8_Reliability Center Maintenance (RCM)__Brent Condrey_24AUG23.pdf

RCM – COR/Industry Partner Introduction by Brent Condrey & Charles Prince

24 AUG 2023

Improving Health and Building Readiness. Anytime, Anywhere — Always

Introduction

CUI

• Brent Condrey – RCM SME

ASNT Level 2A – 2B Level III Vibration Analysis Certifications.

ISO Level II and III Advanced Vibration Analysis Certifications.

ASNT Level I and II Infrared Thermography Certification.

ASNT Level I Mechanical/Airborne Ultrasound Certification.

20+ Years of RCM/PdM experience.

Introduction

CUI

• Charles Prince – RCM SME, Mechanical Engineer

ASNT Level 2A Vibration Analysis Certification.

ISO Level II Vibration Analysis Certification.

ANST Level I Infrared Thermography Certification.

ASNT Level 1 Ultrasound Certification.

Certifications in Engineered Sealing Systems, Multi-stage pumps, and

Mechanical Gas Seals for Compressors.

10 years of RCM/PdM Experience.

What is RCM?

• RCM is a methodical process used to determine the best maintenance strategy for the defined system, in its operating context and condition.

• The RCM process uses several different tools to ensure efforts are focused on the right asset, at the right time, in the most efficient manner.

• Criticality Analysis: Scoring system used to determine which assets have the largest impact to the facility, if a failure should occur. To align with Risk Factor conventions 1-6 in the RPSS, the lower the RCM criticality value, the higher the impact to the facility had a failure occurred. The process uses questions from several categories including; safety, health, environmental, spares availability, workaround availability…etc.

• Failure Modes and Effects Analysis (FMEA): identifies each failure mode possible to each component of the defined asset and which mitigation tactics to employ on said component. (PdM/CBM, Run to failure, or PM)

CUI

What is RCM?...cont.

• Preventive Maintenance Optimization (PMO): Invasive failure finding tasks which leave the asset out of service for the duration, often cannot detect common failure modes such as bearing spalling, smearing, bearing fluting, lubrication contamination ..etc. Preventive Maintenance Optimization (PMO) replaces, where required, the classic invasive PM tasks with Predictive Maintenance (PdM) tasks outlined during the FMEA (or pulled from historical asset data from similar facilities) * Historically, PM man hours are reduced drastically after PMO implementation.*

• Predictive Maintenance (PdM): Just as a doctor uses an EKG to read heart activity in a patient, PdM tools can read machinery activity with quantifiable results. PdM is mostly performed while the asset is in a running, standard operating state with no interruptions to service. a.k.a. CBM

• Data Trending: Quantifiable data is used for trending machinery condition. Identified corrective tasks are then performed at the correct time, on the correct component.

• Uses quantifiable scientific data to drive corrective maintenance.

Why RCM/CBM?

DHA RCM Contractor Execution

• DHA Way:

O&M Contractor implements RCM as follows:

IAW comprehensive RCM SOP DHA developed.

IAW RPSS database identifying RCM Criticality values, traditional PMs, and

CBM tasks.

DHA provides RPIE inventory identifying equipment to include.

During new contract competitive bidding process, Contractors provide technical approach on how they will accomplish implementation and sustainment.

Actual costs identified on proposal CLINs (base and option years).

Allows DHA to see actual costs/savings over the life of the contract

RCM contracts have been awarded for the following sites

Site TA Fiscal Year Scope Type Status Date

Keesler Bob 2022 New Completed 1/31/2022

BAMC Fort Sam Bob 2022 Existing, Refine Completed 9/30/2022

Wright Patterson Curtis 2023 New Completed 2/1/2023

Walter Reed Bob 2023 New Completed Awarded

RCM will be awarded at the following sites

Site TA Fiscal Year Scope Type Status Date

Eisenhower Army Medical Center, Fort Gordon John/Curtis 2028 New 5/30/2023

5/9/2023New Mobile contract set to end 12/31/2023

Fort Bragg Bob/AOR-4 O&M

TA TBA 2023 Redo Completed 5/9/2023

Balboa Naval Hospital Bob 2023 New Completed 5/9/2023

Ft. Knox Barr/ Prince 2023 Existing, Refine Completed 4/30/2023

Fort Campbell, KY 2023 Existing, Refine 4/14/2023 11/14/2023

Fort Hood 2023 Existing, Refine 5/30/2023 12/31/2023

Weed Army Community Hospital, Fort Irwin 2024 New 7/29/2023 2/29/2024

RCM sites cont.

Site TA Fiscal Year Scope Type Status Date

Fort Polk 2024 Legacy site 7/29/2023 2/29/2024

Fort Riley 2024 New 8/3/2023 3/3/2024

Fort Drum - Guthrie AMC 2024 New 6/15/2023 1/15/2024 Fort Rucker 2024 9/30/2023 4/30/2024

Fort Belvoir Community Hospital, Fort Belvoir 2024 New 6/14/2023 1/14/2024

Scott AFB 2025 New 5/30/2024 12/31/2025 Andrews AFB 2026 New 12/30/2025 7/31/2026 Fort Jackson 2026 New 1/31/2026 8/31/2026 Fort Carson 2026 Refine 12/30/2025 7/31/2026

Fort Leavenworth Ambulatory Center, includes CUP 2026 New 4/30/2025 11/30/2025 Nellis AFB 2026 New 12/30/2025 6/30/2026

Fort Bliss Kevin Cox 2026 New 12/30/2025 6/30/2026

RCM Deliverables

• RPIE verification report – The list of specific RPIE verified to be monitored with CBM technologies.

• PMO gap report – Highlights the changes made during the Preventive Maintenance Optimization process to include work hours reduced by percentage.

• Baseline report – Highlights all defects found during the first pass of CBM testing.

• Monthly reports – Highlight all defects for the month including defects repaired, new defects, and defects awaiting repair.

• Case Studies – Highlight a specific problematic RPIE which had a fault that was repaired and documented using the case study format.

RCM PWS - Implementation Schedule

For implementation of the RCM program, the contractor shall utilize the following schedule.

RCM Phase Required Completion Date

• 1. Complete Verification of RCM-Eligible Equipment On-site contract start (OSCS) + 60 Calendar Days (CD).

• 2. Have RCM qualified/certified personnel available to administer RCM program OSCS + 60 CD.

• 3. Complete Equipment Criticality RPSS Crosswalk OSCS + 90 CD.

• 4. Complete Verification of Baseline Measurement Requirements OSCS + 120 CD.

• 5. Complete Setup of CBM Procedures for RCM eligible equipment OSCS + 120 CD.

• 6. Complete Final Draft of Contractor Implementation Plan for Gov’t Review OSCS + 120 CD.

• 7. Commence AEM Data Collection Period OSCS + 120 CD = Baseline report.

• 8. Complete AEM Data Collection Period OSCS + 485 CD = 12 Monthly Fault Reports.

• 9. Initiate De-Activation of Standard PM Procedures IAW Implementation Plan OSCS + 485 CD.

• 10. Complete De-Activation of Standard PM Procedures IAW Implementation Plan OSCS + 515 CD.

RPIE Verification Report

• List of RPIE which are feasible to monitor IAW the RPSS designated technologies and procedures.

• The RPSS is a single source nomenclature library with PM procedures and CBM tasks associated to each applicable record.

• Field verification will be required to determine which technologies can be applied to each RPIE.

• Lists RPIE which may need modification to monitor with CBM technologies.

PMO Gap Report

• Lists which PM’s have been identified as needing optimization.

• Existing PM’s will be combined with CBM technologies for the first year to satisfy the AEM requirements.

• Once the AEM requirement period is met, existing PM’s can be optimized for improvement by incorporating value added tasks with CBM technologies.

• Identifies reduction in labor hours by removing non-value-added tasks (invasive failure finding tasks).

Baseline Report

• Lists each defect found during the first pass of CBM data collection.

• Provides details such as: Severity of defect, WO#, analysis comments, reason codes, technology, and repair recommendations.

• Report will have defects found using all applicable technologies in a single report.

• Report will have sufficient supporting data associated with each defect (FFT spectra, waveforms, trends, thermal images, ultrasound spectrums/waveforms, oil analysis results, and visible light images depending on technology used for each specific defect). Baseline report

Monthly RCM Metrics Report

Lists:

• Summary of all defects found for the month.

• Summary of all defects repaired for the month.

• Number of defects awaiting repair.

• Quantity of quality checks for the month using the CBM technology which found the defect originally (verifies the RPIE is defect free and below alarm levels after repair).

Case Studies

Fort Benning May

A case study is a highly detailed report of defects repaired or lessons learned with supporting evidence.

RCM Purchase Specifications

• A document providing examples of high reliability equipment configurations and their specifications needed for increased reliability in your facility.

• A great tool for planners to get the most reliable equipment the first time.

• Example – AC Induction motors connected to a VFD:

These require advanced electrostatic grounding protection to the motor shaft for reduction of bearing fluting. All specifications for motor and grounding ring are listed.

DHA Purchase Specs

Procedures and Qualifications

• Procedures and qualification for the DHA RCM program can be found below.

• https://community.max.gov/x/ZKFTYg https://community.max.gov/x/ZKFTYg

Lessons Learned – Keesler AFB

• RCM contractor had past performance in designing and sustaining the original MEDCOM legacy RCM programs.

• Most likely thought “business as usual” during Keesler’s RCM implementation.

• RCM is now rolled out in tandem with the O&M program, the contractors were not aware of the drastic redesign of said RCM program.

• Technical exhibits and RCM SOP were not adhered to by RCM contractor.

• Spent months on creating criticality analysis values although criticality values were pre-loaded into the RPSS before award.

Vibration Analysis

• Measure acceleration, velocity, and displacement via 100mv/g accelerometer/piezo sensor.

• Excellent for diagnosis of rotating equipment.

• Can detect bearing defects, electrical issues, VFD harmonics, misalignment, resonance, cracked or broken gear teeth, imbalance…etc.

AHU’s require remote vibration sensors and infrared inspection ports (for belt driven fans) to be inspected using vibration analysis without changing the running state of the equipment or interruption to service.

Remote Sensor overview attached.

CUI

AHU - Remote Senors

Remote Vibration Sensors

Infrared Analysis – Mechanical

• Excellent for detecting belt, sheave, bearing, and lubrication issues.

• Can be used for leak detection, HVAC air balancing/troubleshooting, and piping identification.

• Easily demonstrated and understood.

Infrared Analysis – Electrical

• Measures thousands of points to create a thermal image.

• Quickly identifies loose connections, phase imbalance, corrosion, and more.

• Combine thermal data with amperage readings to identify root cause.

Ultrasound Analysis – Mechanical

• Measures ultrasonic frequencies from 20khz to above 50.0khz.

• Can be used for structure borne analysis and airborne analysis using its different sensors.

• Greatly aides in finding and quantifying loss from air leaks and steam leaks relative to db.

Ultrasound Analysis – Electrical

• Detects ultrasonic sound above the human hearing range.

• Detection is adjustable from 20Khz up to 100Khz on newer instruments.

• Excellent for detection of corona discharge, tracking, and arcing.

• Widely used in industry for pre infrared safety scans.

• Can be used on high voltage from safe distances.

Ultrasound Analysis – Electrical

• New Installation of a faulty transformer.

Oil Analysis (aka Tribology)

• Can detect wear particles, contaminants, viscosity degradation, and additive makeup within equipment lubrication.

• Many vendors supply reduced price oil analyses with a supply agreement, making a stand-alone oil lab unnecessary. (Signum, MobilSerV..etc)

• Excellent in detecting faults in Generators, Chillers, Gearboxes, Vacuum Pumps, Compressors.

Motor Circuit Analysis - MCA

• Detects current imbalance, capacitance, voltage imbalance, insulation degradation, and THD.

• Quantified measurements are used for trending and/or Spectral analyses.

• Can perform stator air gap/rotor eccentricity analysis and loose rotor bar/cracked end ring analysis.

• Trends the overall health of the motor’s windings and poles.

• Not a current DHA requirement.

RCM – COR/Industry Partner Introduction

Thank You!

BACKUP SLIDES

1. RPIE Verification and Documentation

• IAW Section 5.3.5.1 of the PWS Accomplished during on site contract start + 60 calendar days.

Creates a list of CBM (Condition Based Monitoring) eligible RPIE.

Field verification of which technologies should be applied to which

RPIE.

May differ slightly from the RPSS records containing a single source nomenclature for the same equipment type.

Deliverable - RCM RPIE Verification Report (highlights all in-scope

RPIE).

• REF Section 4.1.2 of the RCM SOP

RPIE Verification….cont.

• Bearing codes, RPIE capacity, voltage, amps, and bearing geometry are identified and documented for the building of the technology databases and routes – all nameplate data is documented.

• Time for the RCM performance team to add field verification to all procedures pulled from the RPSS source documents for that RPIE record. How do we apply them to this specific RPIE in the field? Is a reach pole, mounted remote accelerometers, or infrared/inspection ports needed?

2. Have RCM qualified/certified personnel on site to administer RCM Program

• IAW Section 5.3.5.11 of the PWS Accomplished during on site contract start + 60 calendar days.

RCM personnel qualifications can be found in MAX at the below link.

• https://community.max.gov/x/ZKFTYg

• REF section 6.0 of the RCM SOP

3. Complete equipment criticality RPSS crosswalk

• IAW section 5.3.5.1 of the PWS Accomplished during on site contract start + 90 calendar days.

RCM criticality has been standardized enterprise wide and published in the RPSS.

RCM performance team to update DMLSS database with RCM criticality values for each applicable RPIE.

The Equipment Criticality Assessment is a process for determining the relative ranking of RPIE items in a system.

Follows the same numeric conventions as “RCM Risk Factor” in the

RPSS (1 = most critical 6 = least critical).

• REF section 4.1.3 of the RCM SOP.

4. Complete verification of baseline measurements

• IAW section 5.3.5.4.1 of the PWS Accomplished during on site contract start + 120 calendar days Publish baseline report.

Lists each defect found during the first pass of CBM data collection.

Provides details such as: Severity of defect, WO#, analysis comments, reason codes, technology, and repair recommendations.

Baseline report will have all defects found using all applicable technologies in a single report.

Report will have sufficient supporting data associated with each defect (FFT spectra, waveforms, trends, thermal images, ultrasound spectrums/waveforms, oil analysis results, and visible light images depending on technology used for each specific defect).

• REF section 4.1.5 of the RCM SOP

5. Complete setup of CBM procedures

• IAW Section 5.3.5.7 thru 5.3.5.9 of the PWS Accomplished during on site contract start + 120 calendar days.

Build technology databases in each proprietary software for each technology IAW the RCM SOP.

• CBM procedures are used to establish monitoring techniques and data collection specifications for each technology

• All condition-based monitoring (CBM) procedures for each technology can be found at the link below

• https://community.max.gov/x/ZKFTYg

• REF Section 4.2.1 thru 4.2.3 of the RCM SOP

6. Complete final draft of contractor implementation plan

• IAW section 5.3.5.3 through 5.3.5.5.1 of the PWS Accomplished during on site contract start + 120 calendar days.

Will include the Enhanced Maintenance Plan (EMP) identifying which RPIE are monitored with which technologies.

Will include the results of the Preventive Maintenance Optimization

(PMO) with PM’s identified for deactivation.

Highlights the reduction in labor hours from the de-activation of classical PM’s (once the AEM period has been satisfied).

• REF section 4.1.4 of the RCM SOP

7. Commence AEM data collection period

• IAW section 5.3.5.4 of the PWS Accomplished during on site contract start + 120 calendar days.

Baseline report is Gov’t. approved, then the AEM period can begin.

The Joint Commission’s Alternative Equipment Maintenance (AEM) policy requires 1 full year of CBM data to be obtained before the de-activation of traditional PM’s on monitored equipment is completed.

Fault reports should be submitted to the COR every month highlighting any defects found and their status.

• REF sections 4.1.4.3 and 4.1.4.4 of the RCM SOP

8. Complete AEM data collection period

• IAW section 5.3.5.5 through 5.3.5.5.1 of the PWS Completed during on site contract start + 485 calendar days.

1 year after AEM period starts.

Compiles one year of CBM data as evidence to de-activate.

traditional PM’s while continuing with CBM.

• REF section 4.1.4.1 through 4.1.4.4 of the RCM SOP

9. Initiate de-activation of standard PMs

• IAW section 5.3.5.5 through 5.3.5.5.1 in the PWS Occurs during on site contract start + 485 calendar days.

De-activation of standard PM’s is based on schedule in approved implementation plan.

PMs identified during the PMO process will be de-activated in DMLSS and replaced with new RCM tasks.

De-activation of traditional preventive maintenance procedures will always be at the discretion of the FM and staff.

All CBM tasks are published in the RPSS for each RPIE and technology.

• REF section 4.1.4.3 through 4.1.4.4 in the RCM SOP

10. Complete de-activation of standard PM’s

• IAW section 5.3.5.3.1 through 5.3.5.3.2 of the PWS Completed by onsite contract start + 515 calendar days.

30 days from start of de-activation of PM’s.

PMs identified for de-activation during the PMO process will be de-activated in DMLSS.

Labor hour reductions will be calculated and included in the final implementation plan submitted.

• REF section 4.1.4.1 through 4.1.4.4 of the RCM SOP

RCM Sustainment

• IAW section 5.3.5.6 through 5.3.5.10 of the PWS Occurs during on site start + 515 calendar days.

Occurs once all implementation activities are completed.

Recurring monthly reports highlighting all defects found with all technologies.

Case studies demonstrating value added techniques for diagnosis, avoidance of failure, and/or root cause analyses will be generated.

Continuous improvement towards a reliable facility and maintenance culture.

• REF section 4.2 through 5.0 of the RCM SOP

DHA RCM Implementation Process – RRE’s

CUI

Attachments

DHA RCM SOP

RCM High Level Overview

DHA RCM Process Overview

Attachments

CUI

DHA RCM SOP

RCM High Level Overview