BUSINESS SENSITIVE

Jerad A. Ford

Research Scientist

fordj@battelle.org

(614) 424-3266

Painting Innovations Painting Innovations

Increase Production Increase Production

and Decrease Waste at and Decrease Waste at

Hill AFB (OO-ALC)Hill AFB (OO-ALC)

BUSINESS SENSITIVE

Today’s Briefing

• Overview

• History and Scope

• Current Conditions and Requirements

• Design, Downselect and Fabrication

• Delivery, Training and start-up

• Next Steps

• Summary

BUSINESS SENSITIVE

OverviewDesign:

One-of-a-kind Portable Paint Booth Modules (PPBM) for C-130 Wheel Wells for OO-ALC/MABP

Downselect and Procure:

Off-the-Shelf Plural Component Paint Dispensing Systems (PCPDS) and paint booth modules for MABP

Procure and Implement Turn-key System

Procure, deliver, conduct training and implement booths and paint units at OO-ALC

Report:

Provide business case to justify full implementation of PCPDS

BUSINESS SENSITIVE

History and Scope

• FY2001 Battelle Completed PSOA on Painting for OO-ALC/EM (now 75th CEG / CEVC)

• Identified significant savings from installation of plural component paint dispensing systems (PCPDS), and quick curing paints

• One unit was procured for F-16 wheel well painting

BUSINESS SENSITIVE

History and Scope

• New Mindset: Building 225 transformation project – Battelle and Standard Aero

– Cellular layout (everything stays w/ the plane)

Current Paths With Proposed C-130 Repair Cell

Before1200

Scheduled Moves150

miles of travel

After100

Scheduled Moves30

miles of travel

BUSINESS SENSITIVE

History and Scope

• MABP requested design of PPBM to conduct painting of wheel wells at any time during maintenance cycle

• ASC/ENVV with Battelle Contractor Support successfully advocates for Pollution Prevention funding for FY04 to qualify PCPDS (paint) and PPBM (booth) systems.

BUSINESS SENSITIVE

History and Scope, Out of Cycle Painting– Out-of-sequence or out-of-cycle approvals are based on the Aerospace

NESHAP. These represent touch-up and repair exemptions for painting that can only be efficiently performed while the aircraft is in a disassembled state in a maintenance area outside of a paint booth.

AF wheel well

BUSINESS SENSITIVE

History and Scope, Out-of-Cycle Painting

• main and nose gear wheel wells• nose and main landing gear• flight deck• cargo floor • belly skin panels• 041 horizontal tail bracket• cockpit floor• cargo area D rings• 737 longeron• 737 bulkhead• 737 skings• flight control coves• engine and fuel panels• inside beaver tail• radome bulkhead• fire extinguisher access panels• wing tip caps• cells back of engines and corner fittings• nacelles and pylons• aircraft belly above the aft landing gear door

Sample of operating instruction for out-of-cycle painting

BUSINESS SENSITIVE

History and Scope

• C-130 Wheel Well Painting Issues– Current “line” painting is allowed in the maintenance

bays if painted area does not exceed 16 ft2, and is <15 minutes in duration

– Painting occurs on graveyard shift with out incident for most out-of-cycle painting -- do not directly impact production

– Full (NAVY) Wheel Well painting requires evacuation of maintenance area and opening of hangar doors

– Directly affects F-16 work by displacing mechanics in bldg. 225

– Lost productive man-hours on F-16 line are estimated at 1,650/yr.

– Requires extensive masking and clean up

BUSINESS SENSITIVE

WW process diagram

BUSINESS SENSITIVE

How to address C-130 WW issues

Need ability to paint Wheel Wells at any time without affecting other work, increase efficiency, and decrease waste.

Answer:– Portable, contained systems to fit right, left and nose

landing gear wheel wells

– Portable environmental control equipment capable of removing nearly all contaminants from exhaust air, including VOCs

– Incorporation of common filters for easy maintenance

– Incorporation of Alodine and rinsewater catch basin

– Select and procure COTS plural component paint dispensing equipment

BUSINESS SENSITIVE

Design, Downselect and FabricationPlural Component Paint Dispensing Syst.

• Compiled baseline of material usage

• Reviewed COTS PCPDS (paint) equipment

• Completed downselect for wheel well and other select applications

SAMPLE

BUSINESS SENSITIVE

Design, Downselect and FabricationPlural Component Paint Dispensing Syst.

• Graco ProMix Easy selectedElectronic two-part proportioning

A) Paint and B) Catalyst

Highly accurate, eliminates

rework

Easy to use and maintain

Provides estimated 90% reductions

in labor and waste paint and

75% reductions in

solvents in most cases

BUSINESS SENSITIVE

Design, Downselect and FabricationPlural Component Paint Dispensing Syst.

• Two Dedicated Graco ProBatch Units were delivered– 2-part primer

– 2-part polyurethane

• Solvent flush incorporated into system

• Portable Unit will be able to move to other maint. areas

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

• Worked directly with vendor to establish equipment design, interfaces, filter requirements, etc.

Environmental Control Module

Concept

1st stage

2nd stage

3rd stage

NESHAP

(12) 24x24x4”Carbon Cells

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Nose Landing Gear Wheel Well Booth

Concept

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Main LandingGear Wheel

Well Concept

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Main Landing Gear Booth

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Nose Landing Gear Booth•Fits contour of C-130 nose•Same features as main landing gear wheel well booth

Nose Well

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Environmental Control unit

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

PPBM Key Features– COTS Explosion Proof Lighting

– Tailored Alodine and Rinsewater Catch Basin

– Integrated Pre-Filter Wall, using COTS filters

– COTS hand jacks to raise booth into place

– Portable and towable

BUSINESS SENSITIVE

Design, Downselect and FabricationPortable Paint Booth and Env. Modules

Environmental Module Key Features– Activated Carbon Filters to capture all VOCs, calculated to

treat 3 sets of wheel wells before regeneration

– 3-stage NESHAP filters

– Load adjusting fan to compensate for filter loading

– Independent Magnehelic® gauges for measuring pressure drop across filters

– Integrated infrared gas monitor measuring highest constituent VOC of effluent, with audible alarm

– Portable and towable

BUSINESS SENSITIVE

Delivery, Training and start-up

• Units were delivered on 21 MAR 2005 to Hill AFB

• Training was conducted in conjunction with equipment vendors on 24 MAR, for both painting and booth equipment

• Estimated start-up: 4 APR 2005

BUSINESS SENSITIVE

Summary of WW business case

BUSINESS SENSITIVE

Summary of full Implementation of PCPDS/PPBM on C-130

BUSINESS SENSITIVE

Next Steps

• Recently completed update to Business Case for (a) C-130 Wheel Well and (b) implementation on C-130 Hangar and small parts painting

• Generate final report

• Initiate talks to procure more systems across C-130 painting operations, as part of transformation

BUSINESS SENSITIVE

Next Steps

Address the current blast booth process, and design equipment based on current as-built drawings for paint booths

BUSINESS SENSITIVE

Questions?