1. ICAS and Remote Monitoring Informational Brief
AMG2CC Workshop
25 Feb 2015
PRESENTED BY
Michael DiUlio
NAVSEA 05Z
Distribution Statement A: Approved for Public Release; Distribution Unlimited

2. What is ICAS?
Navy’s ACAT IVM Program of Record (POR), via COTS hardware/software, for on-line automated machinery condition monitoring and assessment enabling Condition Based Maintenance (CBM), Remote Monitoring, & Remote Technical Assistance
ELEMENTS OF ICAS
SOFTWARE
Operating System
ICAS Shell
Over 30 Interfaces
Industry Standard, Open, etc.
HARDWARE
1-5 Computer Workstations
High-security Firewall System (HFS)
Multiple View Node Capability
Fiber Optic LAN
Portable Data Collector (PDT)
Sensors for selected equipment
I/O Devices
CONFIGURATION DATA SET (CDS)
Engineering Knowledge Base built on Reliability Centered Maintenance (RCM) and Failure Mode Effects Analysis (FMEA)
List of Equipment, Alarm Thresholds, Logsheets, Failure Modes, Rules Based Diagnostic System, Event Capture, Trends
Varies based on Class, Hull, and System Configuration
Distribution Statement A: Approved for Public Release; Distribution Unlimited

3. Data Logging / Situational Awareness
ICAS Capabilities – Afloat
Data Logging / Situational Awareness
CBM implementation tool
Machinery Data Trending
Rules based expert system
Vibration Analysis
Troubleshooting Aid
Event capture
Operational Assessment
Material Assessment
Plant Situational Awareness
Assessment Visit Support (Availability Planning)
A tool to enable reduced manning
ILS
Access and linkage to PMS, EOSS and IETMs
Electronic Logsheets
Currently installed on:
106 Ships; 7 Classes
Surface, Carrier
Continuous Analysis
ICAS Expert System:
performs a continuous analysis of machinery data.
automatically generates maintenance advisory
Distribution Statement A: Approved for Public Release; Distribution Unlimited

4. Seamless Data Offload via NIAPS Server Manual Data Submission
Remote Monitoring
Brings ISEA Knowledge Base to Maintenance Team Cell
Distance Support
MELS
IPARs
Formats &
Presents Reports
Seamless Data Offload via NIAPS Server
Manual Data Submission
IPAR - ed
ISEA Review of IPAR
ICAS
Collects & Process Data
Maintenance
Community
2-KILO
Via TYCOM Process
Distribution Statement A: Approved for Public Release; Distribution Unlimited

5. Machinery Control System
Remote Monitoring Data Flow
Data Processing and Posting
Data
Qualification
Data Acquisition
Data Packaging and Transmission
Machinery Control System
ICAS
RMU TM
HFS
NIAPS
NSWC
Crane
MELS Central RMU
MELS
P&D Engine
SHIP
SHORE
Provides Firewall protection between Machinery Network & Shipboard Network
ICAS Processes, Qualifies, & Stores Data
RMU packages change data for transmission to NIAPS Server
NIAPS Server holds ICAS Data until Shipboard Server replicates with Shore Server
NSWC Crane passes data from NIAPS Shore NIAPS Server to MELS.
MELS Data Processing and IPAR Generation
IPAR
Posted
Equipment Sensors
ICAS PROGRAM
SHIPBOARD
SHORESIDE
Acronyms:
MELS – Maintenance Engineering Library Server
CBM – Condition Based Maintenance
NIAPS – Navy Integrated Applications Server
DS – Distance Support
NSWC – Naval Surface Warfare Center
HFS – High-Security Firewall System
NSWCCD-SSES – NSWC Carderock Div – Ships Systems Engineering Station
ICAS – Integrated Condition Assessment System
RMU – Remote Monitoring Utility
MCS – Machinery Control System
TM – Transfer Manager
Distribution Statement A: Approved for Public Release; Distribution Unlimited

6. Same Data, Different Cut
IPAR vs. ePAR
Platform Specific
System Specific
Same Data, Different Cut
Distribution Statement A: Approved for Public Release; Distribution Unlimited

7. MELS – IPAR View “Hovering” makes detailed fault information available
Bars are a histogram of the failure/fault modes, information, vice raw data.
“Hovering” makes detailed fault information available
“Single Click” displays supporting data
System Faults
Distribution Statement A: Approved for Public Release; Distribution Unlimited

8. DDG GTG High Startup Vibrations
MARMC Change out request
Ship contacted and begins troubleshooting
(waterwash, transducer inspection, etc) +
MARMC SME performed borescope inspection. Damage found on 4th stage blade
First ICAS data offload received
First RDS Event for Ship
SME Performance review complete
Data Verified by SME and compared to failure library
ICAS Install
Recommendations documented in pdf
Time: -30 Days
Time: 0 Day
Time: + 1 day
Time: + 3 days
Time: + 11 days
Time: +11days
Background
Ship preparing for 18 month SEA SWAP deployment
All Gas Turbines were thought to be in good condition
Problem identified with first data offload after install
Analysis performed
Startup vibrations compared to DDG80 GTG high vibe problem that resulted in engine replacement due to 4th Stage turbine blade damage
Vibe signature matched and suspected 4th stage turbine damage on GTG#1
Action Taken
Ship notified (in POM period) and begins troubleshooting
MARMC performs borescope inspection during connection of independent vibration gear
Borescope revealed, (as suspected), 4th stage turbine blade damage
Results\Benefits
Engine replacement accomplished stateside prior to ship deployment
Reduced replacement cost
Increased Ship/System Readiness
Distribution Statement A: Approved for Public Release; Distribution Unlimited

9. IPAR Expansion / Evolution
The GTG ISEA, RMC & ICAS team has further evolved the GTG IPAR
“Start Vibrations High” discovered (2005 – Gonzalez)
applicable to approx 180 GTGs monitored by ICAS
Further analysis yielded an unsat amount of “false positives”
Failure mode split between “Cold start”, “hot start” or “running high” vibe condition
Better assessment with close to zero false positives
Distribution Statement A: Approved for Public Release; Distribution Unlimited

10. LPD-17 Remote Monitoring
Remote Monitoring used to identify and solve in service problems
Below LPD 17 MPDE EPAR is used to identify class wide problem
Engine light loading condition identified over 95% of operational time during the last 365 days on LPD-19
Lower right depicts an LPD-19 IPAR data screen used to identify that the existing system design is not capable of maintaining the Diesel fluids operational temperatures within design specification
25 Feb 2015
Distribution Statement A: Approved for Public Release; Distribution Unlimited

11. DDG AC Compressor Surge
A/C ISEA
(Code 921)
reviews performance data
ICAS Data received
from ship
IPAR sent to ship. ISEA s ship through TYCOM on two different occasions.
Ship responds to TYCOM with action taken based upon ISEA recommendations
ICAS Data processed
into MELS
Data Verified by ISEA
Recommendations documented
Time: 0 Days
Time: + 1 Day
Time: + 30 Days
Time: + 33 Days
Problem Description
ISEA review of IPAR data indicated possible compressor surging on AC Plant No. 2 and AC Plant No. 3 based on the combined motor current spike, suction pressure/temperature increases, and chilled water inlet/outlet temp increases.
Analysis performed
Day 1: ISEA ed ship and TYCOM directly addressing possible compressor surging. IPAR sent to ship.
Day 30: ISEA ed ship for the second time and TYCOM directly addressing possible compressor surging. IPAR sent to ship.
Action Taken
Ship ordered 15 cylinders of R-134a and have recharged AC Plants Nos. 1, 1A, and 2. Ship’s force has scheduled NSSA to assist in repairing leaks on AC Plant No. 3 during upcoming CMAV.
Results\Benefits
ISEA was able to remotely identify fault conditions while conducting weekly IPAR reviews. Using Distance Support the ISEA was able to alert ship’s force to the fault and provide recommended maintenance actions in a timely manner.
This prevented possible AC Plant Compress failure.
Estimated cost avoidance = $500k
Distribution Statement A: Approved for Public Release; Distribution Unlimited

12. ISEA Reviewed IPAR 2-Kilo CLOSING THE MAINTENANCE LOOP
Effort (IRI2K)
Allows ISEAs the ability to view available maintenance data (CSMP) in addition to MELS diagnostics in order to make informed recommendations and generate trackable work candidates
Creates (“J” coded) 2Kilos that can be attached to an IPAR
Less work for the Ship (no need to create 2Kilos from IPAR)
Better data collection (can see which jobs were completed and how long they took)
Allows validation of ICAS/MELS fault logic
The 2Kilos are injected into the shipboard OMMS making them part of the CSMP
Improved shore side (ISEA) analysis
Better recommendation based on current CSMP and history
Began implementation in FY14
CLOSING THE MAINTENANCE LOOP
Distribution Statement A: Approved for Public Release; Distribution Unlimited

13. ICAS RM Process w/ CSMP Link
Distribution Statement A: Approved for Public Release; Distribution Unlimited

14. DDG 101 Case Study EA01-J022
11/21/2011
11/23/2011
11/27/2011
12/5/2011
11/21/2011
EA01-J022 opened in CSMP
EA01-J022 closed in CSMP
AC2 Run again
12/5/11: Problem Description
ISEA noted that AC#2 plant returned to “GREEN” IPAR on Insufficient SW flow, review of closed WC EA01-J022 indicated that S/F troubleshoot and investigated SW system found it properly aligned but also noted that the SW strainers were fouled. They were cycled and cleaned.
11/21/11: Problem Description
ISEA review of AC#2 indicated SW flow Low or insufficient. 2K candidate EA01-J022 issued with IPAR
Limited run time on AC # 2 during this time period
Next IPAR on 12/5 indicated condition cleared. Fault remained green for subsequent IPARs.
Summary Inadequate SW flow can lead to poor heat exchange, leading to poor AC plant performance, excessive strain on the compressor, and internal damage requiring a compressor overhaul. This example shows that review by the ISEA can lead to remotely triggered maintenance actions and correlate those actions/solutions to Failure Modes and logic improvements as well as maintenance and energy savings
Restricted SW flow to the unit could lead to serious damage and increased energy consumption
Distribution Statement A: Approved for Public Release; Distribution Unlimited

15. ICAS & Energy ICAS Energy Dashboard CNRMC ICAS Support Discussions:
4/15/2017
ICAS Energy Dashboard
R&D Efforts (funded by FRRDP – NAVSEA 05T)
Shipboard ICAS tool that presents energy & fuel usage real-time
Provides feedback against established “Energy Profiles”
Provides energy saving recommendations
Data sent off-ship to support Energy Summary Reports
Initiated in 2010, started with DDG-51 FLT IIA Class
Proof of Concept completed in 2012
Currently installed on 6 ships (DDGs 90, 95, 100, 102, 103, 108)
Prototype efforts in progress for LPD-17 & DDG-51 FLT I
Implementation Efforts (funded by COMPACFLT & USFF, N43)
Install ICAS Energy Dashboard on 5 FLT IIA DDGs in FY-14
DDGs 92, 94, 97, 109, 112
DDG-51 FLT IIA implementation funding to transition to PMS400F in FY-15
CNRMC ICAS Support Discussions:
- Purpose of discussions were to address ICAS RMC support, specifically at the detachments
Two meetings: Aug 12, Oct 12
CNRMC agreed to look at staffing and skill set for ICAS support throughout the RMCs
NSWCCD to provide training for RMC ICAS Staff
TSRA:
- Purpose of effort is to formalize integration of remote monitoring into the ICMP/TSRA model
Leverage Remote Monitoring Tools to automate TSRA shipboard procedures, wherever possible
Intent is to increase efficiency and effectiveness of TSRA visit as much as possible
Remote Monitoring Tools: ICAS/IPAR, ORTSTARS
INSURV:
Contacted SSES for assistance in integrating ICAS/IPARs as part of the INSURV ship visits.
As part of each of Material Inspections (MI), INSURV wants to audit Remote Condition Monitoring Maintenance in three phases:
I. Is the required data coming off the ship? Is an IPAR going back?
II. Is the ship taking appropriate action on the IPAR?
III. Can INSURV use the IPAR to tailor its inspection plan?
Distribution Statement A: Approved for Public Release; Distribution Unlimited

16. Energy Summary Reports
4/15/2017
Energy Summary Reports
R&D Efforts (funded by FRRDP – NAVSEA 05T)
Initially modeled after IPARs to present monthly Energy/Fuel Usage
Evolved to include operational equipment lineups and act as energy “report card”
Distribution modeled similar to IPAR community
Support efforts (funded by COMPACFLT, N43)
FLEET is funding development of Energy Summary Reports in FY-14
Energy Summary Report Automation Tool (ESRAT)
Developed to automate data processing in the Energy Summary Report
ESRAT v2.0 released in Dec. ’13
Next generation of ESRAT currently in development stages
Support Efforts (funded by COMPACFLT, N43)
Tasking to develop interface from MELS/ESRAT to Fleet Energy Conservation Dashboard (FECD)
CNRMC ICAS Support Discussions:
- Purpose of discussions were to address ICAS RMC support, specifically at the detachments
Two meetings: Aug 12, Oct 12
CNRMC agreed to look at staffing and skill set for ICAS support throughout the RMCs
NSWCCD to provide training for RMC ICAS Staff
TSRA:
- Purpose of effort is to formalize integration of remote monitoring into the ICMP/TSRA model
Leverage Remote Monitoring Tools to automate TSRA shipboard procedures, wherever possible
Intent is to increase efficiency and effectiveness of TSRA visit as much as possible
Remote Monitoring Tools: ICAS/IPAR, ORTSTARS
INSURV:
Contacted SSES for assistance in integrating ICAS/IPARs as part of the INSURV ship visits.
As part of each of Material Inspections (MI), INSURV wants to audit Remote Condition Monitoring Maintenance in three phases:
I. Is the required data coming off the ship? Is an IPAR going back?
II. Is the ship taking appropriate action on the IPAR?
III. Can INSURV use the IPAR to tailor its inspection plan?
Distribution Statement A: Approved for Public Release; Distribution Unlimited

17. Energy – Complementary Tools
ICAS Fuel Management System (FMS) SBIR
SBIR Effort (funded by SBIR Program Office & FRRDP)
Currently Phase II SBIR (ESRG)
Shipboard ICAS tool that provides planning info for
fuel/equipment configurations
Prototype installed on DDGs 95, 100
Complementary to ICAS Energy Dashboard
New SBIR contract awarded May 2014
TRITON
Navy Propellers are inspected & cleaned twice per year: Hulls are inspected at the same periodicity, but cleaned every 3-5 years
The goal of this project is to develop, install and optimize a system capable of reporting in real time when a ship’s powering condition has degraded due to increased drag from biofouling.
Any improvement in fuel economy results in more days on station and/or fewer UNREPS during a deployment
Distribution Statement A: Approved for Public Release; Distribution Unlimited

18. REDI - Data Interface Overview
4/15/2017
Single unified view of maintenance & logistics data
Assist Reliability Engineer with planning and assessing all work candidates in an electronic format
Validate work packages and track deferrals
Add and order parts during assessment periods to created 2Ks
Provides visibility and tools for planning maintenance into prescribed periods
View Technical Manuals
SKED
RMAIS
Ship 3M/OARS
AWN/OMMS
CDMD-OA
REDI
ICMP
TDKM
REDI is not replacing any tools. It is providing access to Program of Record Logistics & Maintenance Tools at the Point of Performance in a Single, Enterprise Solution
Distribution Statement A: Approved for Public Release; Distribution Unlimited 18

19. REDI Screen Captures
OMMS/AWN: Assessor is two clicks away from submitting 2K candidate to OMMS/AWN
Configuration information and standard statements assist
INSURV: Digitized CHECKLIST with Automatic Discrepancy Generation
Discrepancy to Work Candidate Functionality Reverse Parts Identification SearchTech Manual to APL Verification CHECKLIST with Automatic
CDMD-OA(configuration data managers database) Search: By key fields: location, work center, HSC, equipment system description and equipment function description
EOSS
PMS
TDKM
CSOSS
Distribution Statement A: Approved for Public Release; Distribution Unlimited

20. Machinery Control System
Closing the Maintenance Loop
Machinery Control System
ICAS- NG
(eRM)
RMU TM
HFS
NIAPS
NSWC
Crane
MELS Central RMU
MELS
P&D Engine
Prognostic Engine
SKED 3.2
IPAR
Assessment Team / RMC /
Ship’s Force
AWN or
OMMS-NG
2 KILO
IRI2K
2 KILO
REDI
CSMP
REDI
On NIAPS
REDI
REDI
FUTURE STATE
SHIPBOARD
SHORESIDE
ICAS PROGRAM
Distribution Statement A: Approved for Public Release; Distribution Unlimited

21. ICAS is a Program Of Record for CBM
ICAS vs CBM
ICAS is a Program Of Record for CBM
CBM is more than just any single program
It’s a Policy
It’s a Process
It’s the People
It’s the Requirements
It’s the Resources
Add a “+” and it’s the Prognostics
It’s a Commitment
Distribution Statement A: Approved for Public Release; Distribution Unlimited

22. Cyber Certification and Accreditation
Distribution Statement A: Approved for Public Release; Distribution Unlimited

23. Challenges CBM is a systems engineered solution
CBM as an end-to-end solution crosses many organizations, programs and swim lanes
Individual programs band-aided together to form an end-to-end solution
90% of 90% of 90% yields 73%
Everyone not always on same page
Can’t come to parade ground every time someone doesn’t agree
Sensors (and systems) are determined during procurement phase
Limitation on sensors results in limitations on algorithms
Maintenance community needs a voice up front regarding parameters, sensors, etc.
Not inculcated in daily practice
Policies not reinforced
Some think CBM is not a requirement
ICAS is ACAT IVM program from 1996
School house starts ICAS training in 2015
CBM is a systems engineered solution
Distribution Statement A: Approved for Public Release; Distribution Unlimited

24. BACKUPS
Distribution Statement A: Approved for Public Release; Distribution Unlimited

25. ICAS Equipped Ships
Distribution Statement A: Approved for Public Release; Distribution Unlimited

26. ICAS Monitored Equipment
per Class
Distribution Statement A: Approved for Public Release; Distribution Unlimited

27. Detailed – DDG - AC Parameters
MCMAS is the ICAS Interface to the Machinery Control System (MCS) pulling data once per second
All MCMAS “type” data is automated
All portable “type” data is manual
Engineering Logsheets are developed from:
Technical Documentation
IPAR Requirements
CHENG Additions
Distribution Statement A: Approved for Public Release; Distribution Unlimited

28. Detailed – DDG – GTM Parameters
Distribution Statement A: Approved for Public Release; Distribution Unlimited