1. Intelligent Ships Symposium: Condition Based Maintenance Plus Best Practices to Meet Modern Surface Ship Technical Challenges of COTS Electronics May 21, 2015

2. Contact Information
Ruben Ortiz
Reliability, Maintainability & Safety Engineering
General Dynamics Mission Systems

3. Disclaimer
The views expressed herein are strictly the personal opinion of the author

4. Presenter’s Opening Thoughts
Rings true to modern day surface ship and submarine platforms
Technological changes have greatly influenced maintenance and sustainment strategy
Adapting to meet these innovative technical challenges is critical to mission success
CBM+ is an adaptive maintenance strategy that strives to meet these challenges
How does CBM+ help get us there?

5. CBM+ overview: comprehensive maintenance strategy
Maintenance Strategy Elements
Hardware—system health monitoring and management using embedded sensors
Software—decision support and analysis capabilities; diagnostics and prognostics; automated maintenance information
Design—open system architecture; enabling maintenance decisions based on equipment condition
Processes—RCM analysis; a balance of corrective, preventive, and predictive maintenance processes; trend-based reliability and process improvements;
Communications—databases; off-board interactive communication links
Tools—integrated electronic technical manuals (i.e., digitized data) (IETMs)
Functionality—low ambiguity fault detection, isolation, and prediction; optimized maintenance requirements and reduced logistics support footprints; configuration management and asset visibility.
Reliability Centered Maintenance (RCM): a method which identifies applicable and effective maintenance tasks needed to maintain the inherent reliability of systems or equipment at minimum cost
Interactive Electronic Technical Manual (IETM): a portal to manage technical documentation

6. CBM+ Infrastructure

7. CBM+ Enables Affordable Life Cycle Maintenance
Evolution

8. The CBM+ Role in the Total System Life Cycle

9. CBM+ Opportunities and Cost Reduction
65 – 80% of ship total ownership costs are from operational and support phases during systems sustainment.
Seek opportunities to apply CBM+ strategies during this phase of the product life cycle.

10. CBM+ Analytics (Classifications)
Only 13% of companies make extensive use of predictive capabilities
Most organizations are stuck at lower-value descriptive analytics
It is reported the 75% of companies plan to add more sophisticated predictive and predictive analytics in the future.

11. Predicting Failures
Detection of the potential failure should provide sufficient time for resolution planning

12. Integrated Product Management Dashboard Suite
Condition Monitoring Dashboard
Life Cycle Supportability Dashboard
Reliability Dashboard
Master Equipment Database

13. CBM+: Reliability Dashboard
Failure tracking/reporting:
Top failure reporting
Failure identification by life cycle phase and configuration item
Trend Analysis plots

14. Condition Monitoring Data Collection
Create asset unique Health Assessment Reports by integrating meter data collection of conditions found with failure history and service life through custom Reliability Dashboard
Analyze data to provide yard planner with inputs for Maintenance Planning decisions
History Database
Health Assessment Reports
Yard Planner

15. CBM+ Analytics: Equipment Health Management Dashboard Module

16. CBM+ Analytics: Life Cycle Supportability Dashboard Module
Provides snapshot of product supportability throughout the life of the program

17. Optimizing Maintenance Intervals
* Costs versus maintenance intervals
**RCM Cost simulation PM optimization plot
PM initial cost at frequent intervals high and decreases as interval is extended. CM costs initially low due to frequent interval between PM tasks, but increases as PM interval is extended due to increased downtime
Provides technical justification for maintenance decisions, flexibility to maintenance planning, and inputs for sparing estimates and supportability
* Illustration courtesy of Cadick Corporation (Adapted from figure of NFPA Standard 70B, 2010 edition)
**illustration courtesy of Isograph Inc.

18. Prognostic Health Management (PHM)
Prognostics health management (PHM) consists of methodologies focused on assessing the reliability of a product based in actual life cycle conditions to predict incipient failures and mitigate system risks:
Monitor and interpret performance degradation or deviation from expected values
Detect physical or electrical degradation
Track changes in life cycle profile (usage duration, ambient temperature, humidity etc.)

19. Reliability Modeling and PHM
Limitation of traditional reliability modeling
MIL-HDBK-217
PRISM
Telcordia
Assumed constant failure rates: lacked accurate stress and operational factors
Potential for poor designs and logistic decisions
Traditional Operational Availability models empathize redundancy based on fault-tolerant systems and diagnostics
Increasing complexity of systems and cost are requiring more efficient system engineering and RAM modeling approach

20. Reliability Modeling and PHM
Center for Advanced Life Cycle Engineering (CALCE) with government support developed new PHM based methodologies:
Physics of Failure (PoF)
Design for Reliability (DfR)
New PoF and DfR reliability modeling approach utilize life cycle loading and environmental stress data to improve accuracy
CALCE PHM Methodology: more holistic approach:
Failure Mode, Mechanisms, and Effects Analysis (FMMEA)
Failure: Inability of a system to perform its intended function
Failure precursors: measurable variable used in detection of impending failures
Failure mode: an observable failure to meet an intended function of a component, subsystem, or system
Failure cause: the process, design or environmental condition that initiated the failure
Failure mechanism: actual physical defect or condition causing the failure mode
Overstress
Wear-out

21. Reliability Modeling and PHM
Fuses and canaries
Existing sensor/BIT data
PoF models
Remaining life assessments
Life-cycle cost analysis

22. Reliability Modeling and PHM
Table of Failure Precursors for Electronics:
Electronic Component
Failure Precursor
Power Amplifier
Gain
Phase
Gain Margin
Phase Margin
Crossover Frequency
Power Dissipation
3dB Roll off Frequency
Settling Time
Rise Time
Propagation Delay
Antenna
Bandwidth
VSWR
Power Supply
Efficiency
Ripple
Noise
Harmonic Distortion
IGBT
Output Voltage
On-state Resistance
UPS Battery
Impedance
Output Current
Charge Capacity
Voltage Controlled Oscillator
Output Frequency
Power Loss
Phase Distortion
Transformer
Insulation Resistance
Frequency Response
Fans
RPM
Airflow

23. PHM of Electronics Accelerated Failure Testing Methods:
Thermal Oscillation and Combinational Environment
The temperature test chamber accelerated testing subjects the device under test (DUT) to environmental stress to accelerate the aging process to its wear-out region
To accelerate the aging process the applied voltage is increased above the device specified voltage threshold while simultaneously maintaining the maximum nominal operating temperature to force the DUT to operate beyond its operational limits

24. PHM Implementation Opportunities Challenges: Naval Fleet:
Maintenance Availability Planning
Preventive Maintenance Optimization
Mission Operational Planning
Operational Availability Modeling
Supply Chain Management
Parts Inventory
Product Recalls
Warranty methodologies
Components and Circuit Boards
Canary devices
Leverage existing diagnostic bus structures (JTAG, I2C , VME etc.)
Interconnect Prognostics
Component to circuit board to system PHM
Challenges:
Complex Systems
Data Standardization
Data Management:
Storage and transmission costs
Maintaining data integrity
Data processing adequacy
Verification and validation methods
Data Driven methodology versus Physics of Failure (PoF) methodology
Integrated Circuits and Gate Devices
Increasing complexity
Production schedules
Interconnect anomaly detection techniques
False alarms and safety implications

25. Prognostics for Servers and Circuit Boards
Utilize available PHM features in servers and associated circuit boards
Adapt I2C bus architecture to extract component health data with minimal system intrusion
The Intelligent Platform Management Interface (IPMI) is a set of computer interface specifications for an autonomous computer subsystem that provides management and monitoring capabilities independently of the host system's CPU, firmware (BIOS or UEFI) and operating system
*Illustration Author: U. Vezzani
American MegaTrends
16 June 2010

26. Emerging Health Monitoring Technologies
Neural Networks (NN)
Micro-electro Mechanical Systems (MEMS)
Insulated Gate Bipolar Transistor (IGBT) Condition Monitoring
Corrosion Health Monitoring (CHM)
Infra-Red Thermography
Frequency Response Analysis (FRA)

27. Neural Network Research- Induction Motor
Major Faults of electric machines: stator faults, rotor faults, bearing faults, and all other
Non-invasive Feed-forward neural network methodology utilized to detect and classify faults
NN trained using measured time domain single phase stator currents converted to frequency spectra for monitoring
Adaptive backpropagation algorithm is able to automatically identify rotor status (discern between “healthy” and “faulty” induction motor)
Determines the extent of faults.
Useful for early fault detection and preventive maintenance.

28. MEMS Technology Overview
Typical applications: accelerometers, gyros, tilt sensing, pressure, biomedical, temperature and flow sensors

29. Piezoelectric technology versus MEMS technology
Mature user base
Performance
Packaging
Versatility
High modules of elasticity
Rugged
Extremely high natural frequency
Linear over wide amplitude range
Adaptable to harsh environment
Evolving user base
Miniature
Functional Integration
Sensor
Amplifier
A/D converter
Memory
Low power consumption
Advanced Signal Processing

30. MEMS Vibration Health Monitoring Benefits
Benefits of Functional Integration
Utilization of advanced signal processing
FFT Spectral Alarms
Correspond to machine-health monitoring vs. time profile
Capture historical vibration data for analysis of machine wear-out behavior
Store FFT records to assist in maintenance and safety planning
* An Introduction to MEMS Vibration Monitoring, Mark Looney, Analog Dialogue, June 2014

31. MEMS Vibration Health Monitoring Benefits
Simplistic monitor states correlate to typical machine maintenance cycles:
Normal
Warning
Critical
Reduced maintenance costs by scheduling maintenance tasks based on vibration data
Integration of Inertial Sensing

32. IGBT Health Monitoring
Study on condition monitoring opportunities of Insulated Gate Bipolar Transistors (IGBTs)
An IGBT is like a MOSFET and a bipolar junction transistor (BJT) combined
High input impedance and switching speed
Low saturation voltage
Power semiconductor device
Bipolar power transistor for electronic switching
Provides isolated gate control input
Useful in mission-critical applications on surface ship motor drives

33. IGBT Health Monitoring
Common failure modes
Latch-up
Secondary breakdown due to thermal runaway
Failure mechanism:
Coefficient of thermal expansion mismatches
Repeated temperature cycling leads to device failure due to mechanical fatigue
Condition Monitoring Opportunities:
Health parameters to monitor:
Output ON voltage VCE
On-state resistance RDS
Infra-red thermography
Monitor Localized hot spots

34. IGBT Health Monitoring
Study Results:
Transistor turn-off time identified as precursor
Testing by monitoring turn-off time during switching cycles
Six transistors in “out of the box” condition compared with 2 aged faulty transistors
Latch-up failure mode condition emulated
Turn-off times greater for the faulty transistors under the same operating conditions
Demonstrates aged and healthy transistors can be distinguished
* Turn-off Time as a Precursor for Gate Bipolar Transistor Latch-up Faults in Electric Motor Drives, Annual Conference of the Prognostics and Health Management Society, 2010

35. Corrosion Control Through Condition Monitoring
Defense Science Board report on Corrosion Control (2004):
Corrosion costs the DoD an estimated billions of dollars per year
Estimates are at 30% cost avoidance through prevention and mitigation of corrosion during sustainment, design, and manufacture
Reduce Life cycle costs of weapons system corrosion by doing more or better preventive maintenance
Implement non-destructive corrosion sensing/measurement in the field as feedback to prognostic and condition based maintenance tools
Predictive Capability Needed for Design
Integrated corrosion modeling
Equipment failures
Mission Readiness
Corrosion related failure modes (pits, cracks, crevices etc.)
Application of neural networks

36. Corrosion Control Through Condition Monitoring
Impact of Corrosion:
Imposes increased loading stresses
High maintenance costs
Accelerates deterioration of structure
Increases the hydrodynamic drag
Reduction of ship life cycle
Degradation and loss of ship communications
Corrosion in Marine Environment:
Galvanic corrosion
Crevice corrosion
High temperature corrosion
Microbiological corrosion

37. Corrosion Control Through Condition Monitoring
Corrosion Monitoring and Health Assessment Stages:
Direct Measurement
Measure parameters directly affected by corrosion processes
Indirect Measurement
Provides data on parameters that affect or are affected by corrosion of the environment
Define corrosion zones
Data collection (design, construction, environmental, maintenance, and corrosion control)
Select assessment techniques (visual survey, photographic, non-destructive tests etc.)
Corrosion assessment criteria (coating failure, ineffective cathode protection, Defects/Distortion leading to corrosion etc.)
Determine the CH condition of individual zones
Corrosion Health of ship structure: determine overall CH of ship structure
Provide CH ratings and associated recommendations

38. Corrosion Control Through Condition Monitoring
“Smart Coating” technology:
Corrosion sensor detects the early stages of coating degradation
Condition monitoring to assist inspection of materials
* Corrosion Protection and Condition Monitoring Using “Smart” Appliques, Guy D. Davis, Terrence G. Vargo, Andrew W. Dalgleish, Douglas Deason; Materials Performance August 2004

39. Corrosion Control Through Condition Monitoring
respectively, for a standing wave ratio of:
                               
Corrosion Control Through Condition Monitoring
Voltage Standing Wave Ratio (VSWR): Detect corrosion in antennas

40. Thermography

41. Thermography

42. Thermography Infrared (IR) Invisible radiant energy
Extends from nominal edge of the red spectrum (700 nanometers 430 THz) to 1mm (300 GHz)
IR technology used in IR camera thermal imaging
Condition Monitoring opportunities using IR cameras

43. Object distance, ambient temperature, and humidity effects
Thermography
Emissivity: the radiation of energy from the surface of target objects
Objects with high emissivity will produce a more accurate temperature measurement than objects with low emissivity
Object distance, ambient temperature, and humidity effects

44. Thermography Condition Monitoring/Predictive Maintenance
using IR camera mounted on a Pan-Tilt:
Monitor system health parameters autonomously
Software user interface to analyze data
Alarm and critical threshold trends drive maintenance decisions

45. Frequency Response Analysis (FRA)
Studies done on Condition Monitoring to evaluate transformer windings for signs of degradation:
Predictive analytics approach to mitigate risk of high cost failure event
Utilize FRA methodology to detect winding deformations
Technique strives to measure frequency responses of varying inductances in the windings and compared to established baseline inductances
Results indicated that very minor changes in the frequency response due to deformation effects of the windings are easily detectable

46. Conclusions
CBM+ offers cost savings through multiple operational improvement opportunities in key areas such as; reliability and maintainability engineering, systems engineering, supply chain management, data management, health management, materials management
Embrace cultural changes:
Create environment of firm commitment and consistency
Apply proactive parts selection decisions that take into account condition monitoring
Research advanced technology sensor and network infrastructure solutions
Utilize knowledge and experience to become more proficient at upward trending predictive maintenance practices
Promotional Opportunities:
Market CBM+ with stakeholders as an enabler of process improvement and a conserver of resources over the equipment life cycle
Motivate equipment manufacturers to design-in Environmental Health Monitoring features
Value to the Fleet:
Reduction in crew size
Improved maintenance availability planning
Reduction in downtime
Increased ship operational availability and combat readiness
Lower maintenance and total ownership costs

47. Backup Slides

48. Applied CBM+ Analysis Example
CBM+ Sensor Gap Analysis Network Infrastructure UPS
Applied CBM+ Analysis Example
Failure Mode
Current Maintenance
RCM Recommended
Maintenance
CBM Gap
Low or no battery voltage
Perform Manual UPS Battery Test
Test Battery Capacity
Monitor battery impedance
Report string voltage
Report cell voltage
Overcharged Battery
None
Inspect Fans for damage
Monitor fan status and report over BIT
Harmonic distortion beyond tolerance
Perform Harmonic Measurements
Monitor harmonics and report over BIT
      ® Possible with R&D
      ® Already doing it
      ® Can do with existing design - in process
      ® Can do with redesign
      ® Beyond current state of the art