NAVSEA’s Condition Based

Maintenance Plus (CBM+)

Initiative

PRESENTED BY

Marc Borkowski
NAVSEA

December 4-7, 2017

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America’s Navy: The Next Generation

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 BLUF
• CBM+ builds upon DoD’s CBM strategy of performing maintenance
based on the objective evidence of need as determined by RCM

• NAVSEA is embracing advanced technology to optimize maintenance

costs while increasing materiel readiness through the use of sensor
based technologies and prognostic health monitoring

• NAVSEA is moving forward with CBM+ to increase use of CBM+

technologies where applicable and cost effective

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 CBM+ Expected Benefits

Improve Readiness and Availability of Assets

Improve Equipment Health to Achieve

Expected Service Life (ESL)

Maximize Efficiency and Reduce Life-cycle

Maintenance Costs Through Data-driven
Maintenance Decisions

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 CBM+ Increases Material Readiness:
Proactive vs. Reactive Maintenance
REACTIVE MAINTENANCE
DOWNTIME NON-AVAILABILITY
SUMMARY (DAYS)

DIAGNOSTICS
NON-PREDICTED
FAILURE Log Delay 5
WRENCH TIME

Wrench Time 1

1 DAY 5 DAYS LOGISTICS DELAY

Total Downtime 6

PROGNOSTICS

5 DAYS LEAD TIME FOR PART

Log Delay 0

Wrench Time 1
PREDICT FAILURE
Total Downtime 1
PROACTIVE CBM+
DOWNTIME

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 RCM is the Basis for CBM+
• Classic RCM is the Engineering Analysis Process used
to develop Organizational, Intermediate and Depot
level maintenance requirements for new equipment
and systems
• Backfit RCM is the Continuous Process Improvement
review of existing approved Organizational,
Intermediate, and Depot
level maintenance tasks
• Both processes are fully described in
MIL-STD-3034A and are essential to – CBM+ connects the maintenance tasks that
achieving CBM+ RCM tells us to do with the cost-effective
• Since 2001, NAVSEA has trained and certified 6773 in technology available to assist in evaluating
system and equipment performance.
Backfit RCM and 4419 in Classic RCM
– CBM+ uses RCM analysis to determine failure
• NAVSEA has instituted online training for our Backfit modes. This aids in sensor placement.
RCM certification via ePMS Gateway:
– CBM+ uses prognostics to schedule
https://epmsgateway.pmsmis.navy.mil maintenance to REDUCE DOWNTIME

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 NAVSEA RCM & CBM+ Relationship
1. RCM Developed Maintenance
Requirements Index

2. Select Preventive Maintenance Task

3. List and Identify Specific Failure Mode(s)

NO 4. Do CBM+ Technologies YES

Resort to Non-technology Exist That Can Accurately and 5. List Each Technology and Link
CD, TD, or FF Task Consistently Detect The Onset to the Failure Mode(s) Identified
of the Failure Mode?

6. Comparing
the Cost and Reliability
NO of CBM+ Technology With Manual YES Test CBM+ Technology in
PM, Does Any Identified CBM+ Intended Application Before
Technology Have a Greater ROI Full-scale Buy or Lease
Than Existing Low-tech
KEY: Methods?
CD - Condition Directed FF - Failure Finding NAVSEA CBM+ TECHNOLOGY DECISION LOGIC TREE
TD - Time Directed PM - Preventive Maintenance Source: MIL STD 3034A (Appx. F)

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 Technology & Tools: NAVSEA CBM+ Enterprise
System IT Applications
Integrated Condition Assessment System (ICAS) is:
• Program of Record
• NAVSEA’s common tool to support Condition Based Maintenance (CBM) for the past 20 +
years
• Installed on over 100 ships across the Fleet
• Monitoring mechanical and electrical systems including:
Gas Turbine Engines Fuel Oil System Main Reduction Gears
Propulsion Diesel Engines Potable Water Controllable Pitch Propeller
Refrigeration Plants Gas Turbine Generators Lube Oil System
Air Compressors Ships Diesel Generators Line Shaft Bearings
Distilling Plants Sewage & Waste Water
Air Conditioning Units Evaporators

• Performing diagnostics, parametric trend analysis and providing condition alerts via
Consolidated Machinery Assessment System ashore (CMAS)
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 Enterprise Remote Monitoring (eRM)
• The Navy is moving to replace ICAS with eRM beginning FY18
• eRM Improvements over ICAS Include:
– Government owned/developed system
– Increased cybersecurity posture
– Enhanced diagnostics, fault analysis & trending
– Enhanced feedback to ships force
– Highly scalable, faster data processing
– Supports rapid development and revision of CBM+ algorithms
– Phased transition to automated predictive analytics/prognostics
– Digital Twin capability
– Linkage to existing and new Navy policy and doctrine, infrastructure,
business strategy, architectural framework, RCM, and open systems and
data strategy

OBJECTIVES: Real-Time Equipment Health Monitoring & Reduced Downtime

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Goal: CBM+ eRM Closed Loop Process

CMAS is in The Early Stages of Realizing Digital Twin Capability for CBM+
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 Conclusions

• NAVSEA’s CBM+ process, when properly executed and resourced, will

ensure:
– The right maintenance is performed
– On the right equipment
– At the right time
– For the right cost
– And improve operational availability
• CBM+ technology must be considered as a key attribute in ship design
and be ingrained into the acquisition, modernization, sustainment and
management processes that are critical to ensuring ship material
readiness throughout service life

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 QUESTIONS?

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 RCM & CBM+ Policy
The following policy documents require or govern the use of RCM, CBM and CBM+
across DoD and NAVSEA:
• DODI 4151.22 CBM+ for Materiel Maintenance - Capstone policy instruction that drives CBM+ policy for
NAVSEA.
• OPNAVINST 4790.16B (CBM and CBM+ Policy) - Establishes policy and responsibility for the implementation
and integration of Condition-Based Maintenance (CBM) and Condition-Based Maintenance Plus for naval
ships, carriers, submarines, expeditionary equipment, aircraft, and associated systems, equipment and
infrastructure.
• OPNAVINST 4700.7L (Maintenance Policy for US Navy Ships) - Establishes maintenance policy for U.S. Navy
ships and directs the common use of NAVSEA’s Reliability Centered Maintenance (RCM) methodology in
developing maintenance requirements.
• OPNAVINST 4790.4F (Ships’ Maintenance & Materiel Management Policy) - Establishes policy and assigns
responsibilities for the Ship’s 3-M System which is designed to provide for managing maintenance and
maintenance support to achieve maximum equipment operation readiness.
• NAVSEAINST 4790.27A (RCM, CBM, & CBM+ Policy for Ships, Ship Systems and Equipment) - Aligns
NAVSEA policy with DoD and OPNAV’s RCM, CBM and CBM+ policies, specifically, requiring RCM based CBM
program that includes organizational, intermediate and depot level maintenance requirements.
• MIL-STD-3034A (Reliability Centered Maintenance (RCM) Process) - Delineates the 12 phase fully detailed
RCM Process and includes the associated Data Item Descriptions (DIDs) for each phase. Also contains the
Backfit RCM process. Appendix F describes relationships between RCM and CBM+. It is available for use by
all Services.

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 Technology Demonstrations That Will
Shape the Enterprise Solution - eRM
• LCS Machinery Readiness Management System (MRMS)
– Predictive analytics/prognostics to be demonstrated as part of demo
– Ship-to-Shore concept for centralized analysis and data warehousing
• Onboard equipment health monitoring and maintenance scheduling integration also planned
– Web-based user-interfaces planned for onboard and ashore teams (digital twin)
• General Electric (GE) Smart Signal
– Exploring options for enhanced CBM+ architectures, including predictive analytics and shipboard data
visualization, across six ship classes
• DEI and NSWCPD Main Reduction Gear Health Improvement
– Improvement of Main Reduction Gear health through unlocking of ICAS inherent capabilities
– Employ elements of DEI PreMA for system prognostics
– Identify improvements in system assessment capabilities with enhanced DDG 51 Class sensors; e.g., lube
oil sensors
• Ship’s Force Machinery Vibration Analysis Program (Including Thermal Imaging)
– Allows ships force to identify mechanical/electrical problems on over 400 pieces of installed machinery
before failures occur

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 Technology Demonstrations That Will
Shape the Enterprise Solution - eRM
• CBM+ Pilot Projects
– Using Penn State University support, include online condition monitoring, diagnostics, and vibration
based predictive analytics for high pressure air compressors, trim & drain system, and CO2 scrubbers
• (INSCAT) Integrated Naval Ship Condition Assessment Toolset
– Provides automated structural health monitoring data management from hull sensor data. Current Phase
II SBIR effort (lab-environment only to date)
• Distributed Sensor Network for Structural Health Monitoring
– Structural health monitoring technology uses installed sensors to monitor hull condition. Current Phase II
SBIR effort (lab-environment only to date)
• CBM+ Sense & Respond Crew Interface Technology
– Monitors & analyzes system performance data on LCS. Provides potential failure alerts, system health
status and troubleshooting enhancements to currently installed computer network. Current Phase II SBIR
effort (lab-environment only to date)
• Diesel Engine Data Analytics (CTMA)
– Four phase project with first phase to collect sample diesel engine run data and evaluate effectiveness of
CBM+ algorithms
– Have recently begun data collection on several diesel powered test ships
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