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.