2024 DHA Industry Day_MST RCM Brief.pdf

MST RCM Briefing – 13 Aug 2024

Charles Prince DHA / NIKA Solutions

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.

Former turbine specialist on Westinghouse 501B team

Former Georgia-Pacific Reliability Lead holding multiple OPEX certifications

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.

Former petrochemical industry pump, compressor and seals SME

DHA O&M Organization Chart

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Deputy Branch Chief -

Marvin Hsie

AOR 1-6

O&M Program Manager - Mark Kerr

AOR 1 & 6

Kevin Cox

John Acierno Technical Advisor

O&M Program Manager -

Jim Blackman

AOR 2 & 4

Kevin Cox

Dave Duvall Technical Advisor

O&M Program Manager –

Federico Aguilar

AOR 3 & 5

Curtis Barr

Technical Advisor

Brent Condrey Charles Prince

DHA RCM

Bob Sachuk

Policy & Procedures

RCM/CBM Site Selection Criteria

• Initially implemented at larger facilities (Walter Reed 2M sq ft)

• As contract end dates align, both large and smaller facilities will get a CBM program (examples below)

• Fort Bliss – 1.2M sq ft

• Fort Irwin – 250K sq ft – CBM program RPIE identified/verified

• Fort Novosel - 249K sq ft -CBM program RPIE identified/verified

• Business occupancies will be case by case – Best ROI when combined with GTO or limited RCM scope

RCM awarded at the following sites

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Award Date RCM StatusScope Type Site

Feb 2022Contract AwardedNew RCM ProgramKeesler

July 2022Contract AwardedLegacy Program, Refine RCM ScopeBAMC Fort Sam

Sept 2022Contract AwardedNew RCM ProgramWalter Reed

Mar 2023Contract AwardedNew RCM ProgramWright Patterson

May 2023Contract AwardedLegacy Program, Refine RCM ScopeFort Liberty (Bragg) Aug 2023Contract AwardedNew RCM ProgramBalboa Naval Hospital Nov 2023Contract AwardedLegacy Program, Refine RCM ScopeFort Campbell, KY Dec 2023Contract AwardedNew RCM ProgramFt Eisenhower Army Medical Center Dec 2023Contract AwardedLegacy Program, Refine RCM ScopeFort Cavazos (Hood) Feb 2024Contract AwardedNew RCM ProgramWeed Army Hospital, Fort Irwin

Mar 2024Contract AwardedLegacy Program, Refine RCM ScopeFort Johnson (Polk) Mar 2024Contract AwardedLegacy Program, Refine RCM ScopeFort Riley

Future RCM sites

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Date RCM StatusScope Type Site

Jan 2024Contract AwardedNew RCM ProgramFort Belvoir Community Hospital Apr 2024Contract AwardedNew RCM ProgramFort Novosel (Rucker) Apr 2024RCM Scope CompletedLegacy Program, Refine RCM ScopeCONUS Apr 2024RCM Scope CompletedNew RCM ProgramCONUS

2024RCM Scope In ProgressNew RCM ProgramCONUS 2024RCM Scope In ProgressNew RCM ProgramOCONUS 2024RCM Scope In ProgressNew RCM ProgramOCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS

Future RCM sites

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Date RCM StatusScope Type Site TBAPending Review New RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewLegacy Program, Refine RCM ScopeCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramOCONUS TBAPending ReviewLegacy Program, Refine RCM ScopeCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewNew RCM ProgramCONUS TBAPending ReviewLegacy Program, Refine RCM ScopeCONUS TBAPending ReviewNew RCM ProgramOCONUS

Why RCM/CBM?

RCM PWS - Implementation Schedule

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

RCM Phase and Required Completion Date:

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

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

• **Installation of AHU remote vibration sensors, exterior junction box, and inspection ports where applicable

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

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

• 5. Complete Scheduling of CBM Procedures for RCM eligible equipment OSCS + 120 CD. DHA DSS function

• 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.

Fort Detrick – USAMRIID RCM Baseline UE & IRM

• Bearing defect - Fluting

• Mode - Rotor Capacitance due to excess VFD interference

• Mitigation - Inboard side electrostatic grounding ring

• AHU Exhaust for Logoff2 area

• Repair procedures provided

• Possible warranty claim if incorporated into design award

Fort Detrick – USAMRIID RCM Baseline UE, IRE, & IRM

• Coil/Tap Defect – Warranty claim candidate

• Mode – Internal looseness

• Mitigation – Acceptance testing before commissioning

• 4th floor transformer

Rm.4SA846

• Repair/inspection procedures provided

Fort Detrick – USAMRIID RCM Baseline UE, IRE, & IRM

• Defect – Sealed bearings with excessive red lithium grease flowing into the rotor/stator gap

• Mode – Improper lubrication

• Mitigation – A dedicated lubrication tech assigned in the maint. group

• DWBP-PP1.2-1M Rm. 1SA102

• Repair and mitigation procedures provided

USAMRIID – Cost Savings and Failure Avoidance Summary

• 38 Defects found during the first pass of UE, IRE, and 30% IRM

• 27 Defects involving improper lubrication maintenance practices from previous contractor. Greasing sealed bearings, incompatible lubricants, and lubricant contamination

• 10 Electrical transformer defects

• 1 Motor bearing advanced fluting defect found with ultrasound

• Vibration analysis visit in coming weeks will find more confirmed bearing defects in motors, pumps, and other rotating assets

USAMRIID – Cost Savings and Failure Avoidance Summary

• Cost of failure/risk avoidance is highly dependent on department and BSL level of area affected.

• 27 Defects involving improper lubrication maintenance practices from previous contractor. Motors installed range from $6K-$25K in the private sector.

• 10 Electrical transformer defects – average price each $89K-$190K

• 1 Motor bearing fluting defect found with ultrasound – price $3-5K

• Vibration analysis visit in coming weeks will find more confirmation of bearing defects in motors, pumps, and other rotating assets

RCM Purchase Specifications for MILCON projects

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

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

• Example – AC Induction motors connected to a VFD:

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

DHA Purchase Specs

MILCON Acceptance Testing and Warranty Period CBM

• Recommend CBM acceptance testing before commissioning

• Why commission a piece of equipment if it has an existing undetected defect?

• Greatly enhances TAB results due to increased reliability and confirmed free of defects

• Reduces warranty claim disputes due to minimal run time hours

• RCM team will coordinate with the MILCON team for timely performance

Baseline/Acceptance testing 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, highlighting all warranty claims recommended

• 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