking 8. CMMS Interface 9. Analysis © 24/7 Systems, Inc. - 2006

  9. Step 1 – Get Started • Turn on Tango Database for Plant • Establish Motor Management Program Goals • Establish how success will be measured • Assign a Motor Manager and train on Tango © 24/7 Systems, Inc. - 2006

  10. Required for Reliability Information Management • Standardize • Integrate • Communicate • Accountability • Analyze © 24/7 Systems, Inc. - 2006

  11. TANGO User Interface Options Desktop Application TANGO Web Service This is the workhorse program that provides administration, correction, entry of any information, reports and analysis. Completely web based interface provides all TANGO reports and some analysis features along with very limited information entry. Web-Hosted Database TANGO Condition Assessment Task Management Maintenance & Process Inspections This application allows plant groups and contractors to enter Condition Assessment Results. Allows the setup and loading into a PDA of visual, inspection and gauge readings, with alarm and out of bounds warnings. Also allows creation of condition entry. Repair Tracker™ Interface specifically designed for repair shops to enter design, failure and overhaul information. © 24/7 Systems, Inc. - 2006

  12. Example Motor Management Goals 1. Gain a high quality and standardized root cause of failure analysis from all motor repair shops 2.  2. Standardize repair reporting among all motor repair vendors 3.     3. Integrate information from all vendors into a single database which would allow the creation of a long term history and analysis of failure patterns 4.     4. Expand repair tracking program to all repairable assets 5.     5.Completely eliminate repair vendor written documentation transmitted by mail or email 6.     6. Track equipment installed at functional locations 7 Associate multiple equipment condition results (vibration, MCA, IR) with plant equipment to highlight equipment that may require repair soon © 24/7 Systems, Inc. - 2006

  13. How do you measure reliability?How do you know its improving? • MTBF by equipment type, location… • Faults by fault type, equipment type • Root cause of failure by equipment, location • Cost of failure by equipment, location © 24/7 Systems, Inc. - 2006

  14. Step 2 – Motor Inventory • How are we going to build the motor database • Import from other systems • Survey • Incremental as sent for repair © 24/7 Systems, Inc. - 2006

  15. Identification • Brass Tag • Serial No • Barcode • ID chip © 24/7 Systems, Inc. - 2006

  16. Motor ID Tag and Nameplate © 24/7 Systems, Inc. - 2006

  17. Design data for tag# 17100 © 24/7 Systems, Inc. - 2006

  18. Design Data by Motor Type • AC Induction Motor • AC Synchronous • AC Wound Rotor • Permanent Magnet • DC Shunt • DC Series • DC Compount • DC Stabilized • Gear Motor – AC Induction • Servo • Stepper • DC (All Types) © 24/7 Systems, Inc. - 2006

  19. Name Plate Data is not enough © 24/7 Systems, Inc. - 2006

  20. Plant Tag* 17100 Serial Number* 01man66439-g001-ab Frame Size* 449hp Materials Master Number* 1184080 Model Number* ? Motor Mfg* Reliance Power* 200 HP Speed* 1190 RPM Voltage - Stator* 460 V Air Gap Bars - Rotor (cnt) Bearing ID Number - DE Bearing ID Number - NDE Comments Solid Coupling. Adaptor Base. Connection Config (Stator) Current - Full Load (Stator) 223 A Current(Secondary) - Full Load (Stator) Duty Efficiency Formed Coil Insulation Class Key Value For MCE Lubrication ID Maximum Install Interval (Days) - Current Maximum Install Interval (Days) - Specified Maximum Storage Interval (Days) Motor Enclosure TEFC, Totally-Enclosed, Fan Cooled Mount Flange Nema Design Code Nema Power Code (AC) Orientation Vert, Vertical Poles Power Factor Power(Secondary) Resistance - Stator Service Factor Shaft Single/Straight Slots - Stator Speed(Secondary) Stock Number Taper Straight Target MTBF (days) Temp - Max Rated Ambient Variable Freq Voltage(Secondary) - Stator Weight 2750 lbs Equipment ID 11123 Design Details © 24/7 Systems, Inc. - 2006

  21. Search Ability © 24/7 Systems, Inc. - 2006

  22. Installed Accessories • Break Wheel • Coupling haves • Filters • Blowers • Tach • Modifications © 24/7 Systems, Inc. - 2006

  23. Design Documents • Manual • Wiring diagram • Service Bulletins • Lubrication Specification • Photos • Baseline test © 24/7 Systems, Inc. - 2006

  24. Purchase Information • Vendor • Cost • PO # • Warranty • Specifications © 24/7 Systems, Inc. - 2006

  25. Step 3 - Repair Tracker • Tango web portal for repair shops • Repair vendors do information entry • No plant data entry • Results in history of failures and repairs • No plant location information needed at this point © 24/7 Systems, Inc. - 2006

  26. Repair and Failure Tracking Motor Shop Input • Design details • Failure mode confirmation • Repair actions & cost • Warranty information • Linked documents – damage photos, load tests, balance reports Internet Tango™ Web-service • Secure access via user name login • No plant firewalls to cross when entering information • Users retrieve information via browser – no software to install Plant User’s Tools • View a list of what’s out for repair • Search inventory by design details • Retrieve complete equipment lifecycle history • Analyze dominant failure modes • Report cumulative repair costs • See linked documents – damage photos, load tests, balance reports © 24/7 Systems, Inc. - 2006

  27. Repair Documentation © 24/7 Systems, Inc. - 2006

  28. Repair Documentation © 24/7 Systems, Inc. - 2006

  29. © 24/7 Systems, Inc. - 2006

  30. Steps 4-6Begin Tracking Motor life cycle History • Stores • Installed locations • Out for repair • Scrap © 24/7 Systems, Inc. - 2006

  31. Tango™ Equipment Management Functions CMMS • Cost of Repair • New Purchase Equipment • In place Maintenance Tango Equipment Inventory OLAP Database Data Mining INSTALLED SPARE OUT 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 © 24/7 Systems, Inc. - 2006

  32. Stores Shop Ships Equipment Scrap Send Equipment For Repair Shop Repairs Equipment Tango™ Equipment Lifecycle Flow MTBF Equipment Purchase Overhaul Due, Problem Detected, Equipment Fails Equipment Installed In Service Location Ongoing Events Condition Assessment Operator Observations Operator Data Logging Inspection Tasks In-place Maintenance Remove Equipment From Service Location Plant Receives Equipment No True Causes of Failure Repair Cost Repairable? Yes No Yes Quote Approved? © 24/7 Systems, Inc. - 2006

  33. Step 4 - Stores Management Plant Receiving & Stores Repair Shop Production Area Functional Location Rack/Bin © 24/7 Systems, Inc. - 2006

  34. Stores Motor Management Functions • Receive Motor from repair shop • Incoming inspection / test • Are accessories Installed? • Check Info in Tango and release to pay Invoice • Place in stores rack, track in Tango • Periodic inspection/ test/ rotate • Ship to production area and designate action in Tango © 24/7 Systems, Inc. - 2006

  35. Stores Structure © 24/7 Systems, Inc. - 2006

  36. Equipment Traveler © 24/7 Systems, Inc. - 2006

  37. Anonymous Locations © 24/7 Systems, Inc. - 2006

  38. Step 5 Location Structure © 24/7 Systems, Inc. - 2006

  39. Step 6 Location Tracking • Typically performed by reliability engineer in each production area • Move from Anonymous to specific functional location • Specify in Tango when sent for repair © 24/7 Systems, Inc. - 2006

  40. Tango™ Equipment History Report Get Design, Life Cycle Movement, & Repair Details Click this row to unfold equipment design data Click a paper clip icon to view linked documents Click a yellow row to see purchase and warranty details Click a red row to see repair, failure mode, and shop documents Click a green row to unfold location information © 24/7 Systems, Inc. - 2006

  41. © 24/7 Systems, Inc. - 2006

  42. © 24/7 Systems, Inc. - 2006

  43. Tango™ Location History Report Retrieve history of all equipment that’s been in service See all different equipment ID’s that have been in the service location Click any row to access the equipment history report © 24/7 Systems, Inc. - 2006

  44. Step 7Know Condition of Motors and prevent failure in service • Predictive Monitoring • Maintenance/ Production Inspections • Integration of results • Work scheduling • Validation of repairs © 24/7 Systems, Inc. - 2006

  45. Present asset-centered health status • Results from all technologies being applied to a piece of equipment are posted under a common location name • Problems are prioritized with color coding; equipment with most serious ‘red’ conditions show up at top of the list © 24/7 Systems, Inc. - 2006

  46. Allow information users to drill down for as much detail as they want • Details are available from each technology reporting on a piece of equipment © 24/7 Systems, Inc. - 2006

  47. Including the technical detail if they want it... © 24/7 Systems, Inc. - 2006

  48. Tango™ Condition Manager Program Integrate, Organize, and Communicate Condition Monitoring Results Oil Thermography Vibration Electrical Ultrasonics Process © 24/7 Systems, Inc. - 2006

  49. Tango™ Integrated Condition Status Report Quickly View All Known Health Issues on Critical Equipment Work Order Status shows if work has been initiated for each Condition Entry Case Closure shows that work has been completed and is ready for condition confirmation Pie chart quickly shows how many assets in a user’s area are in states of problem severity Findings from multiple condition monitoring technologies are shown for each asset component Color coded list prioritizes problems according to severity © 24/7 Systems, Inc. - 2006

  50. Rounds Logging of Parameters & Observations Measurements Gauge Readings Observations Barcode Point ID © 24/7 Systems, Inc. - 2006

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