Appendix_O_-_RCM.pdf

Appendix O

1.0. Reliability Centered Maintenance (RCM)

RCM is the process that is used to determine the most effective approach to equipment maintenance. RCM involves identifying actions that, when taken, will reduce the probability of equipment failure and which are the most cost effective. RCM includes the entire life cycle of the equipment starting with the equipment design, manufacturing/ construction and installation. RCM seeks the optimal mix of Condition-Based Actions, other Time- or Cycle-Based actions, or a Run-to- Failure approach. The ultimate goal of RCM is to minimize maintenance and operational costs. This appendix is a very condensed version of RCM related topics with a focus on electrical and motor acceptance testing utilizing predictive and/or proactive technologies, resulting in the creation of baseline data for each equipment asset and hopefully a more reliable piece of equipment.

1.1. RCM Acceptance Testing with Baseline Data

Baseline data is condition monitoring information that is representative of equipment in a new and/or properly operating condition. The baseline data is the foundation of the predictive trending analysis required to forecast equipment condition. It is important that this data is established as early as possible in the life of the equipment. The baseline readings and periodic monitoring data should be taken and recorded under the same conditions (or as close as can be achieved), and will be used for acceptance testing. The Equipment Engineering Flight organization, 76 MXSS/MXDEA, will provide acceptance testing of equipment components using advanced technology listed in section 1.2. Final acceptance of the equipment will include a signature by the RCM Engineering Team Lead verifying equipment reliability; see section 1.5 of Appendix K. When the equipment has been accepted by the Government, the final data obtained will be used to establish the original installed equipment health baseline data for this equipment or system.

1.2. Thermography

Electrical—The Government will perform a thermographic survey on all electrical distribution equipment, motor control centers, and transformers during the start-up phase of the installation.

Motors and Bearings— Large machines shall be scanned closely. Abnormal hot spots on the body may indicate flaws in the stator windings. The surface temperature of a motor is normally lower than the winding temperature. Bearing temperatures are normally higher than the housing temperature.

Any defects noted by an observable difference in temperature of surveyed components or unexplained temperature rise above ambient shall be corrected by the Contractor at no additional expense to the procuring organization. The Government will re-survey repaired areas to assure proper corrective action has been taken.

There are two basic criteria for evaluating temperature conditions; differential absolute temperature. Each is described below.

a. Differential Temperature (T) - Temperature difference criteria are simple, easy to apply in the field, and provide an adequate qualitative screening system to identify thermal exceptions and problems. The T criteria compares component temperature to the ambient temperature and may be used for electrical equipment. T may also be used for mechanical components.

b. Absolute Temperature—Absolute temperature criteria are generally specific to an equipment model, type of equipment, class of insulation, service use, or any of many other salient characteristics. As a result, absolute temperatures are more suited to quantitative infrared thermography and critical temperature applications. The mechanical temperature specifications come primarily from manufacturer’s manuals. Electrical temperature specifications are set by three principal electrical standards organizations:

National Electrical Manufacturers Association, (NEMA).

International Electrical and Electronic Engineers, (IEEE).

American National Standards Institute, (ANSI).

1.3. Airborne Ultrasonics

The Government shall perform an airborne ultrasonic survey during the start-up phase of the installation. The Government shall survey electrical equipment for indications of arcing or electrical discharge, including corona. Piping systems shall be surveyed for indications of leakage. Baseline all electric motors for db levels using contact probe. All defects or exceptions noted by the use of airborne ultrasonics shall be corrected by the Contractor at no additional expense to the procuring organization. The Government will re-survey repaired areas to assure proper corrective action has been taken.

1.4. Motor Analysis

The Government may perform a motor analysis survey during the start-up phase of the installation in order to verify motor operating characteristics as detailed in 1.4.1 through 1.4.5. All defects or exceptions noted by the Government shall be corrected by the Contractor at no additional expense to the procuring organization. The Government will re-survey repaired areas to assure proper corrective action has been taken.

1.4.1. Motor Circuit Analysis (Complex Phase Impedance)

Upon motor installation, the Contractor shall take and provide to the procuring organization the following acceptance/baseline readings and measurements, first for the motor alone, and then, for motor and circuit together:

Conductor path resistance

Inductive imbalance

Capacitance to ground

1.4.2. Motor Current Spectrum Analysis

With the motor installed and operational, the Contractor shall conduct an acceptance/baseline spectral analysis on the loaded motor at 75% or greater load, when specified by the procuring organization.

1.4.3. Insulation Resistance

Upon installation, the Contractor shall take and provide to the procuring organization the following acceptance/baseline readings and measurements; initially, for the circuit or for the motor alone, and then, for the motor and circuit together:

Dielectric Absorption Ratio (for all motors)

Leakage current at test voltage

1.4.4. Surge Testing

The Contractor shall perform surge testing and high potential (high-pot) resistance testing of the motor(s) prior to their installation and procuring organization’s acceptance. The Contractor shall provide to the procuring organization documentation of test results, including test voltage, waveforms, and high potential leakage current.

1.4.5. Start-up Tests

With the motor installed and operational, the Contractor shall collect and provide to the procuring organization the following baseline data:

Coast-down time

Peak starting current

1.5. Leveling of Equipment Upon Installation

The Contractor shall level all installed rotating electrical and mechanical machinery in accordance with original equipment manufacturers (OEM) specifications and this PWS. The Government may check the level of the machinery to verify accuracy. Any discrepancies detected by the Government will be corrected by the Contractor. The Government will re-survey the installed equipment to assure proper corrective action has been taken.

1.6. Equipment Health Assessment Checklist

The Equipment Engineering Flight organization, 76 MXSS/MXDEA, will utilize the Equipment Health Assessment Checklist shown on pages 4 – 5, along with the requirements detailed in sections 1.2 through 1.4 of Appendix K, in order to verify the equipment health and precision installation of the installed equipment as part of the equipment acceptance criteria and to establish the equipment health baseline data of the equipment. Contractor shall fix/ repair any discrepancies found. The Government will then re-run that portion of the checklist until all discrepancies are corrected and the equipment is acceptable to the Government. The RCM Engineering Team Lead will then sign the filled out Equipment Health Assessment Checklist showing no remaining issues to verify the equipment is acceptable. Once the equipment has been accepted by the Government, and the warranty period begins, the Government will continue to utilize the Equipment Health Assessment Checklist, shown on pages 4 – 5, on a periodic basis to detect equipment anomalies or issues that may require warranty attention. The Equipment Engineering Flight organization, 76 MXSS/MXDEA, will then contact the owning equipment’s engineering office of responsibility who, in turn, will then contact the Contract Officer (CO) when a problem is detected.