ICAS (Enterprise Remote Monitoring)

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Integrated Condition Assessment SystemICAS(Enterprise Remote Monitoring)DoD Maintenance Symposium13 Nov 2007Statement A: Approved for Public Release; Distribution is s.navsses.navy.milMichael DiUlioNAVSEA 05Z3michael.diulio@navy.mil(202) 781-3566

Integrated Condition Assessment SystemNavy’s CBM/RM ChallengeSurface CombatsAmphibiousMid LifeNewacquisitionSubsCarriersMid LifeMine ta AcquisitionFunctionalityFunctionalityNo CBMNo RM13 Nov 07HandheldPDAs(PalmPilots)Hybrid System(Combination ofHandhelds &Automated Readings)Fully SensorizedAutomated Readings2

Integrated Condition Assessment SystemCommercial Industry using Remote DiagnosticsOnStar Vehicle DiagnosticsSubscribers receive monthly e-mail updates on thecondition of the vehicle's key operating systems.Condition and time-based maintenancerecommendations are included.Approximately every 30 days, the vehicle automaticallytransmits diagnostic data on the following systems: Emissions Systems Air Induction System Fuel Management System Engine Cooling System Throttle Control System Variable Valve Timing System Ignition System including Misfire Detection Active Fuel ManagementTM/Displacement on Demand Engine Electrical System Transmission Control System Antilock Braking System Traction Control System and StabiliTrak (whereapplicable) Supplemental Restraint System including AirbagDeployment Mechanisms and related sensors OnStar System13 Nov 07http://www.onstar.com/us english/jsp/ovd/index.jsp3

Integrated Condition Assessment SystemICAS Capabilities - Afloat CBM implementation toolData Logging / Situational Awareness– Machinery Data Trending– Rules based expert system– Vibration Analysis Troubleshooting Aid– Rules based expert system– Event capture Operational Assessment– Material Assessment– Plant Situational Awareness– Assessment Visit Support(Availability Planning) A tool to enable reducedmanningILS– Access and linkage to PMS,EOSS and IETMs Continuous AnalysisElectronic Logsheets13 Nov 07ICASICASExpertExpertSystem:System: performsperformsa machinerydata.data. automatically nceadvisoryadvisory4

Integrated Condition Assessment SystemRemote Monitoring - AshoreBrings ISEA Knowledge Base toMaintenance Team Cellrtdeodp oapu fflSe sOsiDMELSIPARsc lesnta mtDaeaSaFormats &Presents ReportsRMCICASCollects &Process Dataemailed13 Nov 07Evaluate SEANAVSEA00005

Integrated Condition Assessment SystemIntegrated Performance Analysis Report“Ship/System Level”Electronics& DatabaseSubject MatterExpertsICASFinal ProductRMCIPARMELSISEARMU"The right maintenance, at the right time, at the right cost."13 Nov 076

Integrated Condition Assessment SystemEnterprise Performance Analysis Report“Fleet wide view of a system”ICASRMCMELSIPARISEARMUShip 1ICASRMCMELSIPARISEARMUShip 2ICASRMCMELSIPARISEARMU13 Nov 07Ship n7

Integrated Condition Assessment SystemDDG 51 Class DestroyerAUTOMATED SHIP OFFLOAD (DS ICAS’ RMU)SHIPS Configured for DS13 Nov 07DDG 51 Class DestroyerHULLNIAPS Version15-Jul07DDG51 7May0764714348

Integrated Condition Assessment SystemSWE Remote Monitoring SWE Bridge PlotIPAR SummarySep 06 – Aug 07RM - IPAR Report CT– 81 Separate Ships 91% ICAS Surf Ships High Month: Jun 07: 45– 554 IPARs were released High Month: Aug 07 : 101 Business Rules– Currently optimizing process viaSWE– Process Metrics presented toSWE BOD13 Nov 07CT in Days High Month: Aug 07: 36120151050JanFe -06bM 06aA p r -06M r-06ayJu - 06nJu -06Au l- 06Se g- 06pOc - 0 6N o t -06D e v- 0c 6Ja - 06nFe -07bM -07arA p -07M r-07ayJu - 07nJu -07Au l- 07g07– 2871 Ship data submittals110100908070605040302010025 MPDE, GTM, GTG, AC, HPAC,LPAC, EVAP, RO, Refer, etc# of Monthly Reports– 12 System IPARs completeData Processing TimeDraft Report TimeSME Review TimeEntitlement CTBaseline FPYTotal # of ReportsRemote Monitoring is an Integral Part of theSurface Warfare Enterprise9

Integrated Condition Assessment SystemCNSF GTG Metric StudyTwo-Year1B4B CostAveragesICAS vs Non-ICAS GTG Repair CostsA ve C o st k250201200150 154.5k125 90k100055NonICAS50ICAS206FY 90k per yearNonICASICAS105 ICAS AveragePer-Ship Cost 108Average CostsICASNon-ICAS Non-ICAS AveragePer-Ship Cost 154.5k per yearMaintenance Savings Can Be Realized Using TheICAS System13 Nov 0710

Integrated Condition Assessment SystemCOMMONALITY The Integrated Condition Assessment System (ICAS) isthe poster child for Fleet Commonality– Surface Combatants– Amphib & Minesweeps– Carriers(60/100)(24/34)(6/11) The same ICAS software is utilized on all installations––––13 Nov 07Enterprise class based system trainingShared logistics costsShared system support costsShared implementation costs11

Integrated Condition Assessment SystemA Cross Platform, Common SolutionVarious Sources of RequirementsLegacy Fleet9Log Sheets9Trends9Events.DDG Mod9Client Sever9Thin ClientSEA 089Relational Database910,000 SensorsDDG 10009TSCEI9DiagnosticsLCS9Data Qualification9Remote MonitoringEnterprise Remote Monitoring (eRM)9Commonality9Reduced Life Cycle Costs9Shared/Reduced Development Costs9Reduced Installation Costs9Reduced In Service Costs13 Nov 0712

Integrated Condition Assessment SystemEnterprise Remote Monitoring“The Path to the SFullyFullyAutonomousAutonomous ngShipboard Generated IPAR’s (w/ rec’s)IPAR Virtual Subject Matter Expert2 Hour IPAR Turn AroundTiered Remote Monitoring Team(Upside Down Pyramid of Support)IPAR Case Based ReasoningDedicated eRM Response CenterPMS Identified & Scheduled RemotelyRemote Real-Time Tech AssistIPAR Standard StatementsMachinery Control System LAN Secure InterfaceRemote Monitored 2 Kilos GeneratedShore Side uploaded ShipboardHigh Security Firewall –Multi Level Network CardIPARs Delivered to Ship via Web ServiceElectronic Data SubmittalsIntegrated PerformanceAnalysis Reports (IPARs)Shipboard AutomatedDiagnosticsShipboardDataStorageShipboard Generated IPAR’s (w/o SME rec’s)Interface with ISNS LANManual Data SubmittalsShipboard data qualification(trends, events, transientanalysis, alarms)StatusFurther PlanningRequiredPlanned & EstimatedUnder DevelopmentDevelopment Complete,Deployment UnderwayShipboard Monitoring & Alarming13 Nov 0713

Integrated Condition Assessment SystemNavy’s CBM/RM ChallengeSurface CombatsAmphibiousMid LifeNewacquisitionSubsCarriersMid LifeMine ta AcquisitionFunctionalityFunctionalityNo CBMNo RM13 Nov 07HandheldPDAs(PalmPilots)Hybrid System(Combination ofHandhelds &Automated Readings)Fully SensorizedAutomated Readings14

Integrated Condition Assessment SystemBackup Slides

Integrated Condition Assessment SystemDDG 66 GTG High Startup VibrationsReverse Distance Support TimelineMARMC Change out request10.0DDG80 GTG3 and DDG66 GTG1 VIBS vs RPM9.5Ship contactedand beginstroubleshootingDDG66 TG1 VIBSDDG80 TG3 VIBS9.08.5THIS IS A COMPARISON BETWEEN DDG66GTG1 VIBS WITH DDG80 GTG3 VIBS, BOTHVERSUS RPM. DDG80 GTG3 WAS REPLACEDDUE TO 4TH STAGE TURBINE DAMAGE FROM2ND AND 3RD STAGE SHROUD FAILURE. BOTHGTG'S EXHIBIT PEAK VIBS IN THE SAME RPMZONE. COULD THIS INDICATE TURBINEDAMAGE ON DDG66 GTG1?8.07.57.06.5(waterwash,transducerinspection, etc)5.5MILS First ICAS dataoffload received6.05.04.54.03.53.0 First RDS Eventfor Ship2.52.01.5MARMC SMEperformedborescopeinspection. Damagefound on 4th 700080009000100001100012000130001400015000RPMData Verified bySME andcompared tofailure libraryICAS InstallFeb 5, 2005March 4, 2005 Recommendationsdocumented in pdfTime: 1 dayTime: 3 daysTime: 11 daysTime: 11daysProblem DescriptionAnalysis performedAction TakenResults\Benefits High Startup Vibes onGTG#1Identified During RDS event4 March 2005This is the first data offloadand first RDS event for ship13 Nov 07 High vibes compared to DDG80GTG high vibe problem thatresulted in engine replacement dueto 4th Stage turbine blade damageVibe signature matched andsuspected 4th stage turbine damageon GTG#1 Ship notified (in POM period)and begins troubleshootingMARMC visits ship after waterwash and troubleshootingcompleteMARMC performs borescopeinspection during connection ofindependent vibration gear Borescope revealed, (assuspected), 4th stage turbineblade damageMARMC recommended enginereplacement based on damageand ship schedule16

Integrated Condition Assessment System ICAS (Enterprise Remote Monitoring) DoD Maintenance Symposium ICAS (Enterprise Remote Monitoring) DoD Maintenance Symposium 13 Nov 2007 https://mels.navsses.navy.mil https://icas.navsses.navy.mil Michael DiUlio NAVSEA 05Z3 michael.diulio@navy.mil (202) 781-3566

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