Life Cycle Approach to Maintenance Engineering & Planning CAPT Timothy Corrigan November 16, 2010
The Brief Will Cover • The Challenge of Ship Lifecycle Maintenance. • How the Ship Maintenance Requirement is developed • How the Ship Maintenance is tracked.
Focused on meeting the mission.
2
Surface Ship Life Cycle Mandate • To meet mission of the Navy, requires attainment of 313 ships by 2020. • Attaining 313 requires 240 of today’s hulls to remain in service • Maintenance strategy must be aligned in support of: – Individual ship Current Readiness – Fleet Response Plan (FRP) Ao – Expected Service Life (ESL) Life Cycle Plan to support Current Readiness, FRP and ESL
3
The Challenge:
NIMITZ Class
Complexity
Date Deployed: May 3, 1975 Unit Cost: About $4.5 billion Propulsion: Two nuclear reactors, four shafts. Length: 1,092 feet Displacement: 97,000 tons Speed: 30+ knots Crew: Ship's Company: 3,200 Air Wing: 2,480. Armament: Multiple NATO Sea Sparrow, Phalanx CIWS, and (RAM) mounts. Aircraft: 60+ Plan is to maintain the USS NIMITZ for 50 years.
4
The Challenge:
Technology
NIMITZ Class
NIMITZ Class will support several new variations of aircraft over the 50 years of service.
F4 F14 F18 Hawkeye 2000 F 35 Next Gen 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025
# of PCs
Trilogy Alteration
40 0 New capabilities added over time
4,000
? 5
The Challenge:
NIMITZ Class
Mission
Supports 11 NMETS (Navy Mission Essential Tasks.) - 65 Functional Areas - 517 major systems; - 12,483 equipment systems - 150,000 major pieces of equipment (Does not include ice cream maker.) … and the wide range of Sailors and skills required. Numerous systems & equipment required to meet the mission.
6
The Challenge:
NIMITZ Class
# of Systems
HM&E Equipment Systems • • • • • • • • • • • • • • • • • • • • • • • • •
Life Support Systems Steam Generators/Steam System Controls Auxiliary Equipment and Fluid Systems Diesel Engines Systems Power Transmission Systems Gas Turbine Systems Electric Power Systems Logistics Data Condition Assessment Systems & Video Systems Sensors Systems & Wireless Sensor Systems Machinery Controls HM&E Networks Integrated Bridge Systems Aircraft, Vehicle, Ship & Material Handling Cargo/Weapons Handling & Stowage Systems Launch Recovery and Hydraulic Systems Hull Outfitting & Habitability Climate Control & Compressed Air Systems Auxiliary Machinery Controls Fasteners Fuels and Lubricants Coatings & Corrosion Control Thermal Insulation, Gaskets, Packings & Seals Water Chemistry Liquid and Solid Waste Systems
Condition Assessment Systems & Video Aircraft, Vehicle, Systems Ship & Material Handling Auxiliary Machinery Controls
Auxiliary Propulsion Systems
Climate Control & Compressed Air Systems Launch Recovery and Hydraulic Fluid Systems Systems Fuels & Lubricants Water Chemistry
Diesel Engines System
Logistics Data
Cargo/Weapons Handling & Stowage Systems
Sensors Systems & Wireless Sensor Electric Power Systems Systems Life Support Systems Hull Outfitting & Waste Water Habitability Engineering
Steam System Controls Machinery R&D Interface Machinery HM&E Networks Controls Integrated Bridge Systems
NIMITZ Class: Hull Machinery & Equipment Major Systems
1
7
What’s Most Important in Ship Maintenance? Lifecycle Requirements and Work Package Integration SEA 21/SURFMEPP
De-Commissioning
Commissioning Maintenance Team Execution Integration Individual Ship Waterfront Experts
Fleet Readiness Plan FRP TYCOM/CLASSRON
Workups Surge & Deployment Current Readiness Ship’s Force/ISIC
Depot
Balancing Resources and Requirements from all Perspectives Mandates opening “apertures” across the End – to – End process
8
Class Maintenance Plans • Class Maintenance Plans (CMP) are the “maintenance manual” of the ship class. Specifically included are: – Maintenance Delivery Plan including required dry-docking intervals – Engineered maintenance requirements such as equipment overhauls, shaft replacements, and corrosion protection – System certification requirements (nuclear, subsafe, flight deck)
• CMPs are continuously updated based on class maintenance history Class Maintenance Plans (CMP) = “Automobile’s Maintenance Manual”
9
DDG 51 Technical Foundation Paper Years: Months:
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
#
DDG 51 8/2009
DDG-51
MIDLIFE PERIOD
SRA 1-1
SRA 1-2
SRA DSRA 1-3 1
SRA 2-1
SRA 2-2
SRA 2-3
EDSRA ESRA SRA SRA DSRA 3-1 3-2 2 MIDLIFE
SRA 4-1
SRA 4-2
SRA DSRA 4-3 3
SRA 5-1
SRA INACT 5-2
Delta at 35 Years 25 6.7 6.5
52 6.7 6.5
79 6.7 6.5
106 31.5 30.9
133 6.7 6.5
160 6.7 6.5
187 6.7 6.5
216 47.6 47.6
247 6.7 6.5
274 6.7 6.5
301 6.7 6.5
328 31.5 30.9
355 6.7 6.5
382 6.7 6.5
411
TFP LRMS
3.8
7.9
8.6
35.2
6.5
11.8
6.7
52.1
27.4
12.2
8.7
39.6
6.7
7.8
8.6
TFP LRMS w/aging (Notional)
3.8
7.9
8.6
35.2
7.5
12.8
7.7
52.1
27.4 13.2
9.7
39.6
8.7
9.8
Months: PR11 Tailor: OPNAVNOTE 4700 (8/09)
EDSRA mid life requirements spread out so that maintenance and program alts can be accomplished within contractual constraints.
438
465
492
516 -
Baseline
34.5
6.6
11.1
63
10.6 35.5
8.6
13.1
74
Supports 35 or 40 Expected Service Life
Dependent on End of Life Strategy
Notional done by AVAIL
The plan to reach expected service life.
10
SURFMEPP Focus
USS XYZ SRA
Technical Planned Foundation Maintenance Paper
Results in decreasing operational availability and increasing operational risk
SRA CMAV
SRA
DSRA
DSRA SRA
DSRA CMAV
CMAV
SRA
SLEP
Ship Sheets
SRA
DSRA
CMAV
CMAV
SRA
CMAV
DSRA CMAV
SRA PSACMAV
CMAV SRA
BAWP & Actual AWP Investment
Expected Service Life Define Requirements and Track Against Actual Investment
11
Summary • Ship maintenance is a complex challenge that requires overall system integration. • Maintainability requirements developed from the system requirement and at the individual equipment level are incorporated into the CMP. • Ship maintenance is tracked at the equipment level and lessons learned used to improve future readiness. Warships Ready for Tasking … Now and in the Future.
12
Questions?
13
