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Maritime Logistics Community News : Autumn 2010
22 NAVY SUPPLY NEWSLETTER AUTUMN 2010 The CBM approach is based on an actual, real-time knowledge of an asset's condition, rather than its assumed condition, the latter being the philosophy underpinning a large proportion of current RAN maintenance practices. This research assists Navy in shifting its maintenance program philosophy from the current rigid, planned maintenance regime -- largely guided by the Original Equipment Manufacturers -- to one that is based on the actual asset condition. This approach is referred to as Condition-Based Maintenance (CBM), i.e. particular maintenance tasks are driven by observable deterioration in the functionality or performance of an asset. The CBM program introduces a requirement to monitor the health and performance of assets over their time of operation. For example, for a PDE, the monitored parameters may include: oil, coolant and exhaust temperature; oil pressure; and running hours. The majority of shipboard assets are controlled and monitored by an existing network of some 3,500 sensors and alarms known as the Control and Monitoring (C&M) system. The C&M system provides the primary source of all existing condition monitoring data for the Anzac Class. To date, there has been no useable facility to collect the C&M data on these ships, which is crucial to any implementation of CBM. A study commissioned in 2005 and undertaken by IMES Australia investigated the feasibility of enhancing the C&M system by continuously capturing any or all C&M sensor and alarm data, and transferring it to a shore-based database for diagnostic and prognostic analyses. The study indicated that such an enhancement was both technically and economically feasible. Under the MSD sponsor program, DSTO has built an interface unit to provide a means of transferring any or all of the C&M data from the ship's C&M system via satellite to a shore-based database that resides on the Defence Restricted Network (DRN). This database is then accessible for maintenance decision support (Figure 1). The sensor data can be presented with and compared to other related maintenance data (e.g. failure data) via a generic web browser interface called the CBM Toolkit. The Toolkit is a DSTO-developed data abstraction and interrogation tool for CBM analysis that provides filtering and presentation functions, as well as facilitating exportation of the data to other software packages for analysis. The Toolkit includes a hidden interface to a large number of disparate data sources, including: the Asset Maintenance Planning System (AMPS); the Configuration Management Tool (CMT); the Defence Records Management System (DRMS); and, Urgent Defect Notices (URDEF's). The CBM Toolkit produces significant labour savings due to its ability to collect, collate and disseminate data in a usable format. A direct consequence will be improved effectiveness of the follow-up actions at all levels. Toolkit users will be able to generate insightful reports, literally at the push of a button, on trends for nominated parameters for specific assets, either for individual platforms, platform class or potentially on a fleet-wide basis. This relatively low cost capability will, for the first time, provide easy access to an immense amount of valuable Anzac sensor and alarm data that has not previously been available for analysis. The Toolkit database will be a vital tool in assessing asset condition to assist decision making in the maintenance planning process. A six month trial of the SIU was conducted on HMAS BALLARAT over 2008 and 2009. This trial was successfully validated the SIU design as it was shown that the SIU could effectively collect, buffer and transfer selected data from the C&M system, via INMARSAT, to an onshore database, where it was available for analysis. The selected data for this trial was the subset of data representing the 74 sensors associated with the MTU port and starboard propulsion diesel engines. The SIU has since continued to operate onboard HMAS BALLARAT and has not encountered any technical problems, malfunctioned in any way or suffered any type of failure. Some minor changes have been made to resolve sampling threshold issues; the success of which will be determined over time. Unlocking the data in the Anzac Class's Control and Monitoring System With Maritime Systems Division (MSD) sponsorship, DSTO is currently engaged in a program to improve maintenance practices for the Anzac Class frigates, through the introduction of Condition- Based Maintenance (CBM) procedures, with the initial focus being on the Propulsion Diesel Engines (PDEs). MS HALINA SCOTT FIGURE 1: OVERVIEW OF THE C&M CONDITION MONITORING SYSTEM, INCORPORATING THE BLACK-BOX FOR C&M SYSTEM INTERROGATION.