Presentation:The Operational Testing Of The CPC ACF-50

1
This presentation has been cleared for unlimited
distribution by the Public Affairs Office
Security Office at the Naval Air Depot North
Island.
TRI-SERVICE CORROSION CONFERENCE San Antonio,
Texas / 14-18 January 2002
The Operational Testing Of The CPC ACF-50 On The
US Navys S-3B Viking Fleet
Speaker Edwin G. Mullin F/A-18 Structures Fleet
Support Team 4.1.6.0.0 F/A-18FST.3 Naval Air
Depot North Island COMM 619/545-0745 FAX
619/545-5160 DSN 735-0745 MullinEG_at_navair.navy.mi
l
2
The Problem

• More Maintenance Man-hours are expended on
  Corrosion Control than any other maintenance task
  in Naval Aviation today.
• Any products and/or maintenance actions that can
  reduce the expenditure of excessive Maintenance
  Man-hours must be aggressively pursued.
• This brief addresses Operational Testing of the
  CPC ACF-50 On The US Navy's S-3B Viking Fleet.

3
Discussion

• Viking Mission
• Naval Aviations Operational Environment
• Initial Prototyping of ACF-50 in 1996/1997 and
  the Results of that Effort
• Expanded Prototyping of ACF-50 at
  SEACONTROLWINGLANT and SEACONTROLWINGPAC
• Documenting and Tracking Results
• Lessons Learned
• RCM Logic Recommendations
• Questions

4
S-3B VIKING IS A MULTIPLE MISSION PLATFORM

• As a Tanker

• As a Shooter and surveillance aircraft

5
Naval Aviations Operational Environment!
6
Operational Testing of ACF-50on VQ-5 ES-3A BUNO
158862

• ASPA Inspection - July 1996
• ASPA Team
• Inspection Results
• ACF-50 Application
• ES-3A Operations over the Next 12 Months

7
The operational testing of the CPC ACF-50 on VQ-5
ES-3A BUNO 158862 - cont

• T/M/S -
• S-3B in Lead
• ES-3A in Trail

• First use of ACF-50 on an ES-3A

8
Operational Testing of ACF-50on VQ-5 ES-3A BUNO
158862

• Second ASPA Inspection using Same Team - June
  1997
• Results revealed a 47 REDUCTION in corrosion
  discrepancies
• S-3 Maintenance Engineering Report MER NR.
  002-97, MIL-C-81309, CORROSION PREVENTIVE
  COMPOUNDS CPC, WATER DISPLACING, ULTRA THIN
  FILM, ACF-50, released under DTG NAVAVNDEPOT
  NORTH ISLAND R140908Z AUG 97.
• NAWC Letter 4123 Ser 434100A/4065 of 13 Nov 97
• Aging Aircraft Program AAP, Affordable
  Readiness Initiatives ARI Aircraft Equipment
  Reliability and Maintainability Improvement
  Program AERMIP

9
Expanded Prototype Efforts - Sea Control Wings,
Atlantic and Pacific

• ACF-50 Application
• Fogged 16 S-3B Aircraft, 8 on each Coast
• 13 Non-Fogged Control Aircraft
• Corrosion Baseline Reporting
• Fogging was performed the week of 5 Jun 2000 at
  NAS Jacksonville, VS-24 VS-30 and the week of 2
  Oct 2000 at NAS North Island, VS-29 VS-33
• All Fogging was accomplished by O-Level
  Maintenance Personnel
• Technical Representation
• Lear Chemical Pacific Corrosion Control
• S3FST, RM Engineer
• 308 Day Corrosion Inspection Results Tracking
  Reporting, plus NALDA Equipment Condition
  Analysis ECA

10
Corrosion Verification via Borescope

• Probe / Camera / Light Unit

• TV / Monitor Unit

11
Photographic Documentation of Current Condition

• AFT STB AVIONICS BAY
• Peeling Paint

• TRAILING EDGE,
• STAB WING
• Corrosion

12
Fleet Operational Application / Fogging

• Fogging of the Inner Wing

• Fogging of the Upper Fin

13
Fleet Operational Application / Fogging

• Fogging the Aft Port
• Cargo Bay

• Fogging Inside the Engine
• Nose Cowl

14
Fleet Operational Application / Fogging

• Fogging the Trailing Edge Flap Well

• Fogging STAB Horizontal Stab

15
Fleet Operational Application / Fogging

• Fogging OWP Lower Spoiler Well

• Fogging into Wing Root Drain Holes

16
Fleet Operational Application / Fogging

• Fogging Horizontal Stab
• Using 8 FT. Wand

• Fogging Horizontal Stab
• Using 8 FT. Wand

17
Fleet Operational Application / Fogging

• Fogging Port MLG Wheel Well

• Fogging Inside Nose Radome

18
Information onACF-50 Prototype Effort

• Current Status
• Application Lessons Learned
• Effectiveness of Application
• Tooling
• Pressure Settings

19
ACF-50 Pump System Tooling Lessons Learned
- Length of hoses - Dolly -vs- Cart - Quick
Disconnects - Wands
20
Fogging Lessons LearnedFrom S-3B BUNO 158871
Horizontal Stabilizer
21
CORROSION INSPECTION RESULTS

• Specific data is available in paper.
• Impact of ACF-50 on the Internal -vs.- External
  Airframe Structural Boundaries
• s are Sum of all Corrosion ECA-Malfunction
  Code 170 of entire aircraft structure and
  systems -vs.- s of Fogged Area Only
• - Fogged WINGLANT S-3Bs had 31.6 less corrosion
  then Non-Fogged S-3Bs
• - Fogged WINGPAC S-3Bs had 37.5 less corrosion
  then Non-Fogged S-3Bs

22
Reliability Centered MaintenanceLogic
Recommendations

• Reliability Centered Maintenance RCM Logic
• Is there a return on our investment?
• Have we increased or decreased the
  Organizational Level Maintenance Workload
  Corrosion Control MMHRS?
• Have other levels of Maintenance Intermediate
  and/or Depot been impacted?
• What impacts have been made on material
  requirements and cost?
• Based on our Fleet Support Team analysis RMs
  recommendation is that the use of the CPC ACF-50
  be incorporated into the S-3Bs regular
  Maintenance Plan at the earliest possible date.

23
ACF-50 Is Not a Silver Bullet. However, It Is a
Very Useful and Productive Tool That Enhances the
Ability of Our White Hats to Maintain Our Fleet
Assets at an Acceptable Operational Level!
A VS Maintenance Control Chief
24
Speaker Edwin G. Mullin F/A-18 Structures Fleet
Support Team 4.1.6.0.0 F/A-18FST.3 Naval Air
Depot North Island COMM 619/545-0745 FAX
619/545-5160 DSN 735-0745 MullinEG_at_navair.navy.mi
l
QUESTIONS?
TRI-SERVICE CORROSION CONFERENCE San Antonio,
Texas / 14-18 January 2002
25
Reassignment From The S-3B RM Fleet Support
Team To The F/A-18 Structures Fleet Support Team
Current Contact Information Edwin G.
Mullin F/A-18 Structures Fleet Support Team
4.1.6.0.0 F/A-18FST.3 Naval Air Depot North
Island COMM 619/545-0745 FAX
619/545-5160 DSN 735-0745 MullinEG_at_navair.navy.mi
l