Next Generation CBM

7/28/2019 Next Generation CBM

1/10

NextGenerationConditionBasedMaintenanceforFleetOperators

1

Ken Krooner

ESRG Solutions

Jim Stascavage

ESRG Solutions

ABSTRACT

Manyshipowneroperatorsaresearchingforacosteffectiveandtechnicallyfeasibleprocesstocontinuously

digest,analyzeanddisplaydiagnostic/predictiveresultsofshipboarddataformaintenance,operationandto

supportcompliance reportingneedswhile shipsarepiersideorunderway. Thiswouldallowbetteruseof

existing data onboard ships for planning efforts to (a) occur concurrent with operations, (b) afford the

flexibilityof changingmaintenanceplansbasedonactualmachinerycondition, (c) support thedeployment

resultinginreducedmachineryfailuresduringdeployment,(d)reduceonsitetroubleshootingandassessment

effortsandtheassociatedcostsand (e)enableautomationofcompliance reporting requirements.Working

closelywith

ship

owner

operators,

ESRG

was

able

to

develop

and

deploy

aprocess

to

conduct

assessment

proceduresremotelyutilizingactualmachinerydataandfailurealgorithms.Thisprocesseliminatedtheneed

to have an assessment team come onboard the ship and have the crew operate machinery to conduct

assessmentprocedures.Foroneorganization,thisprocesswasfirstappliedsuccessfullytoasmallnumberof

shipsandhassincegrowntoover100+ships. ThisadvancedConditionBasedMaintenance(CBM)process

hasachieveda14monthreturnoninvestment.

Utilizationofexistingdataavailableonships

Nosensorsorhardwarerequiredforimmediateimplementation

Providediagnostic/predictiveviewsforexistingdata

Decisionmanagementsupport

Costreductionofequipmentlifecyclesustainment

Optimizepreventivemaintenancetasks

Advancedplanningandschedulingofmaintenance

Shipoperators

Reduced dependence on shipboardmanpower throughmore effective utilization of support

ashore

Operatorawarenessofimpendingequipmentriskstopreventcascadingandcollateralfailures

Increasedequipment readinessgainedbymoreeffectiveandmore flexible repair availability

planningpriortoandduringoperatingperiods

TotalOwnershipCosts

WillreduceandoptimizesustainmentTOC

Increasessystem/equipmentuptime


2/10

Generati

INTRODU

The need

improveme

initiatives t

Shipboardequipment

maintenanc

to equipmeclass of shi

flexibility t

ship and brecommend

In todays

successful

affordably lreturn on in

pieces. FirCM systemand alarm

maintenanc

may be ass

Figure

nConditiCTION

or reducin

ts, reduce

o operation

ondition mperformanc

e based on

t operationor a fleet

monitor i

equipmeations to th

environme

land-based

everage exivestment (fi

t, a rule setitself andonditions

e document

ociated wit

1

onBased

Total Ow

crew size

l imperativ

nitoring (Ce over ti

aterial con

s inside thef ships is a

dividual shi

t model, aships lead

t of multi

CM syste

sting technogure 2). Th

tailored foronfigured tased on ex

tion. Alter

failure but

Maintena

nership Co

and remote

es in the w

M) and tree, anticipa

ition. Ho

lifelines ofentral piec

p equipmen

d provideership in a t

le require

should fil

logies ande land-base

each applicships as a

isting tech

atively rul

are not, in

nceforFl

t (TOC) f

monitorin

ke of the

ding systeing failure

ever, shipb

one ship.that allow

t data fed fr

a means bmely mann

ents com

l a need,

T infrastru, or central

able equippropriate.ical manua

sets may

and of the

etOpera

r ships th

has neces

conomic sl

s providebased on

ard system

ey to optioperationa

om the site

which thr (figure 1)

eting for

rovide an

ture, and s, system sho

ent modelThe rule ses, ships d

e designed

selves, sp

ors

ough OEM

sarily shifte

owdown of

n effectivehistorical

s by their na

izing remand mainte

CM system

y can feed.

ver more

approach t

ould demould consist

hould be crt may refleawing or a

to alert to s

cific failur

partnering

d from wo

the past fe

means of odata and

ture are co

te monitorinance mana

s, aggregate

back mai

carce reso

at is user-

strate a mef three ove

ated externt normal, any type of

ecific tren

s. Second,

2

design

thwhile

years.

servinglanning

strained

ng for agers the

data by

tenance

rces, a

riendly,

surablearching

al to thebnormalplanned

s which

a land-


3/10

Generati

based CMdown to in

over time.

and semi-aship and all

data collecinformatioplanners, a

(satellite u

land-based

PLANT-B

A land-bas

to it in a

informatiooperational

should con

Interface

Figure

nConditiystem shoividual eq

hird, a lan

tomated minterested

ion systemfrom eachd (3) a ti

derway; int

omponent,

SED CON

d condition

imely man

to the shipand suppor

ist of the fo

ith shipbo

2

onBasedld provideipment fau

-based CM

intenance rarties. An

onboard eship and diely means

ernet conne

the other tw

DITION

monitoring

ner. Altho

oard user, inetwork e

lowing co

rd data bu

Maintena

graphicalt modes an

system sho

commendaeffective e

ch vessel,splays it into transmit

tion in port

o will be ad

ONITORI

system mus

ugh a plan

s completeternal to th

ponents:

ses. The sy

nceforFlinterface thd viewing

ld provide

ion reportsterprise C

(2) a centra useful mthe infor

). Althoug

dressed brie

G

t have a pla

-based sys

value is reaship. At a

stem shoul

etOperat providesquipment

a user with

based on thsystem co

l (land-basanner for tation from

this white

fly.

t or ship-b

em should

ized when iminimum,

be able to

orsa user witherformance

the ability t

latest datansists of thr

ed) applicate maintenathe ship to

paper will

sed system

gather and

t can providan effective

ollect data

a means ofacross faul

provide au

received baee main par

ion that agce and opthe central

ocus heavil

feeding inf

display ac

e informatiplant-base

at intervals

3

drillingt modes

tomated

k to thets: (1) a

regatesrationalsystem

on the

rmation

tionable

n to thesystem

equired


4/10


4

by the user, even up to once per second. It may rely on a third party historian (depending the numberof sensors), but it should not have to in the vast majority of cases in which the number of measuredsensor is in the hundreds or thousand vice tens of thousands.

Incorporate a tailorable rule set. Rules for how equipment should operate based on OEM technical

manuals or other user-supplied documentation should be developed and configured for each model ofequipment. The rule sets should be changeable outside of the CM system code so that future changesto the rule set will not necessitate recompilation and redeployment of the base software itself.

Provide real time or near real time sensor data displays. The plant-based system should be able totake industry-standard sensor tags and map them to rules designed to reflect sensor value to theoperational parameters assigned for each piece of equipment. The sensor data values should beavailable to a user in real time or near real time.

Provide historical data for trending. Equipment trending across sensors as well as discrete events(equipment starts, stops) should be available across a user-selectable time period.

Provide failure mode level information for units. Individual pieces of equipment should bemodeled in such a manner that failure modes for each unit are displayed at both the unit level and thesystem level, and each failure mode can be drilled down to provide actionable information for the user.

Tablet-based manual log keeping. Equipment readings that are not available on a data bus should be

able to be easily logged on an electronic tablet, such as an iPad

. Transferring manually collected data

from the tablet to the shipboard system is as simple as connecting the tablet to the CM hardware.

The plant-based CM system ideally should provide all the information required for establishing acondition-based maintenance process. However, the realities of reduced manning, aging equipment

and increased repair costs work against the shipboard-only paradigm. The complete solution requiresgetting the gathered data off the ship and into the hands of the maintenance managers in as timely amanner as possible.

The plant-based system should not be constrained to the shipboard engineering plant. Any system thateither monitors sensor data or has the ability to manually log sensor data can and should beincorporated into the shipboard CM system:

Combat systems hydraulic, pneumatic and motor systems

Stores and ammo elevators and conveyors

Ballast and deballast systems

Damage control remote operated valves, water mist and fire door systems

Small boat engine data

Organic air asset performance data


5/10

Generati

Figure 3 sgeographic

Figure

TIMELY

The onboar

data is tran

port may ofollow-on

processing

require datprocessing)

LAND-BA

Land-basedbased syste

technicallyimplemente

Continuou

the plant-bon a daily

values qual

against othprovide m

infrastructuwhen to beallowable f

CM syste

participatedaway from

nConditiows how bl history of

3

RANSMI

d, fleet, lan

mitted bet

t for traditiystem sho

by those u

processing.

ED CM:

CM systein an inte

accurate ad in three

remote as

sed systemasis for sub

fied by a ta

r units in aintenance

e. Whenst accomplinding. On

and poten

in a long-any shore-b

onBasedllast opera

events.

SION OF

d-based an

een them.

onal T-1 lild be conf

its (e.g., sh

once per d

HE VALU

s will proviface that is

d specificajor areas:

sessments (

on a frequeject matter

lored rule s

system. Ar watch st

aintenancesh maintenae case study

ial shortco

erm deployased mainte

Maintena

ions have

ATA

enterprise

hips under

es. The fregurable by

ps may tra

ay. The dat

E

e a clear vaboth user-fr

o a particu

deployed a

cy of up toexpert (SM

t, against t

interactivnder reco

actions arence actionsfrom the U

ings of a

ent progrnance orga

nceforFleen integra

CBM syste

ay may tra

uency at wthe user a

smit data s

a pending

lue if they ciendly and i

ar unit, a l

d non-dep

once per h) review.

e historical

workflowmendation

required, tbased on s.S. Navy br

trictly ship

m in whicization) wh

etOperated with sh

ms should

smit via E

hich data isnd indepen

ix times a

rocessing s

an replicatenteractive.

and-based

oyed ships

ur can beMEs can r

trend of tho

allows thes to the s

e ship andhips missiongs home

board instal

the ship sile the crew

orsipboard GP

e agnostic

F or SHF

transmitteddent of the

ay, but the

hould be st

the data prWith infor

M system

. Informati

erged, procview curre

se sensor va

ME to chaip and the

maintenann, upcominoth the vali

lation. A

tayed on strotated on

S data to p

with regard

ystems and

from a shifrequency

end user

red until r

vided by eaation that i

can be co

on transmit

essed and dt equipme

lues for tha

nge fault stshore-side

e team cacommitm

dity of a la

S Navy d

tion (and tand off. T

5

ovide a

to how

ships in

to anyof data

ay only

ady for

ch ship-timely,

fidently

ed from

splayedt sensor

unit, or

tus andsupport

decidents andd-based

stroyer,

ereforee plant-


6/10


6

based CM system onboard indicated excessive vibrations for one of the ships gas turbine electricalgenerators, but no investigation occurred until it was reviewed remotely by SMEs. Through remoteassistance feedback to the ship, the shore establishment recommended borescoping the engine. Thedetermination was made to change out the engine, thereby minimizing the operational impact of losingone of three generators. The active engagement of shore-based expertise via a robust, land-based CM

system is estimated to have saved the U.S. Navy $750,000 had that engine failed catastrophically.

1

Another U.S. Navy destroyer was able to use the historical data available in the land-based CM systemto prove that a vibration problem in an out-of-warranty engine actually began while the engine wasstill under warranty, thereby providing the basis for a claim against the manufacturer.

2

Periodic Surveys. While nobody today would suggest that the data and SME support provided by aland-based system should wholesale replace the myriad equipment and material inspections andassessments required to keep a fleet operational, clearly the value that the data can provide in advanceor as a complement to many of those inspections is significant. ESRG compared remote assessmentsand onboard assessment of 25 air conditioning plants indicated that the accuracy of remoteassessments could reduce the need for on-site visits by 62%. Intrusive inspections, while not the

norm, can be focused on those pieces of equipment indicating greater probability of failure in thefuture. Moreover, as overhaul maintenance planners struggle to fund ship repairs, they cancorroborate or challenge planned depot level repairs to equipment based on historically trendedperformance. The flexibility and timeliness of a land-based CM system linked to a shipboard systemmean that maintenance resources can be reallocated literally as new data becomes available.

Compliance Reporting. Fuel resources and environmental restrictions (and the penalties that comewith violation) will control more and more maritime operations in the future. Today, more than ever,naval and commercial fleets have to make the most out of every dollar spent. Both ship-based andland-based CM systems can be configured with many types of rule sets that can measure fuelconsumption (and make best engine/speed combinations based on the most current consumption

trends), ballast and sewage tank operations, emissions measurements, geographical positionif it isavailable on a shipboard data bus, in can be consumed, qualified and analyzed. A shipboard systemlinked to a shore based system can improve both the volume and quality of that analysis. Since thedata is taken from a bus, compared against rules and displayed in some meaningful format with nohuman in the loop, the credibility of the data with regard to compliance enforcement is greatlyenhanced.

Extended Use of Data. The data, once warehoused in the land-based CM database, can be used forextensive data mining, reporting, automated generation of work requests and ordering of supply parts.Harnessed to an enterprise service bus, the data can be used to streamline every step in the repair

1 Savage, C., DiUlio, M., Finley, B., Krooner, K., Martinez, P., & Horten, P. (2005).EnterpriseRemote Monitoring (ICAS & Distance Support), Tomorrow's Vision Being Executed Everyday.

White Paper, p. 8-10.

2 Ibid


7/10

Generati

process (fig

Figure4

LAND-BA

A comprehconsist of t

A web-bas

too slow, n

should pres

A rule ed

recompilat

the data as

based systeremoved fr

easily to co

Replicatio

nConditiure 4).

ED CM:

nsive land-e following

d, user-fri

n-intuitive

ent informa

tor and s

on of CM

qualified b

, the user im a syste

sume the d

of the fai

onBased

RITICAL

based CM scritical co

ndly grap

or unreadab

ion in the n

ip configu

ode. The l

the rules i

s able to puor operatio

ata as requir

lure mode

Maintena

COMPON

stem thatponents:

ical interfa

e, it wont

tural order

ration util

nd-based r

n the same

l that datanal paramet

ed.

drill down

nceforFl

NTS

orks seaml

ce. If a sof

e used. Cl

n which a u

ty that ca

le sets take

manner as

or all shipser set point

capability

etOpera

essly with it

ware applic

an, simple

ser would

n react to

the data pr

n the ship-

under his pare change

for each

ors

s shipboard

ation is too

screens wit

ant it.

machiner

vided from

ased syste

rview. Asd, the rule

nit config

counterpart

ifficult to

logical dril

changes

the ship an

, only in t

ensors areets can be

red for ea

7

s should

avigate,

l downs

without

display

e land-

dded orodified

ch ship


8/10

Generati

transmitti

roll-ups for

ability of s

supervisory

An enterp

platformshigh failure

have had re

A capabili

shipboard dsent directl

of SMEs aequipment

air conditio

Robust an

to provide

business inprogram m

Figure

nConditig data to t

each piece

ips force t

personnel a

rise tool t

n which irates on pa

air work c

y for shor

ata, modifyto the ship

shore is man be a sub

ing plant a

lytic capa

remote sup

elligence tnagers, wat

5

onBasedhe land-ba

of equipme

identify.

nd can be e

evaluate

is installerticular ship

nducted by

-based tec

statuses anand its sup

ch larger tstantial mo

sessment e

ility. Since

ort for de

ols to analerfront mai

Maintena

ed system.

t and can

system lev

panded for

performan

. Maintens or for shi

specific fac

nical sup

insert maiort infrastr

an on a shey saver, a

amples.

a land-base

kplate pers

ze data intenance per

nceforFlThe rule

e used for

el stopligh

more seriou

ce of indi

ance and lis deployed

lities.

ort. Subje

tenance orcture. Thi

ip. Moreoevidenced

d system le

onnel, it o

whateversonnel and

etOperaapplied to

roubleshoo

type displ

s pathology

idual mo

ecycle manto particul

ct matter e

repair recos is clearly

er, SME rby the U.S.

erages the

ly makes s

anner is dfloat units.

orsunit sensorpotential p

ay can prov

of machine

els of eq

agers can dr areas or e

perts shoul

mendationforce mult

mote assesNavy gas t

arger pools

ense that it

sired and r

provide diroblems be

ide a quick

conditions.

ipment ac

etermine caven for shi

d be able t

via a timeliplier since

sment of srbine gener

of technical

should inc

eport result

8

gnosticond the

iew for

ross all

uses fors which

review

y reportthe pool

ipboardator and

experts

orporate

s out to


9/10


9

CONCLUSION

Shipboard CM systems are a vital and necessary part of a fleet condition-based maintenance strategy;

however, they are only one part (figure 5). Coupled with a land-based component and a reliable data

link between the two, the enterprise CM system brings the ability to provide critical support, when

needed, halfway across the world to shipboard engineers and home port maintenance planners. Theremote monitoring and technical expert access that a land-based CM system brings to the table has

been proven in the U.S. Navy to save both maintenance, personnel and travel dollars and is well worth

the investment to maximize a fleets operational readiness and optimize the expenditure of scarce

maintenance budgets.

CONTACTS

Ken Krooner

[email protected]

Mr. Krooner, President ESRG Solutions, LLC based in Virginia Beach, VA, is a graduate of OldDominion University (BS Engineering Technology). He has over twenty years of experience inoperations, planning, and program management in the marine engineering field. He has over 15 yearsexperience with designing, developing, and implementing condition based maintenance (CBM) andcondition based operations (CBO) strategies within the Navy and commercial industry, using theShipboard Level and Enterprise level Performance and condition monitoring technologies.

Jim Stascavage

[email protected]

Mr. Stascavage holds an MS in Computer Science from the U.S. Naval Postgraduate School. He hasover eleven years of shipboard engineering operations and maintenance experience during his 28 yearcareer as an officer in the U.S. Navy. He currently serves as Vice President of Engineering for ESRG.

DEFINITIONS, ACRONYMS, ABBREVIATIONS

CBM: Condition Based Maintenance

CBO: Condition Based Operations

CM: Condition Monitoring

EPAR: Enterprise Performance Analysis Report


10/10


10

IPAR: Integrated Performance Analysis Report

eKB: Engineering Knowledge Base

RM: Remote Monitoring

Date post:	03-Apr-2018
Category:	Documents
Upload:	ho-fa
View:	217 times
Download:	0 times

Next Generation CBM

Documents