Tango - Condition Manager

Tango™ Condition Manager

The objective on Tango's Condition Manager function is to facilitate the "Elimination of Failures in Service."

In Service Failures on Critical Plant Equipment can be eliminated by the rigorous application of condition monitoring (PdM), physical inspections and special testing of plant equipment. This approach is often called Condition Based Maintenance. Tango™ provides a systematic approach that allows you to achieve integration, communications, accountability and performance metrics in your condition based maintenance program.

For More Information View:

Putting the Pieces Together
Bridge Between Condition Monitoring and Maintenance
Condition Manager Brochure

Eliminate In-Service Failures
Figure 101: Condition Manager Flow Chart

Tango™ Integration Condition Reporting for work order generation helps you bridge the gap between condition data and maintenance action.

Reliability Flow Chart
Figure 102: Tango™ Equipment Condition Information Manager

Often it is difficult for a plant to consistently move from condition data that indicates a machinery problem to successful, timely repair of the equipment. Problems that interfere with the process are the usual suspects: Information integration, communications and accountability. Many large industrial facilities have wrestled with these problems and over time have evolved technologies for improving their record of performance.

Tango™ provides a web based condition manager system which allows condition analysts to enter each condition problem and then integrates their results with information from other technologies, providing a complete view of the equipment conditions. The Tango™ Reliability Dashboard displays all pending critical problems, their severity, aging and work order status.

Tango™ provides a standardized condition entry form (Figure 105) for analysts to enter their evaluation of equipment problems. The condition entry form is the same format for all condition technologies and analysis results in actionable information which is ready for use by plant maintenance and management.

Plants using Tango™ typically use the Integrated Report (Figure 106) as a planning and prioritization tool. Often this report is projected in weekly staff meeting as and reviewed in detail. From the Tango™ Integration Condition Report Details view, Tango™ allows a maintenance planner to create a work order by copying information from Tango™ into the plant CMMS or by an automated interface which creates a work order and receives the resulting work orders.

Once a work order is created, there may be many operational and logistical reason it is not immediately scheduled for execution. Tango™ provides an easy to view summary of open work orders, the length of time since the condition problem was entered and the work order number for each condition problem.

Tango™ Provides Communication & Accountability "Plants often struggle with knowing how well condition monitoring results are being used to drive maintenance execution."

Many industrial plants have technically proficient predictive maintenance programs using technologies such as vibration analysis, IR thermography and motor testing. However, those same plants often struggle with knowing how well condition monitoring results are used to drive maintenance execution.

All too often a plant's condition monitoring team (or service contractor) may report on the same equipment health problem time after time for many months, yet the maintenance organization does not respond until the equipment actually fails. Successful condition-based maintenance organization create accountability for resolving condition-based work requests.

The metrics begin with the Integrated Condition Status Report (ICSR). Users can sort to show the highest severity or criticality issues at the top, and planners can interact with the report to show that work orders have been issued or completed. This interaction makes it convenient to update work order status, and that in turn provides current information every time a user opens the ICAR. The "Days Awaiting Checkoff" column provides an aging statement showing how long each identified problem has been open; the Work Order Status" and "Work Order Numbers" columns show whether or not work orders have been generated, and the reference number from the plant's CMMS./ The broad distribution of this status information helps drive the accountability mentioned earlier. Once all the condition driven work orders for an asset component have been closed, the "Close Entry" button alerts users that it is time for a follow-up measurement to confirm that the problem has been eliminated.

Integrated Condition Report
Figure 103: Integrated Condition Status Report

Trend Analysis
Figure 104: Condition Entry Trend Analysis

Measuring Performance

Measuring Condition-Based Maintenance Effectiveness with Tango™ Web Service

Tango™ Condition Entries Standardize the Reporting of Equipment Condition Problems

Just as in human medicine, it is very important that all parties use common terminology when describing machinery health issues. Standardization of condition results mean that everyone inputting findings and recommendations use common equipment location names, faults, and severity levels, and that the output information has a standard look and content regardless of technology analyst, or whether they're plant employees or an outside contractor.

Tango's condition entry function provides a results entry form (Figure 105) that uses pull down lists to enforce standardized terminology. This screen utilizes a standard pull down list for the selection of faults, recommendations and severity. The pull down lists also enforce brevity to make the information easier to understand; an analyst can also write a more comprehensive problem description if needed. Such standardization allows a common look and language between condition technologies, and it also facilitates future mining of the information for common patterns. This simple mechanism for standardizing basic finding and recommendation contact does not exclude technical reporting, as supporting data images and documents can be linked to the condition entry, for retrieval by interested users.

Condition Entry Form
Figure 105: Condition Entry Form

Tango TM may be used to define condition assessment tasks for specific monitoring technologies and plant areas.

Condition Entry Form Details
Figure 106: Condition Entry Form Detail

For example, the monthly vibration analysis for the utilities area of the quarterly oil analysis may be defined in a Tango™ Condition Assessment Task. Task results are specified from a menu of states. These states allow the user to define the machine's state at the time of monitoring. Every task item must be assessed before the task can be closed, so items missed or down must have that state assigned to them. History of the component's health may be maintained and components which have been missed are maintained in a special list for "at risk" components, in need of assessment.

Figure 107: Condition Assessment Task Manager

Managing Condition Monitoring Contractors with Tango™ Reliability Management Service

IR & Ultrasonic Assessment tasks can be loaded into a PDA data collection routing.

Tango™ Web Service, in conjunction with handheld PDS's can provide well defined survey management along with an audit trail for problems found and assets not monitored. In addition, since Tango™ Web Service utilizes a web-hosted database on a server so that outside plant's IT firewall, IR service contractors can use the system and fall under this structured survey management.

The service contractor downloads a survey task into his handheld PDA then follows the PDA screen through the sequence of panels to be scanned. A bar code scan ensures that the IR information is being entered for the correct asset. He confirms the asset has sufficiently loaded for a good scan, then enters the results of that scan:

•Measured, No Problem Found
•Measured, Condition Entry
•Not Measured

Figure 108: Download Survey Task to PDA

Figure 109: Inputting Status through PDA Screen

For problems requiring a condition entry, the contractor references the IR and visual images captured by the infrared system. Once the survey is complete, the information is uploaded from the PDA to Tango™. Condition entries are complete for problems found, and those results are integrated with problems found by other condition monitoring technologies. Authorized Tango™ Web Service users can now view the updated Integrated Condition Status through their web browser.

A plant or corporate reliability engineer can monitor the quality and completeness of the contractor's IR work through the task summary report. This audits how many assets were scanned, which were not scanned and what problems are being found.

Oilography™ provides oil sample management, secondary analysis and Tango™ condition reporting.

24/7 Systems has added Oilography™, a web-based oil analysis management system to our family of Reliability Information Manager tools. Oilography™ provides solutions for these oil program issues:

•Management of sample points, rval and lubricant ID
•Management of sample labels and shipment to lab
•Management of oil lab analysis results
•Presentation of analysis results in an interactive report
•Secondary sample analysis by customized alarms and consultants
•Communication of oil analysis-based work requests to reliability and maintenance managements systems.

A review of this exciting new web-based oil analysis management system is available for you consideration.

Figure 110: Oilography Sample Management Diagram

View the Oilography Brochure Here