Transcript US Steel Implementation Tango Motor Management

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
• No warranty tracking
• No Ability to Analyze Performance
© 24/7 Systems, Inc. - 2006
RELIABILITY ADVANTAGES ARE WELL
KNOWN
World Class
Average
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Average life of electric motors
> 15 yrs
< 10 yrs
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Mean time between repairs for pumps
> 6 yrs
< 3 yrs
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Average vibration levels
< 0.1 in/sec
> 0.3
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Overtime, percent of total hours worked
<3%
> 10 %
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Emergency work
< 5%
> 15 %
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Total maintenance cost as percent of RAV
< 2%
> 3%
“Reliability impacts safety,environmental,quality,service,cost,and CTO”
Source: Bob Taylor SMRP 2003
Why do Motor Management?
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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
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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
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Motor Management is
Information Management
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Identification and Design data
Design documentation
Purchase
Stores
Install and location
Condition Test and Results
Failure, Repair, and Warranty
Collective analysis
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Motor Management Outline
1. Get Started – Goals and Success metrics
2. Build a Motor database - Import any existing
motor design data
3. Failure/Repair Tracking - Set up repair tracker
for all repair vendors
4. Identify and enter stores inventory: Train stores
person to keep current
5. Import Motor functional locations from CMMS
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Motor Management Outline
6. Functional location tracking by Production
Area
7. Condition Tracking
8. CMMS Interface
9. Analysis
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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
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Required for Reliability
Information Management
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Standardize
Integrate
Communicate
Accountability
Analyze
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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.
Condition Assessment
Task Management
This application allows
plant groups and
contractors to enter
Condition Assessment
Results.
Completely web based
interface provides all
TANGO reports and some
analysis features along
with very limited
information entry.
TANGO
Repair Tracker™
Interface specifically
designed for repair shops
to enter design, failure and
overhaul information.
Maintenance &
Process Inspections
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.
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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
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How do you measure reliability?
How do you know its improving?
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MTBF by equipment type, location…
Faults by fault type, equipment type
Root cause of failure by equipment, location
Cost of failure by equipment, location
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Step 2 – Motor Inventory
• How are we going to build the motor
database
• Import from other systems
• Survey
• Incremental as sent for repair
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Identification
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Brass Tag
Serial No
Barcode
ID chip
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Motor ID Tag and Nameplate
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Design data for tag# 17100
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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)
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Name Plate Data is not enough
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Design Details
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
Solid Coupling.
Adaptor Base.
Comments
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)
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Search Ability
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Installed Accessories
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Break Wheel
Coupling haves
Filters
Blowers
Tach
Modifications
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Design Documents
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Manual
Wiring diagram
Service Bulletins
Lubrication Specification
Photos
Baseline test
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Purchase Information
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Vendor
Cost
PO #
Warranty
Specifications
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Step 3 - Repair Tracker
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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
Repair and Failure Tracking
Motor Shop Input
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Design details
Failure mode confirmation
Repair actions & cost
Warranty information
Linked documents – damage photos,
load tests, balance reports
Plant User’s Tools
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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
Tango™ Web-service
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Secure access via user name login
No plant firewalls to cross when
entering information
Users retrieve information via
browser – no software to install
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Repair Documentation
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Repair Documentation
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Steps 4-6
Begin Tracking Motor life cycle
History
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Stores
Installed locations
Out for repair
Scrap
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Tango™ Equipment Management Functions
CMMS
• Cost of Repair
Tango
Equipment
Inventory
INSTALLED
SPARE
• New Purchase Equipment
• In place Maintenance
OLAP
Database
OUT FOR
REPAIR
• In Place Maintenance
• Store Room
• Repair Shops
• Test & Inspection
• Stores Reliability
Task
• Failure Causes &
Root Causes
• Scheduled Replacement
• Condition Findings/History
• Trend Data & Observed History
• Location Documents
• Cost
• Design
Information
PURCHASE
Data
Mining
SCRAP
• New Equipment
Vendors
• Design
Information
• Cost
• Repaired
Documents
© 24/7 Systems, Inc. - 2006
Tango™ Equipment Lifecycle Flow
MTBF
Equipment
Purchase
Equipment
Installed In
Service
Location
Ongoing Events
Condition Assessment
Overhaul Due,
Problem Detected,
Equipment Fails
Operator Observations
Operator Data Logging
Inspection Tasks
In-place Maintenance
Remove
Equipment
From Service
Location
Plant
Receives
Equipment
Stores
Repair
Cost
Shop
Ships
Equipment
No
True Causes
of Failure
Repairable?
Scrap
Shop
Repairs
Equipment
No
Yes
Quote Approved?
Yes
Send
Equipment
For Repair
© 24/7 Systems, Inc. - 2006
Step 4 - Stores Management
Repair
Shop
Plant
Receiving
& Stores
Production
Area
Functional
Location
Rack/Bin
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Stores Motor Management
Functions
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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
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Stores Structure
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Equipment Traveler
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Anonymous Locations
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Step 5 Location Structure
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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
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Tango™ Equipment History Report
Get Design, Life Cycle Movement, & Repair Details
Click a paper clip
icon to view linked
documents
Click a red row to
see repair, failure
mode, and shop
documents
Click this row to
unfold equipment
design data
Click a yellow row
to see purchase and
warranty details
Click a green row
to unfold location
information
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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
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Step 7
Know Condition of Motors and
prevent failure in service
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Predictive Monitoring
Maintenance/ Production Inspections
Integration of results
Work scheduling
Validation of repairs
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Present asset-centered health status
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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
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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
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Including the technical detail
if they want it...
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Tango™ Condition Manager Program
Integrate, Organize, and Communicate Condition Monitoring Results
Oil
Thermography
Vibration
Electrical
Ultrasonics
Process
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Tango™ Integrated Condition Status Report
Quickly View All Known Health Issues on Critical Equipment
Pie chart quickly
shows how many
assets in a user’s
area are in states of
problem severity
Work Order Status shows if
work has been initiated for
each Condition Entry
Findings from multiple
condition monitoring
technologies are shown
for each asset component
Case Closure shows that
work has been completed
and is ready for condition
confirmation
Color coded list
prioritizes problems
according to severity
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Rounds Logging of
Parameters & Observations
• Measurements
• Gauge Readings
• Observations
• Barcode Point ID
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Step 8 – CMMS Interface
• Often custom based on customer needs
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Step 9 - Analysis
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How do you increase reliability?
How do you make equipment last
longer?
• Know condition of critical equipment and prevent
failure in service
• Know equipment lifecycle history
• Know root causes of failure
• Eliminate causes of failure
• Make operations and maintenance accountable for
Improvement
• Analyze information for patterns and adjust to
improve
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Analyze information for patterns
and adjust to improve
• Need for training or tools
• Operations or design problems
• Quality
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Eastman Chemical customized report:
Response to condition generated work requests
Eastman Chemicals
in 2004:
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91% of vibration
reported problems
were resolved through
August
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Management expects
resolution within 120
days of reporting
“When people know that
the bosses know & care,
prompt response happens”
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Using condition history to spot reliability gaps
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Eliminate causes of failure
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Training
Tools
Design
Quality
Operations
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Analysis
• Root Causes of Failure by equipment and
location
• MTBF by equipment and location
• Cost By Equipment and location
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Data Mining Using Tango
Tango has several predefined data
mining reports which allow you to
determine what equipment or
locations are the least reliable.
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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
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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.
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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.
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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
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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.
© 24/7 Systems, Inc. - 2006