Reliability Update Condition Management

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Reliability UpdateCondition Management

• Turn Condition Monitoring Findings into Effective
  Maintenance Execution

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Who Is 24/7 Systems?

• Started 1998
• Employees have extensive Predictive Maintenance
  and Reliability experience
• Host Tango Databases for over 200 Large
  industrial plants
• Users include ALCOA, Cargill, Mittal Steel,
  Eastman Chemical, Goodyear, A-B, AK Steel,
  Dominion Power, Buckeye, LOOP

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Where do you stand today?

• Lack of standardization across monitoring
  technologies
• Multiple condition reports
• Emailed reports no integration
• Poor communications
• Poor accountability
• No history of condition problems/ patterns
• Weak analysis of results

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Sources of Condition Information

• Plant monitoring groups
• Contractors
• Repair shops
• Inspectors
• Plant Systems

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Integrate Results Not Data

• Severity
• Fault
• Recommendations
• Comments
• Work order status
• Documents

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Condition Task Work Management
Vibration
IR
Tango Condition Assessment Task
Reports History
Oil Analysis
Motor Testing
Ultrasonics
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Integrated Condition Status Report

• Shows how long condition entries have been open,
  awaiting work completion.
• Shows how many condition entries have work orders
  opened.
• Shows assets where all condition entries have had
  work completed and are awaiting confirmation by
  condition monitoring.

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Condition Entry Form
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How the ICR is Used

• Prioritization
• Planning
• Validating maintenance
• Overview

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Communication of Condition Information
Tango Integrated Condition Report
Maintenance Operations Staff Meeting Work
Prioritization
Management Review Oversight
Reliability Repair Validation
Performance Measurements
Planners
Work Order
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Accountability

• High visibility of problems to managers
• Time open provides warning of slow resolution
• Severity and criticality brings major problems to
  top of list
• Validation assures work performed well

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Eastman Chemicals Kingsport, TN - 2005

• Accountability is consistently based on condition
  status and work execution rather than informal
  complaints from operations

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Use of Historical Condition Information

• Identify chronic failure issues target
  reliability improvement initiatives.
• Change work procedures and justify special
  training tools.
• Fine-tune condition monitoring activities.

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Program Results
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Program Results
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Using condition history to spot reliability gaps

• Reduction gearboxes quickly stand out with the
  highest number of faults.
• Drilling into the report would uncover filter
  design and lubrication issues as common
  denominators behind the gearbox faults.

• Eastman has significantly reduced chronic
  equipment problems such as imbalance,
  misalignment, lubrication, and installation
  issues by using historical failure mode
  information to change procedures and justify
  special training and tools.

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Tango Reliability Management
The next step in your condition based maintenance
program
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What Tango Does

• Easy for contractors and plant teams to use same
  database
• Provides work task scheduling and reporting
• Integrates Condition Results
• Communicates HOT problems
• Facilitates prioritization, planning, and
  validating of critical maintenance
• Results accountability

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Why do Plants Use Tango?

• Standardize condition management practices across
  multiple plants.
• Manage condition analysis contractors.
• Measure condition based maintenance performance.
• Increase visibility of problems to prevent
  dropped balls and assure critical repairs are
  scheduled and performed promptly.
• Maintain a history of condition problems and
  patterns.

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Summary of Results at Eastman Chemicals

• Follow-up of predictive maintenance calls now
  consistently tracked.
• Basic maintenance problems related to
  installation, imbalance, and misalignment
  practically eliminated
• Maintenance budget personnel count reduced
  while production capacity slightly increased.
• Operating area bosses know and care about
  whats happening with equipment reliability.

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Whats Your Next Step?