surface maintenance engineering planning program update

SURFMEPP Achieving Expected Service Life…One Ship at a TimeDISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government Agencies and Naval Sea Systems Command (NAVSEA) contractors involved with ship construction and repair. Other requests for this document shall be referred to SURFMEPP.

Surface Maintenance Engineering Planning Program

UpdateFMMS Port Engineer Symposium

Mark Leary, John Murphy, Mark Darwin

01 September 2015


Agenda

Background & Review: SURFMEPP Mission and Products

New/Recent CMP tasks & revisions

Recent Process Changes

Time-Directed Maintenance Strategy (Mark Darwin)

Third Party Planning (John Murphy)

Class Standard Work Templates & Master Spec Catalog

Mandatory Safety Alterations & SURFMEPP role in modernization

Routines and Services standardization effort

Issues and Concerns

2


SURFMEPP Mission and Key References

3

SURFMEPP Mission: Provide centralized surface ship life cycle maintenance engineering, class maintenance and modernization planning, and management of maintenance strategies

• Standard Organization and Regulations of the U.S. Navy (SORM) (OPNAVINST 3120.32D)

• OPNAVINST 4700.7L (Maintenance Policy for U.S. Navy Ships)

• Ships’ Maintenance and Material Management (3-M) Manual (NAVSEAINST 4790.8C)

• Joint Fleet Maintenance Manual (JFMM) (COMFLTFORCOMINST 4790.3)

• Surface Force 3-M Assessment & Certification Program (COMNAVSURFPAC/LANTINST 4790.2 change 1)

Joint Fleet Maintenance Manual

SURFMEPP has an ENDURING focus on the maintenance requirements

SURFACE Force Assessment and Certification ProgramOPNAVINST 4700.7LSORM Ship’s 3M Manual


Evolution of SURFMEPP

2008 Pre – Surface Ship Life Cycle Management Activity (SSLCM)

• 14 people for entire surface Navy• No Technical Foundation Papers (TFP)• No Baseline Availability Work Packages• Ship Sheets at the Class level• Budgets based on averages of historical

costs (MRS) SSLCM – May 2009

• 36 total staff in May 2009• Class Maintenance Plan• TFP for DDG 51 class only• BAWP• Deferral tracking• Ship Sheets based on deferrals

SURFMEPP – Est. Nov 2010• 83 total staff in Nov 2010 • 226 total staff today• Class Maintenance Plans• TFP for all major ship classes• BAWPs for all CNO availabilities• Deferral tracking by hull• Monthly status reports for all Mandatory

Technical Requirements (MTR)• Ship Sheets for every CNO availability• Long Range Maintenance Schedules by

hull• Corrosion Control (CCIMS, TPRs,

LRTPRs)

4


SURFMEPP Global Footprint

5

PACNW DETACHMENT

SAN DIEGO DETACHMENT

PEARL HARBOR DETACHMENT

MAYPORT DETACHMENT

NORFOLK DETACHMENT

ROTA DETACHMENT

BAHRAIN DETACHMENTSASEBO

DETACHMENT

Lead: Don Kultti (428) 304-4579

Lead: George McVey

(619) 556-5243

Lead: Jen Valle (904) 270-5126 ext.

3383

Lead: Jim Batchelor011-81-46-816-9441

Lead: Russ Fitzwater011-81-956-50-6601

Lead: Dan Hengerer011-34-956-82-2714

Lead: Dennis Reinhardt011-973-3838-4673

Lead: Ed McIntyre (757) 443-2650 ext. 1137

Lead: Al Owczarek(904) 270-5126 ext. 3380

SURFMEPP HQPortsmouth, VA

YOKOSUKA DETACHMENT

THE SUN NEVER SETS ON SURFMEPP

PRODUCT AREAS• Availability Analysis Study• Baseline Availability Work Package• Change Management Documentation• Class Maintenance Plans • Class Standard Work Templates• Contracting Strategies • Corrosion Program Management• Deferral tracking by hull

• Integrated maintenance & modernization work packages

• Master Specification Catalog• POM Ship Sheets by hull• Robust Metrics• Ship Sheets• Technical Foundation Papers


SURFMEPP Product Value Stream

Assessment Results

Ship CSMPModernization

Availability Work Package (AWP)

Execute Availability

Avail Close Out(Technical & Financial)

Class Maintenance Plan (CMP)

Technical Foundation

Paper

Ship Sheets(Ship specific

LRMS)

Baseline Availability Work Package (BAWP)

Integrate, Execute, Document and Feedback

Plan Long Range Requirements into Availabilities

Technical Reqts Class Reqts ($) Specific Ship Reqts ($, Schedule)

Plan FRP Cycle

Execute(A-0 through C+0)

Document & Feedback(C+100)

Integrate Package(A-360 through A-35)

Plan Availability(A-540 through A-360)

POM & DON Submission

Deferred Life Cycle Maintenance

(C+150)

6

Work Item Level

Enhanced tracking during AWP planning process


Agenda









Issues and Concerns

7


FY15 CMP Task Additions

LSD Stern Gate Hydraulic Cylinder Overhaul

LSD Stern Gate Transom Gasket LSD, LHD Sea Valves and Waster

Sleeves LPD Caley Davit Overhaul LPD Sea Valves LPD, DDG VCHT Chemical Cleaning LHD, LCC Ventilation Steam Heaters NSWC Below Waterline Space

Assessments LPD Bulwark Overhaul LCC, LHD Condenser Sea Water

Rubber Expansion Joints

8

Additional Info in Backup Section

LSD, LPD, MCM Laundry and Galley Ventilation

Steam Propulsion ISEA Assessment support

DDG, LSD, CG, LHA6, LCS1 Lube Oil Purifier Heater Cleaning and Calibration

LHD, LSD, LPD lower vehicle G1N6

G1N6 bilge area breakout (All classes)

DDG and CG CPP and Lube Oil Settling Tank Heater one-time assess


FY15 CMP Changes / Updates

IR SURVEY: 12 Month IR survey now 36 months

SPS-67: Modified pedestals now 48 month vice 30 or 36 month periodicity

DDG: VLS strikedown crane task inactivated for all DDGs with torpedo strikedown ALT completed

DDG and CG: CSAV and Collimation validated and all LMA/NDD aligned with PHD

MCM MP Air Flask now 180M vs 120M

PC Parasense refrigerant monitor

DDG lube oil cooler tube bundle replacement

Underwater hull preservation

LSD fuel oil purifiers

DDG SVTT assessment

9


10

What Happened to the Requirement? CMP “SWEEP”

• Total Assessment and Repair Tasks– Pre SWEEP: 6,644 tasks: 604 Mandatory A1– Post SWEEP: 2,704 tasks: 316 Mandatory A1

• Assessment tasks:– Pre SWEEP: ~2,800 tasks– Post SWEEP: ~1,800 tasks

• Overall:– 1,546 task modifications– 5,259 task inactivations– 323 new tasks with technical underpinning

• IMPACT:– Right task at the right time in the FRP to maximize investment

Results: Defendable, Accurate, Executable Maintenance Requirements

Right Sizing the CMP


Pre-/Post-SWEEP Mandatory (A1) Maintenance Actions

11

• Non-pedigreed requirements removed.• Technically valid maintenance actions remain.

Wor

k Ite

ms

(by

MR

ID)


Pre-/Post-SWEEP Non-Mandatory (B9) Maintenance Actions

12

• Non-pedigreed requirements removed.• Technically valid maintenance actions remain.• Fully supports TSRA / CAP processes.

Wor

k Ite

ms

(by

MR

ID)


Agenda









Issues and Concerns

13



Shift from MSMO Cost plus Incentive Fee contract vehicles to Firm Fixed Price contracts in all AORs.

• Package lock date moves from A-99/A-75 to A-170.

Single deferral letter required at A-220 ISO Firm Fixed Price availabilities and earlier package lock.

• Previous requirement was one deferral letter at A-240, another at A-120, in support of A-99/A-75 package lock.

• New requirement is only one letter at A-220. Response from Ship Design Manager should be back to MT prior to A-170 package lock.

• This cuts the admin burden of deferral letters in half.• As before, Type Commander MAY write additional deferral requests any time,

as needed.

14



Branding Review (“AR” Category of Work) from A-150 to A-250• First SURFMEPP review of CSMP will still be at A-440, ISO A-410 Mid-Cycle

Review.• Second SURFMEPP review of CSMP will be at A-250. This will give MT time to

put “AR” branded items into work package OR into A-220 Deferral Request.• No new jobs are pushed to the CSMP – this is a review of existing CSMP jobs

for SSEOC impact items. We will notify MT before changing Category of Work.

CMP Situational Periodicity Code change from A-150 to A-360• All CMP tasks with SPC of A-150 will now be due at A-360. Goal is earlier

completion of assessments and earlier work identification ISO earlier package lock.

• No additional assessments, requirements or workload. Just changing WHEN.

15



Non-Mandatory TSRA tasks Closure Method = MA COMPLETE• 811 (A1), 816 (A6), 832 (AR), 833 (AH), and now 849 (B9) Type Sequence Number

are all changed to “MA COMPLETE” via VSB script.• Port Engineer should not have to Customer Close these jobs when MA

executes and closes these jobs in TAAS, AIM or NMD.

Removal of CDNS – Per PE requests, SEA05 has also concurred • First step: All CDNS notifications will be EXEMPT (no auto-generated emails). Deferrals of

MTRs will all be via letter process (AWPM/TDCA can assist).• You will get the pop-up window as a notification but it won’t stop you from screening• 2nd step: remove from VSB altogether

16



Additional Details In Following Slides:• Time-Directed Tank and Void Maintenance Strategy• Third Party Planning• Master Spec Catalog & Class Standard Work Templates with Front Load• Mandatory Safety Alterations

17


Agenda

Background & Review: SURFMEPP Mission, SURFMEPP Products

New/Recent CMP tasks / revisions


Time-Directed Tank Maintenance Strategy (Mark Darwin)





Issues and Concerns

18


Place Holder


PE Symposium Briefing TDMS.pdf

19


Agenda









Issues and Concerns

20


Place Holder

• Third Party Planning (John Murphy)• PE Symposium 3PP slides 20150820.ppt

21


Agenda







• Mandatory Safety Alterations & SURFMEPP role in modernization

• Routines and Services standardization effort

• Issues and Concerns

22


Class Standard Work Templates with “Front Load”

Method:Obtain relevant historic maintenance data from NMD. We

started with the SWLINS with the most growth in CNO avails.

Review current CSWT to identify functional area coverage

Look for repeated /recurring maintenance actions

Compare maintenance actions to the current CSWT:

• If maintenance actions are covered adequately by CSWT, no modification needed

• If maintenance actions are not covered, generate recommendation based on average/median of data

• If an existing reservation is not required, it will be removed

23


Top Growth for all Surface Ships

24


Example: CG Gas Turbine Exhaust Repair

Developed Two CSWTs - One for 1A and 1B and One for 2A and 2B - to include the following reservations:• 10 linear feet of Vee-out and weld repair

• 10 manhole cover studs replaced

• 10 manhole cover bolting ring holes repaired

• 450 ft2 of interior insulation replacement

• 100 ft2 of perforated sheathing panel replacement

• The following CSWTs have been modified to include the reservations:

• CSWT 259-008 1A and 1B Gas Turbine Exhaust; repair

• CSWT 259-002 2A and 2B Gas Turbine Exhaust; repair

25


Agenda









Issues and Concerns

26


MSA Definition

Created and codified via the NMPT in NDE

MSA ALTS identified in NDE by selection of the “Mandatory Safety Alteration” field

Safety risk assessment provided by ALT sponsor

Currently SURFMEPP uses a list of MSAs provided by SEA21 (vetted by SEA05)

27

Official Definition of “MSA” Approved - NDE Being Populated


MSA ID, Tracking and Deferral

SURFMEPP reviews LOA and IDs MSA

Pushes MSA JSN to MT and brands “AS”

• “AS” in JFMM as “Mandatory Safety Maintenance”- Volume II, Part I, Chapter 3- Being added to Appendix “AN” at next JFMM BoD

• Set Due Date to end of CNO avail and notifies stakeholders

Reviewed at E2E meetings (LCPC, A-410, IPTD, and C+70)

Tracked in A-360, Deferral and Closeout letters

Stakeholders notified if LOA change removes MSA

Deferral through LOA change process vice JFMM

28

Deferral from FRP to FRP may be an SSEOC reportable requirement


Agenda









Issues and Concerns

29


CNO Availability Services and Routines

In an effort to standardize Services and Routines and the associated processes need to ensure jobs are on the CSMP, SURFMEPP conducted an analysis to identify tasks needed to support the planning and execution of CNO availabilities

Tasks were divided into two categories, Core and Optional by AOR

Task review is complete in Norfolk

Task review is ongoing in San Diego

30

CNO Services & Routines Under Review For Standardization By AOR


Core Services and Routines

Core Services and Routines are tasks deemed required to support the planning and execution of the CNO availability

The AOR specific Core Services and Routines were developed by SURFMEPP and concurred upon by the TYCOM and RMC

Core Services and Routines will be discussed at LCPC

Core Services and Routines will be pushed with the BAWP but will not be branded mandatory

31

Core Services & Routines are Pushed with the BAWP


Optional Services and Routines

Optional Services and Routines are unique package relevant tasks deemed needed to support the planning and execution of the CNO availability

The AOR specific Optional Services and Routines were developed by SURFMEPP and concurred upon by the TYCOM and RMC

Optional Services and Routines will be discussed at LCPC and the A-410 meeting

Optional Services and Routines will be pushed to the CSMP when requested by the Maintenance Team

32

Optional Services & Routines Pushed at Maintenance Team Request


Agenda

Background / Review: SURFMEPP Mission and Products



Time Directed Tank Maintenance Strategy (Mark Darwin)



Mandatory Safety Alterations &SURFMEPP role in modernization


Issues and Concerns

33


Issues and Concerns

CSMP Management• Tasks must be completely closed out in VSB – Last Accomplished Date does not update until the

JCN is closed out. Job will continue to appear on “overdue CMP task” list until closed.

• Jobs that are NOT complete must stay on the CSMP – If the job is still valid, leave it open so we can put on Ship Sheets and ensure you have the budget for it in the next cycle.

• All DFS need a JCN – A DFS can’t be screened and brokered…only a JCN can be screened and brokered. Without a JCN there is no mechanism to actually get it fixed.

CMP Task Ownership• If it is in the CSMP with an “A” Category of Work it is PE responsibility to Screen and Broker (or

get deferred by SDM).

• When it is assigned to the RMC it is their responsibility to get it accomplished.

• “Upon completion of a mandatory assessment, the assessment team is responsible for creating CSMP-ready repair AWRs”

• BAWP report is distributed every 30 month. Full listing of all “A” Category of Work items in the CSMP with a due date in the current cycle, WITH current status (Avail plus authorized, assigned, rejected, on hold, etc)

34


Issues and Concerns

CMP Task Feedback / TFBR• If a CMP task is not right (not executable as written, wrong periodicity,

mismatch with tech manual, etc.), don’t just “live with it” - give us that feedback so we can fix it.

• If no task exists for a piece of gear, but it should – we can help with that too. We can work with ISEA / TWH.

• You can write your own TFBR in PMSMIS, or you can talk to / email / call your local SURFMEPP detachment. We can either show you how to do a TFBR or we can do it on your behalf.

Deferral Process• Not being fully utilized. We still see items not accomplished but never

adjudicated on almost every closeout letter. If you know it can’t / won’t be done, request deferral. Call your AWPM / TDCA.

• Deferral letters can be submitted at any time. RMC Chief Engineer can also adjudicate tasks during execution, per JFMM.

35


Summary

36

TYCOM and SURFMEPP: One TEAM/One FIGHT • “It’s all about the ships”

SURFMEPP is fully engaged in the Surface Maintenance and Modernization E2E process

• Defining and Defending the requirement

Working with you to improve Surface Maintenance


Questions/Backup

37


Team Ships Organization

38

COMBATANTSOFFICE

Ms. Bilyana Anderson (SES)EXECUTIVE DIRECTOR

PMS 400DDDG51

PM: CAPT Vandroff

Ships Acquisition Management Office

DIRECTOR: B. Budd

DEPUTYDIRECTORC. Teichert

PMS 500DDG 1000

PM: RDML (Sel) J. Downey

DPML. Radocha

PMS 377LHA(R) / SSC / LCAC / AADS / LCU / SC(X)

PM: CAPT Mercer

PMS 317LPD 17/ LX(R)

PM: CAPT Plath

PMS 325Auxiliary Ships /

Small Boats & Craft

PM: M. Kosar

Team Ships StaffChief of Staff

P. Murphy

PROGRAM EXECUTIVE OFFICER SHIPS

RADM David Gale

DEPUTY COMMANDER FOR SURFACE WARFARE

RDML Larry Creevy

DPMM. Sermon

PMS 385Strategic & Theater

Sealift

PM: CAPT Stevens

DPMT. Rivers

DPMM. Lyons

DPMT. Roberts

(acting)

DPMC. Mitchell

SURFACE WARFAREDIRECTORATE

Ms. E. Anne Sandel (SES)EXECUTIVE DIRECTOR

SEA 21IInactive Ships

DIRECTOR:W. Boozer (acting)

PMS 443Surface Ship

Readiness and Sustainment

PM: CAPT CronePMS 326

International Fleet Support

PM: CAPT Dick

PMS 407 Surface Ship Modernization

PM: CAPT Zobel

DPME. Littig

SURFMEPP

CO: CAPT Bauer

DPMB. Smith

DEPUTYDIRECTOR

T. White (acting)

PMS 320Electric Ships Office

DIRECTOR: S. Markle

DEPUTYDIRECTOR

P. Grabowski

AMPHIBIOUS, AUXILIARY& SEALIFT OFFICE

Mr. Jay Stefany (SES)EXECUTIVE DIRECTOR

DPMF. Thompson

DPMT. Conlon

DEPUTY DIRECTORT. Gallagher

SEA 21PChief Financial Office

M. Scott

PMS 339Surface Training

SystemsPM: CAPT Sinclair

SEA 21DDirector, Contract

MgmtM. Reese

As of July 2015


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

CMPs are continuously updated based on class maintenance history

CMP = “Automobile’s Maintenance Manual”

39


Purpose Identify maintenance required to meet the

expected service life (ESL) for CMAV and CNO avails

“Class-level” notional long range maintenance schedule for a well designed and maintained ship. TFP Includes:- Man-days- Availability periodicity - Availability duration for depot level maintenance

Technical Foundation PaperBuilding Blocks

Maintenance Requirem

ents by Availability

Technical Foundation Paper (Sum

mary)

Technical Foundation Paper (Owner’s Manual)

Time Directed

Services

Corrective (CMP)

Corrective (CSMP)

Fleet Alts

Tota

l Not

iona

l R

equi

rem

ent

C+90 Deferral

40


Ship Sheets

Ship Sheets support the annual requirements and budgeting process “at the hull level”

– Dollars and schedule– Technical Foundation Paper is the baseline – Material condition is used to develop ship-specific

requirements– Assessments are critical to document material condition

Two year old process for Surface Navy - improved upon Sub and Carrier model

Deferred maintenance is tracked via MMWP and Ship Sheets

41


42

BAWP

A collection of all Mandatory Technical Requirements ISO CNO Availability Work Package, and includes:• Mandatory Safety Alterations

• Integrated/approved Mod sked & avail duration risk assessment

• CMP Assessment and Repair Tasks

• Mandatory DFS / CLAD items

• Routines and Services

LCPC held/BAWP items reviewed at C+140

BAWP items pushed to CSMP 10 days later

MOD items to CSMP ISO Letters of Authorization at A-360


• End to End Maintenance Process / CNO Availability Milestones

• Baseline Availability Work Package (BAWP) Status– Mandatory work deferred from last cycle – Tank Assessments (G1N5), Preservation and

Repairs– Corrosion Assessments (G1N6) – Infrared Surveys (T1B6)– Additional Items to be pushed– Docking Items / Routines and Services

• Class Advisories (CLAD) / DFS

• Maintenance Events Remaining (TSRA / CMAV) / Establish Milestones

• BAWP Summary

43

SURFMEPP Life Cycle Planning Conference

C+140 Start of the cycle - get everyone on the same page right from the start


• Baseline Availability Work Package (BAWP) Status

• Tank Assessments (G1N5), Preservation and Repairs

• Corrosion Assessments (G1N6)

• Intake / Uptake Assessments (G1E8), Infrared Surveys (T1B6)

• Docking Items / Routines and Services

• Class Advisories (CLAD) / Departures from Specifications (DFS) status

• CSMP review for Lifecycle Critical JSNs (AR Branding)

• Modernization Items / Availability Duration Scorecard

44

SURFMEPP Mid-Cycle Review

A-410 MCR - a key input to the Maintenance and Modernization Work Package


SURFMEPP Closeout Process

• Review Status of Mandatory Technical Requirements (MTR)

• Review MTRs to Re-Program

• Establish notional milestone dates for the next FRP maintenance cycle

• Review the status of Departures From Specification (DFS)

• Review recommendations for SURFMEPP process improvement and possible LEAN initiatives

• SURFMEPP also reviews actual expenditures vs budget and controls (W=X=Y=Z)

45

C+70 Closeout meeting, formal audit report issued C+100

Future state: will also include a review of planned modernization


SSEOC Life Cycle Critical Systems

100Structure

U/W HullSuperstructure / Mast

Sonar DomeDecking, Structure

BilgesTanks / VoidsBulkheads, Structure

Corrosion, General

200Propulsion

Steam TurbinesBoilersMPDEMRGShaftsStrutsHubs / Propulsors

Intakes / Uptakes

Forced Draft Blowers

Main Feed Pumps

Main Steam Valves (>4”)

Gas Turbine Module Mounts

Piping: Fuel Main / Aux Steam

300Electrical

SSDGEDGSSTGGTG Module Mounts

Cabling Distribution

Switch Boards

400Command/Surveillance

SPY Array PCMSMK 82SPG 62

500Auxiliary

Ventilation System - Structure

Ballast SystemsSteeringHangar DoorsRuddersAux Blr /WHBElevators -Aircraft

Boat DavitsStern GatePiping: CHT Firemain CMWD Main / Aux SW

600Outfits/Furnishings

ICCP SystemCorrosion, General

U/W Hull Paint Systems

700Armament

VLSMagazinesElevators - Weapons

JSNs are branded and tracked throughout the E2E process

46


Impact of Non-compliant Deferral Process

47

USS IWO JIMA:

AVAILS CANX TO INCREASE OPERATIONAL SCHEDULE.

RESULTED IN :• TANKS NOT ASSESSED SINCE

COMMISSIONING

• 115 TANKS IN UNKNOWN STATUS

• 25 TANKS REQUIRING 100% RECOAT

• POSSIBILITY OF AVAIL EXTENSION AND LOST Ao

POSSIBILITY OF INCREASED AVAIL COSTS DUE TO MANDATORY DOCKING WORK

USS ASHLAND:

ASSESSMENTS & MAINTENANCE DEFERRED OVER MULTIPLE FRP CYCLES

RESULTED IN :• MULTIPLE AVAIL EXTENSIONS DUE

TO GROWTH/NEW WORK (AVAIL NOW 18+ MONTHS)

• INCREMENTAL DISCOVERY AVAIL(1,600+ RCCs)

• INCREASED AVAIL COSTS (219% G/NW)

• LOSS OF OPERATIONAL AVAILABILITY

USS STOUT: BMD SHIP

TANKS COND 3 and COND 4 REPAIRS DEFERRED.

RESULTED IN :• INCREASE TANK INTERNAL DEGRADATION

• FUTURE AVAIL CHANGED TO DOCKING REPAIRS

• INCREASED FUTURE AVAIL COST TO SUPPORT DOCKING REQUIREMENTS

PLACE HOLDER

IWO TANK PICTURE ; COND 3 TANK


FY14 CMP tasks / revisions

Radiation Hazard Certification

Pointing and Firing Cutouts Certification

LPD 17 SWAN Fail-over Test

MCM Rudderstock Seals Replacement

LHD Laundry and Galley Ventilation

LPD 17 Fiber Optic Cables

LHD Stern Gate Transom Gasket

Stern Gate Cylinder Rebuilds

DDG Collective Protection System

Silicon Aluminum Bronze Union Nuts

• NSWC Below Waterline Space Assessments

48


49

Executing the RequirementDeveloping & Tracking CMP / CSWT Tasks

• Standardizes recurring repair planning – reduces planning costs

• Reduces variance of work scope between ports/contractors

• Provides contract vehicle for detailed technical instructions

• Standardizes cost estimating• Improves cost return analysis for

feedback into the requirement process

• Incorporates best practices/lessons learned

CMP / CSWT(Technical. Req.)

BAWP(Est. $, Scope)

AWP (Gov. Est.)

Execution(Track growth vs. Est.)

Avail Close Out(Variation Analysis)

Analysis

• Review CMP, SWTs, CSWTs, and LWTs

• Technical Doc.• Configuration Data • Failure Analysis • Return Cost Data

Develop Strategy

• Identify Gaps• Engage with ISEA• Identify tasks to be

inactivated, modified or created

• Draft Maintenance Strategy

Approval / Develop Task

• TWH Approval• AP cards• SWTs or CSWTs and IGEs • Fielding Plan• Resource Plan• CMP task in M&SWP

Implementation

• Socialize with the Waterfront• Master Spec Catalog• M&SWP – Go Live• TWH Follow-up

Class Standard Work Template (CSWT)

Currently 5500 templates in the Master Spec Catalog


50

The Good News about…


ICMP Task Number: Q-58420-A01 MRID: 106245 Periodicity: 72M

Short Description: Overhaul Stern Gate Mechanical System

Cost Estimate: Man-days: 54 Material: $210,910 Associated CSWT: 584-024

Class Applicability: LSD 41/49 First Hull: USS ASHLAND (LSD 48)

CMP Task at a Glance:

Background: Stern gate hydraulics and operating equipment are high usage items that are

operated in a harsh exposed environment which can lead to increased corrosion. System downtime can impact amphibious operations and the ship’s ability to meet mission tasking.

Strategy: Preserve Stern Gate Foundation and Cylinder to include rebuilding of the Port

and Starboard Hydraulic Cylinders (and associated components).

Benefit: Time directing the maintenance in the CMP will improve the overall maintenance

strategy for the stern gate equipment, provide a budget for better and lower cost of continuous maintenance, while minimizing the excessive costs of growth and new work; all of which will increase reliability and support the primary mission of the ship.

Questions concerning this CMP Task should be addressed to: [email protected]


51


Stern Gate Transom Gasket

ICMP Task Number: Q-58420-A02 MRID: 106265 Periodicity/Situational Requirement: 36M

Short Description: Replace Stern Gate Lower Transom Gasket

Cost Estimate: Man-days: 89 Material: $10,500 Associated CSWT: 584-001 (41)/ 584-023 (49)

Class Applicability: LSD 41/49 First Hull: USS GERMNANTOWN LSD 42


Background: Stern gate gaskets are damaged during normal operation and require

maintenance every FRP avail.

Strategy: Replace stern gate transom gasket every 36M IAW LSD 41 and LSD 49 CSWTs.Benefit: Time directing the maintenance in the CMP will improve the overall maintenance




52

The Good News about…LSD 41 Sea Valves and Waster Sleeves

ICMP Task Number: Q-52010-A0A /Q-16310-A01 MRID: 93049 /93106Periodicity/Situational Requirement: Every normal docking interval

Short Description: SEA VALVES REQUIRE REPAIR OR REPLACEMENT/ WASTER SLEEVES REQUIRE REPLACEMENT.Cost Estimate: Man-days: 474 / 209 Material: $61,455/8,738 Associated SWT/CSWT/AP: 520-052/163-013

Class Applicability: LSD 41 First Hull: LSD 42 USS GERMANTOWN


Background: Routine work performed on ships in dry dock normally consists of inspect and repair, sea valves and sea chests. Waster sleeves are installed in sea chests to prevent galvanic corrosion of sea chest valves and piping components. Waster sleeve removal facilitates proper inspection of sea chests. Standard waster sleeve configurations require the sea valve to be removed, most times damaging the waster sleeve in the process. Sea valve inspections are preformed to accurately assess the extent of damage requiring repair. Repairs vary in cost, smaller valves often exceeds 50% of the cost of a new valve. Strategy: Replace sea valves 2 ½ inches and below, overhaul sea valves greater than 2 ½ inches within every normal docking interval. Replace waster sleeves in conjunction with the sea valve task.

Benefit: Additional costs to remove sea valves for repair is eliminated, the cost of valve removal is rolled into the cost of the waster sleeve repair. Catastrophic failure to sea valves that are exposed to harsh environments are reduced. Decrease need for costly diving services that pose logistical challenges affecting ships operational requirements.


53


CALEY DAVIT OVERHAUL

ICMP Task Number: Q-58311-A21 MRID: 105373 Periodicity/Situational Requirement: 72 CNO Avail

Short Description: CALEY DAVIT OVERHAUL

Cost Estimate: 154 Mandays Material: $93,657 (Including OEM Cost) Associated CSWT: 583-003

Class Applicability: LPD-17 First Hull: LPD-2 USS NEW YORK


Background: Currently there are no tasks for overhaul the Caley Boat Davits for LPD 17 class ships. The davit suffers from maintainability and reliability issues.

Strategy: Scheduled CMP task to overhaul the Boat Davit and Tow Boom every 72 months.

Benefit: A time directed overhaul strategy will improve equipment lifecycle and readiness requirements while minimizing growth and new work


54

The Good News about…LPD 17 Sea Valves

ICMP Task Number: Q-52010-A0A MRID: 93049 Periodicity/Situational Requirement: Every normal docking interval

Short Description: SEA VALVES REQUIRE REPAIR OR REPLACEMENT

Cost Estimate: Man-days: 1,119 Material: $53,374 Associated SWT/CSWT/AP: 520-001

Class Applicability: LPD 17 First Hull/: LPD 18 USS GREEN BAY


Background: Routine work performed on ships in dry dock normally consists of inspect and repair, sea valves and sea chests. Sea valve inspections are performed to accurately assess the extent of damage requiring repair. Repairs vary in cost, smaller valves often exceeds 50% of the cost of a new valve.

Strategy: Replace sea valves 2 ½ inches and below, overhaul sea valves greater than 2 ½ inches within every normal docking interval.

Benefit: Catastrophic failure to sea valves that are exposed to harsh environments are reduced. Decrease need for costly diving services that pose logistical challenges affecting ships operational requirements.


55


LPD VCHT Chemical Cleaning

ICMP Task Number: Q-59310-A01 MRID: 105989 Periodicity/Situational Requirement: CNO Availability

Short Description: VACUUM, COLLECTION, HOLDING, AND TRANSFER PIPING REQUIRES CHEMICAL CLEANING

Cost Estimate: Man-days: 141 Material: $75,600.00 Associated CSWT: CSWT 593-008

Class Applicability: LPD 17 First Hull: USS ANCHORAGE (LPD 23)


Background: VCHT piping is highly susceptible to corrosion and clogging due to build-up. This can lead to failure of the system and greatly affect ship’s habitability. Waterfront best practice determined chemically cleaning to be necessary on a time/availability directed basis.

Strategy: Accomplish a chemical cleaning of Vacuum Collection, Holding, and Transfer piping every FRP to ensure system operational integrity.

Benefit: Supports Waterfront Best Practices to avoid failure and effective maintenance planning. Reduces growth and new work during CNO availabilities.


56


Ventilation Steam Heaters

ICMP Task Number: I-51200-A05 MRID: 113222 Periodicity: 72 Months (AVAIL PRE-270)

Short Description: ASSESS VENTILATION SERVICE STEAM HEATER SYSTEM

Cost Estimate: Man-days: 50 Estimate provided by NSWCCD-SSES Code 922.

Class Applicability: LHD-1, LCC-19 First Hull/Date: TBD


Background: Ventilation system service steam heaters have become severely degraded are in various states of inoperability, presenting safety hazards to Ship’s Force personnel and other ship equipment.

Strategy: Establish mandatory tasking for ISEA to inspect service steam heaters and piping components, assess operability and configuration, assist Ship’s Force in 2K generation, and provide a written report with a Risk Matrix and ILS recommendations.

Benefit: Increase safety to personnel and equipment, improve system readiness and operability, reduce overall repair costs


57

The Good News about…NSWC Below Waterline Space Assessments

MRID: 108096 Periodicity/Situational Requirement: Dry Dock FRP cycleShort Description: CONDUCT STRUCTURAL ASSESSMENT OF ALL COMPARTMENTS BELOW WATERLINECost Estimate: Man-days: 220 (COMB), 265 (AMPH) Material: N/A Associated CSWT: N/A Class Applicability: All Classes (MCM, PC excluded) First Hull/Date: CURRENTLY BEING FIELDED

CMP Task at a

Glance:

Background: Unidentified structural and corrosion related deficiencies would often lead to growth and new work during docking availabilities. Correction of the deficiencies would often result in availability duration extensions and impact total costs.

Strategy: NSWC-CD will conduct a “below the waterline” structure and corrosion assessment prior to each scheduled docking. The assessment will be scheduled for completion at A-720 during the DSRA FRP cycle. Credit will be given for any G1N6 technical requirement to prevent duplication of effort.

Benefit: Early and consistent identification of structural and corrosion required repairs. Detailed report to include risk matrix, technically valid JSNs and DFS direction. Reduction of growth and new work. Reduction in assessment costs by non-duplication of efforts by multiple activities. Provides early input to the POM budget submission process.


58

The Good News about…LPD-17 Bulwarks

MRID: 107951 Periodicity/Situational Requirement: DRYDOCKShort Description: REPAIR & PRESERVE WITHIN THE BULWARK Cost Estimate: Man-days: 644 Material: $50,020 Associated CSWT: 150-001 Class Applicability: LPD-17 First Hull: LPD-18 USS NEW ORLEANS

CMP Task at a

Glance:

Background: Due to the bulwark design, applied coatings and location, the bulwarks on LPD-17 class have experienced recurring premature coating system failure and subsequent structural degradation. These structural failures have frequently resulted in water penetration to adjacent compartments and running rust on the ship exterior requiring additional repairs and coating application.

Strategy: Every docking availability, bulwarks will receive a directive task with a supporting Class Standard Work Template (CSWT) to repair any structural degradation and preserve the deck plating and structural members utilizing Ultra High Solids (UHS) coatings.

Benefit: The new repair task will maintain the structural integrity of the bulwarks, improve ship appearance by reducing running rust, and result in cost avoidance through reduced growth work and new work.


59

The Good News about…LCC Condenser

Sea Water Rubber Expansion Joints

ICMP Task Number: Q-25600-A05 MRID: 112700 Periodicity/Situational Requirement: Docking Availability

Short Description: Replace Main condenser expansion joints.

Cost Estimate: Man-days: 61 Material: $22,331.58 Associated CSWT: CSWT 256-006

Class Applicability: LCC 19 First Hull: BLUE RIDGE (LCC 19)


Background: Main condenser rubber expansion joints accommodate thermal growth and shock motion of the sea water circulating piping system. In compliance of NSTM requirement 505-3.37.1, “Replace rubber expansion joints in manned spaces at least every 10-12 years”. This supports the O-FRP 36/9 construct.

Strategy: Replace main condenser expansion joints each scheduled docking availability.

Benefit: Avoid catastrophic failures and costly emergent repairs that will affect Operational Availability and Expected Service Life.


60

The Good News about…LSD Laundry and Galley Ventilation

ICMP Task Number: Q-51200-A01/ Q-51200-A02 MRID: 88927/97386 Periodicity/Situational Requirement: Every FRP

Short Description: GALLEY AND LAUNDRY VENTILATION REQUIRES INTERNAL CLEANING

Cost Estimate: Man-days: 129 (LSD 41), 131 (LSD 49) Material: $18,070 Associated CSWT: 512-020 (LSD 41), 512-021 (LSD 49)

Class Applicability: LSD 41 and 49 First Hull: USS RUSHMORE (LSD 47)


Background: Ventilation systems associated with shipboard laundries and galleys that are poorly maintained cause a buildup of dirt, grease, and oil in ventilation ducts; restricts airflow, reduces air flow capabilities, exceeds design pressure and results in elevated temperatures, hazardous environments, loss of ships efficiency and increased operational costs. Most ventilation components are located in constrained spaces, making maintenance difficult for ships force; resulting in repairs and cleaning being accomplished on a fix-when-fail basis. Strategy: Cleaning of galley and laundry ductwork and associated components with NAVSEA approved methods within every FRP cycle. Benefit: Clean ventilation protects personnel and sensitive equipment from potentially hazardous airborne contaminants, fires, explosions, and excessive heat; reduces ships emissions, ship operates more efficiently and lowers operational costs.


61

MRID: 112358 Periodicity/Situational Requirement: “R”: Scheduled at A-270 each FRP cycleShort Description: Steam Propulsion ISEA Assessment Cost Estimate: Man-days: 220 Material: N/A Associated CSWT: N/A Class Applicability: LHD 1-7 /LCC-19 (8 ships/15 propulsion plants) First Hull: USS ESSEX

CMP Tasks

at a Glance:

Background: Errors in assessments/repair planning/execution, lack of critical spare parts, and failure to implement lessons learned have led to CNO Availability propulsion plant growth work, schedule extensions and significant cost increases.

Strategy: Provide ISEA engineering and inspector involvement in critical steam propulsion plant equipment baseline assessments, work package development, onsite technical support during critical repairs, inspections and tests, and participation in post availability IPTDs. This approach applies the proven Boiler Strength and Integrity Inspection process model (PSAI/SAI/ISVs/CAI/IPTD) to critical steam propulsion components and systems. Includes: main propulsion and auxiliary steam turbines, SSTGs, forced draft blowers, heat exchangers, condensers, distilling plants, pumps, piping & valves, all associated automation/controls, etc…

Benefit: Early and accurate identification of deficiencies and associated critical LLTM, technical input and OQE for repair planning, critical QA inspections for complex work packages, proactive onsite assistance with immediate engineering reach back to all NAVSSES Subject Matter Experts and application of lessons learned between repair activities. Result is reduction in growth work, schedule disruption and total costs.

Steam Propulsion Plant ReadinessEnhanced CNO Maintenance Availability ISEA Support


62

The Good News about…Radiation Hazard Certification

ICMP Task Number: I-86113-A03 MRID: 104896 Periodicity/Situational Requirement: 60M

Short Description: Certify Radiation Hazard (RADHAZ) Control Measures

Associated SWT/CSWT/AP: NAVSEAINST 9700.2, NAVSEA S9040-AA-GTP-010/SSCR

Class Applicability: All Surface Ships First Hull/Date: Ongoing Last Hull/Date: Ongoing


Background: NAVSEAINST 9700.2 Integrated Topside Safety and Certification Program for Surface Ships and S9040-AA-GTP-010/SSCR Surface Ships Certification Requirements, Rev 5, Chapter 1, require: “RADHAZ Cert. issued upon confirmation of proper placement of required controlmeasures and is effective for 5 yrs.”

Strategy: NSWC Dahlgren Division Q52 and NSWC PHD A33 requested SURFMEPP CHENG convert existing Routine into a 60M Scheduled Assessment that can be pushed and tracked within the CMP.

Benefit: This Certification, with safety impacts, will be formally tracked and managed by NAVSEA 21 via SURFMEPP.


63

The Good News about…Pointing and Firing Cutouts Certification

ICMP Task Number: I-86113-A02 MRID: 104554 Periodicity/Situational Requirement: 36M

Short Description: CERTIFY POINTING AND FIRING CUTOUTS.

Associated SWT/CSWT/AP: NAVSEAINST 9700.2, NAVSEA S9040-AA-GTP-010/SSCR

Class Applicability: All Surface Ships First Hull/Date: Ongoing Last Hull/Date: Ongoing


Background: NAVSEAINST 9700.2 Integrated Topside Safety and Certification Program for Surface Ships, Encl (1), Para 1.g.(1) requires: “safe, correct and interference free installation of weapon systems pointing and firing cutout (P&FCO) zones whenever a SHIPALT has been accomplished which affects the P&FCO or if it has been more than three years since the last certification.”

Strategy: NSWC Dahlgren Division G73 requested SURFMEPPCHENG convert existing Routine into a 36M Scheduled Assessment that can be pushed and tracked within the CMP.

Benefit: This Certification, with safety impacts, will be formallyTracked and managed by NAVSEA 21 via SURFMEPP.


64

The Good News about…LPD 17 SWAN Fail-over Test

ICMP Task Number: I-4A040-A04 MRID: 97426Periodicity/Situational Requirement: DEPLOY PRE - 180

Short Description: SWAN Fail-over Test.Cost Estimate: 24 M/H Director/Rover; 156 M/H SF Operators. Associated SWT/CSWT/AP: Drawings (see above)Class Applicability: LPD 17 First Hull/Date: LPD 20 USS GREEN BAY


Background: • INSURV Technical Issue Paper 12-003 of 13 Jun 12 cited OPNAVINST 9070,

2009 NVR and DOD Directive 8500.2 in requiring formal demonstration of SWAN redundancy and survivability.

• PEO Ships 317 contracted Raytheon to develop test procedures to meet the requirements and TWH NAVSEA 05WH approved the resulting drawings and mandatory requirement.

Strategy: Implement the 3 drawings, by WAN architecture and hull series, in a scheduled pre-deploy CMP Task with execution funded by PEO Ships 317.• 9002134 Rev B - LPD 17/18• 9003644 Rev D - LPD 22 - 25• 9003734 Rev A - LPD 19 - 21

Benefit: Demonstrate ability to sustain combat ops, mission critical networks and contingency plans required in cited documents.


65


Rudderstock Seals Replacement

ICMP Task Number: Q-56211-A07 MRID: 97726 Periodicity/Situational Requirement: Dry-dock

Short Description: Rudderstock Seal Assemblies Require Replacement

Cost Estimate: Man-days: 28 Material: $46,700.00 Associated CSWT: MCM-1 562-006

Class Applicability: MCM -1 First Hull/Date: USS CHIEF (MCM 14)


Background: A number of US Navy surface ships have recently experienced severe damage to rudder spherical roller bearings (SRB). CG 47,DDG-51, FFG 7, LHD 1-7, LHA 1, LPD-4, LPD-17, MCM and LSD41/49 class ships are susceptible to sea water intrusion into the lower rudder bearing.

Strategy: Create mandatory CMP task and supporting CSWTs to replace Rudderstock Inflatable Seal, Hull Seal, Upper & Lower Bearing Seals, and Sand Excluder Seals every CNO Dry-Docking Availability.

Benefit: Prevent premature bearing failure, cost savings through effective planned maintenance.


66

The Good News about…LHD Laundry and Galley Ventilation

ICMP Task Number: Q-51200-A01/ Q-51200-A02 MRID: 88927/97386 Periodicity/Situational Requirement: Every FRP

Short Description: GALLEY AND LAUNDRY VENTILATION REQUIRES INTERNAL CLEANING

Cost Estimate: Man-days: 112 Material: $18255 Associated CSWT: LHD 512-003

Class Applicability: LHD First Hull/Date: USS IWO JIMA (LHD 7)


Background: Ventilation systems associated with shipboard laundries and galleys that are poorly maintained cause a buildup of dirt, grease, and oil in ventilation ducts; restricts airflow, reduces air flow capabilities, exceeds design pressure and results in elevated temperatures, hazardous environments, loss of ships efficiency and increased operational costs. Most ventilation components are located in constrained spaces, making maintenance difficult for ships force; resulting in repairs and cleaning being accomplished on a fix-when-fail basis. Strategy: Cleaning of galley and laundry ductwork and associated components with NAVSEA approved methods within every FRP cycle. Benefit: Clean ventilation protects personnel and sensitive equipment from potentially hazardous airborne contaminants, fires, explosions, and excessive heat; reduces ships emissions, ship operates more efficiently and lowers operational costs.


67

The Good News about…LPD 17 Fiber Optic Cable Plants

ICMP Task Numbers: I-4A040-A01, 3 & 2 MRIDs: 93145, 96907, 96905 Periodicity/Situational Requirement: DEPLOY PRE – 60 (A6G4) , CNO AVAIL (A6G5, A5G6)

Short Description: FOCP Repair Readiness, Growth Tube and Material Condition Assessments.Cost Estimate: 16, 384 & 80 Man-Hours each. Associated SWT/CSWT/AP: A6G4, A6G5, A6G6Class Applicability: LPD 17 First Hull: USS SAN DIEGO (LPD 22)


Background: ISEA NSWC Dahlgren Division W64 Proposed and TWH NAVSEA 05W Approved creating AP-MRC-based scheduled 60-days-pre-deployment tasks to ensure LPD 17 FOCP material, crew, tools readiness and to assess growth capacity.

Strategy: Implement the following AP Cards as Scheduled CMP Tasks, Funded by PMS 470A6G4 - Fiber Repair Readiness Assessment A6G5 - FOCP Growth Tube AssessmentA6G6 - FOCP Material Condition Assessment

Benefit: Greatly improved Operational Availability. Crew over-the-shoulder training. Improved information for fiber capacity growth planning.


68


Stern Gate Transom Gasket

System Photo


Short Description: Replace Stern Gate Lower Transom Gasket

Cost Estimate: Man-days: 83 Material: $4,680 Associated SWT/CSWT/AP: 584-002

Class Applicability: LHD-1 First Hull: USS BATAAN (LHD 5)


Background: PREPRL and SSEOC noted a need to create Stern Gate CMP tasks. There is a clear shortage of CMP stern gate time directed repair and assessment

tasks. The number of A1 branded repair tasks is currently zero.

Strategy: Replace Stern Gate Transom Gasket (Lower Section) every 27M. Please see CSWT

584-002.





69



System Photo


Short Description: Overhaul Stern Gate Mechanical System

Cost Estimate: Man-days: 140 Material: $163,905 Associated SWT/CSWT/AP: 584-003

Class Applicability: LHD-1 First Hull: USS BATAAN (LHD 5)


Background: PREPRL and SSEOC noted a need to create Stern Gate CMP tasks. There is a clear shortage of CMP stern gate time directed repair and assessment

tasks. The number of A1 branded repair tasks is currently zero.

Strategy: Preserve Upper and Lower Stern Gate Foundation and Cylinder to include

rebuilding of the Upper and Lower Hydraulic Cylinders (and associated components). Please see CSWT 584-003





70

The Good News about…DDG’s Collective Protection System

ICMP Task Number: Q-51200-A04 MRID: 105999 Periodicity/Situational Requirement: One-Time

Short Description: CPS CLEAN SIDE PLENUM ACCESS OPENING REQUIRES REMOVAL

Cost Estimate: Man-days: 7 Material: $115 Associated SWT/CSWT/AP: DDG: 512-029

Class Applicability: DDG 51- 92 First Hull/Date: USS HIGGINS (DDG 76)


Background: During CPS filter change outs, chemical/biological/radiological (CBR)filters are leak tested to verify the filters, housings, andplenums do not leak. During leak testing of CBR filters servingCPS Zone 1 on DDG51 class hulls, leak failures are often identifiedthrough a plenum access plate in Zone 1 bulkhead separating theclean side plenum from the dirty side plenum in CPS fan room 01-110-3-Q. ISEA Advisory 031-13 Rev 1. DTG 121130Z NOV 13.

Strategy: Remove Collective Protection System (CPS) clean side access opening and replace with a new welded plate.

Benefit: CPS integrity, protecting personnel from hazardous CBR environments.


71

The Good News about…DDG Silicon Aluminum Bronze Union Nuts

ICMP Task Number: I-50500-A02 MRID: 101627 Periodicity/Situational Requirement: One-time

Short Description: PIPING SYSTEMS REQUIRE INSPECTION FOR SAB MATERIAL

Cost Estimate: Man-days: 942 Material: $60,854 Associated SWT/CSWT/AP: CSWT 505-007

Class Applicability: DDG (51-92) First Hull/Date: USS JOHN PAUL JONES (DDG-53)


Background: Silicon Aluminum Bronze (SAB) unions have been known to have failed on high pressure air systems. This was first discovered at the beginning of 2000 on DDG 51 class ships, and again in October 2010 on LPD 17 class ships. A series of laboratory tests was conducted and identified specific conditions, stress levels, and defined the limitations of SAB nuts making them susceptible to failure. As a result, Naval Sea Systems Command (NAVSEA) issued Surface Fleet Advisory No. 11-01 Silicon Aluminum Bronze Union Failure, directing the Surface Fleet to conduct ship-wide inspections of systems greater than 300 psi, to identify unions with SAB material, and immediately replace them. This shall be adjudicated by DFS, for later repair.Strategy: Accomplish a one-time, ship-wide inspection of all union-ended valves and takedown joints for the presence of SAB material in piping systems with a design pressure of greater than 300 psi, and replace indentified SAB unions.

Benefit: Prevents risk of union failure and potential of endangering personnel and equipment .

surface maintenance engineering planning program update

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