QUALITY ASSURANCE PROGRAM HIGHLIGHTS

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QUALITY ASSURANCE PROGRAM HIGHLIGHTS

• Presented to the DESC Pacific Petroleum
  Conference Fall 2002
• By
• Lee Oppenheim, DESC-BQ

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AGENDA

• DCMC Quality Assurance Mission Transfer to DESC
• Quality Automation Vision
• Apple Jelly Update

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DCMC Quality Assurance Mission Transfer to DESC
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DCMC Quality Assurance Mission Transfer to DESC

• On Sep 26, 2002, Mr. Aldridge, OSD ATL, signs
  Request to Consolidate Fuel Quality Mission under
  DESC
• Transition in FY03
• DESC to manage total supply chain quality mission

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DCMC Quality Assurance Mission Transfer to DESC

• DESC DCMA discussing transition issues
• Personnel
• Locations
• Budget items
• Computers
• Communication equipment
• Safety equipment
• Govt furnished vehicles
• Return Rights

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DCMC Quality Assurance Mission Transfer to DESC

• IMPACT TO CUSTOMER
• NONE
• NOW one stop complete service

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Quality Automation Vision
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Quality Automation Vision

• Integrated system to track refinery to
  consumption quality parameters
• Central Quality Database - Petroleum Quality
  Information System (PQIS)
• Laboratory Information Management System (LIMS)
• Exceptions, Deviations Waivers (EDW)
• Customer/Depot Complaints (CDC) Product Quality
  Deficiency Reports (PQDR)
• Sample Log
• Commercial Laboratory Orders

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Quality Automation Vision

• Integrated with Inventory, Facilities and
  Contracting information
• Connected to FAS
• Web based
• Automated reporting
• Visible at the local, Command, Staff, Service
  Technical Office levels

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System Functionality

• Have a system of secure, linked databases
  containing information on quality which can be
  accessed by the military services and other
  authorized parties.
• Automate data entry functions and the transfer of
  information in order to become paperless.
• Make the maximum use of any and all new
  technology to accomplish the above.
• Allow interaction among all elements in the
  Quality purview and other CBUs
• Measure contractor compliance with the contract

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B
Analysis Reports available to Quality management
on-line
Complaints
CUSTOMER
Base-Level FAS
Fuel Request
Web Page
Receipt Acknowledgment
Complaints
Complaints
A
E
Submit Fuel Sample
Web Page
Lift Scheduled
Lab Results
Contractor or DFSP
DD250 / DD250-1 filled out
Report of Requirement / Order Discrepancy
D
Lab Data
C
Quality / Quantity Data
Web Page
Cargo / Demurrage Data
Adjusted Fuel Quality Requirement
SYSTEM PART OF FAS
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PQIS Expansion
Quality Assurance Results
Quality Surveillance Results
Customer Results
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Defense Energy Support Center Apple Jelly
Study Program Update
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BACKGROUND

• Occurrences reported since mid - 1990s
• Most often produced during winter or cold
  weather periods
• Primarily involves JP-8 fuel at Air Force
  locations

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BACKGROUND
GRAND FORKS AFB, ND
PEASE ANGB, NH
NAS OCEANA, VA
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BACKGROUND
TINKER AFB, OK
YOUNGSTOWN ARS, OH
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FY 2002 APPLE JELLY OCCURRENCES
LOCATION (1ST REPORTED OCCURRENCE)
Grand Forks AFB, ND (Oct 01) Osan AB,
Korea (Dec 01) Ellsworth AFB, SD (Oct 01)
Kunsan
AB, Korea (Dec 01) McChord AFB, WA (Dec 01)
Barksdale AFB, LA (Jan 02) McConnell AFB,
KS (Dec 01) DFSP Port Mahon, DE (Jan
02) 317th EAMS/LGSF NAS Sigonella, Sicily (Dec
01) Godman AAF, KY (Jan 02) McGuire AFB, NJ
(Dec 01) 913th AFR,
Willow Grove, PA (Jan 02) Thule,
Greenland (Dec 01)
Hill AFB, UT (Feb 02) DFSP Verona,
NY (Dec 01) Fairchild
AFB, WA (Feb 02) JP-5
Fuel Apple Jelly formed in AF R-11 Refueler
JP-8 and JP-TS Fuel
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RECENT AIRCRAFT OCCURRENCES

• Air Force alert of occurrences in C-17 and
  C-9 aircraft fuel tanks, beginning NOV 00
• Heightened visibility of Apple Jelly problem
• given at Flag Officer level
• New level of urgency to solve the problem
• realized

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APPLE JELLY STUDY PROGRAM

• DESC developed plan for independent
  contractor study, coordinated with Air Force,
  December 2000
• Task awarded to Southwest Research
  Institute (SwRI), San Antonio, TX, in
  January 2000

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APPLE JELLY STUDY PROGRAM

• SwRI Project Objectives
• ? ? Determine composition or compositional
  ranges of Apple Jelly
• ? ? Determine mechanism(s) of Apple Jelly
  formation
• ? ? Manufacture Apple Jelly in laboratory
• ? ? Determine potential methods to prevent
  Apple Jelly formation in the field

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APPLE JELLY STUDY PROGRAM

• SwRI Project Overview
• ? ? Obtain samples of Apple Jelly
  from multiple sources with corresponding
  fuel
• ? ? Field investigation (C4e
  Subcontractor)
• Site visits to
• ?? Affected and unaffected bases
• ?? DESC terminals
• ?? Refineries

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APPLE JELLY STUDY PROGRAM

• C4e field investigation final report issued
  in July 2001
• Report provided detailed conclusions and
  recommendations for operational changes in
  logistics system

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FIELD INVESTIGATION SUMMARY

• Floating roof tanks and ineffective geodesic
  domes allow
• water into the fuel system
• Self-cleaning tank design found at some sites
  eases tank-
• cleaning at the expense of fuel quality
• Many of the product recovery sump-draining
  systems
• currently in use are ineffective
• Many filtration systems currently in use are
  not designed
• for additized turbine fuels
• Old DoD standard filter separator vessels and
  
• NSN4330-00-983-0998 coalescer elements
  still in use are
• ineffective in removing water from JP-8

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FIELD INVESTIGATION SUMMARY

• Some additives impact the ability of filtration
  systems to
• remove water and thus aid in the formation
  of Apple Jelly
• Additive-injection equipment and procedures
  need to be
• changed and/or updated at most affected
  locations
• The rapid increase in Apple Jelly reports
  corresponds to
• expanded use of water absorption filters in
  all AF R-11s
• during 1999-2000
• All high-viscosity (thick) Apple Jelly samples
  were found
• in sumps of R-11 F/S equipped with water
  absorption
• media cartridges and downstream of a
  water-adsorbing
• filter.

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RESEARCH FINDINGS

• All Apple Jelly contains extracts from heavy
  fuel components, and from elemental components
  in Static Dissipater Additive (SDA)
• ? ? SDA components primarily responsible
  for dark color Of Apple Jelly
• ? ? Exclusion of SDA would not prevent
  formation of Apple Jelly

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RESEARCH FINDINGS

• Thickest varieties of Apple Jelly caused by
  water absorption media materials from R-11 and
  R-9 refueler trucks
• Significant changes in maintenance of water
  and FSII are required to prevent or reduce
  Apple Jelly formation

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RECOMMENDATIONS

• Move additive injection as far forward as
  possible
• Ensure additive storage and injection
  practices are
• appropriate to provide proper additive
  mixing.
• Ensure bulk storage tank sumps are drained
  
• 1. At least weekly
• 2. Following product receipts,
• 3. Following dramatic temperature drops
• 4. Prior to product transfers.

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RECOMMENDATIONS

• Re-engineer facilities equipment and processes
  to better
• remove water and prevent water intrusion
  from outside
• sources.
• Allow settling time in storage tanks between
  product
• transfers to at least 24 hours for normal
  operations.
• ? ? For periods of surge operations,
  adequate storage
• space and inventory should be
  provided to permit a
• 6 to 12 hour settling period.

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RECOMMENDATIONS

• Find and adopt alternatives to the use Of
  water
• absorption media in the water monitors
  utilized in R-9 and
• R-11 refuelers
• Modify or replace all filter vessels built to
  
• old DoD standards with vessels conforming
  to API
• standards
• Review fuel specifications and use limits to
  determine If
• FSII and other additive limits can be
  reduced or
• eliminated.

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APPLE JELLY DRAFT FINAL REPORT REVIEW

• SwRI Draft report Issued 13 Oct 2001
• Draft reviewed by 10-member panel of
• DoD and Industry Representatives
• Final report released in March 2002

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ACTION ITEMS

• Develop plan to implement corrective actions
  recommended by
• SwRI and C4e (DESC-B within 60 days after
  release of Final
• Report)
• Review of Air Force Technical Order (T.O.)
  42B-1-1 for possible
• change in guidance to water absorption
  monitors replacement
• criteria (Air Force Petroleum Office
  (AFPET) Pending)
• Services will provide input to DESC on
  feasibility of lowering FSII
• concentration requirements at skin of
  aircraft (Services Pending)
• Services will consider permanent FSII
  specification change for
• future DESC procurements, contingent on
  systems program office
• (SPO) requirements an survey of affected
  fuel distribution
• systems (Air Force and DESC-B Pending)