OGISLTECHMaintenance Affordability andMaintenance Affordability and

Readiness Improvements throughReadiness Improvements through

Maintenance Equipment and Processes “Great Ideas” Competition

Jim Martin

2002DoD MaintenanceSymposium & Exhibition

Asset Redistribution andAsset Redistribution andCorrosion PreventionCorrosion Prevention

• Sandia National Labs reports: Corrosion is the leading cause of Weapon Stockpile Degradation

• Atmospheric Corrosion is the most prevalent form of corrosion for weapon systems and military equipment• Prevention always costs < correction.

Corrosion costs U.S. DoD> $20 Billion per year1

Corrosion costs U.S. DoD> $20 Billion per year1

1 Koch, G. H. (2001). Corrosion Costs and Preventive Strategies in the United States, CC Technologies Laboratories, Inc. for the Federal Highway Administration

You can modify the equipment…or change the atmosphere

You can modify the equipment…or change the atmosphere

• Technical effectiveness of CHP• DoD policies on CHP• How & where CHP is applied• Financial benefits of CHP• Optimizing resources to match requirements

Changing the atmosphere throughControlled Humidity Protection (CHP)Changing the atmosphere through

Controlled Humidity Protection (CHP)

In the U.S. the Relative Humidity exceeds 50% over 90% of the time.

Above 50% Relative Humidity (RH)the rate of corrosion is exponential1Above 50% Relative Humidity (RH)

the rate of corrosion is exponential1

Mild Steel

Aluminum

Exposure at 30°C and40% RH 60% RH 80% RH

1 Vernon, W. H. J. (1926). Second experimental report to the Atmospheric Research Committee, British Non-ferrous metals Research Association.

% Relative Humidity0 25 50 75 100W

eigh

t los

s, g

ram

s

Rate of corrosion1

Controlled Humidity Protection (CHP)Controlled Humidity Protection (CHP)

Steel

Non Ferrous

Gold Contacts

Wire Insulation

Molds & Mildew

Lower Limit 30 % RH Upper Limit 40 % RH

0 10 20 30 40 50 60 70 80 90 100% Relative Humidity

Good Marginal PoorLevel of Protection:

Elastomers Gua

rant

eed

perf

orm

ance

Controlling RH reduces the electrolyte (moisture) and mitigates salts’ effects

Controlling RH reduces the electrolyte (moisture) and mitigates salts’ effects

Comparison of both engines of a twin-engine aircraft.“DH” = Operational Dehumidification

Corroded Compressor BladesCorroded Compressor Blades

0 20 40 60 80 1000

0.40.60.81.0

0.2

Relative Humidity (%)

Rel

ativ

e R

ate

Electronic Failures2

Con

trol

led

Hum

idity

Pr

otec

tion

2Sandia National Laboratories

20% of electronic failures arecaused by moisture induced corrosion1

20% of electronic failures arecaused by moisture induced corrosion1

“even in MILSPEC conformal-coated

hermetically sealed parts”1

1USAF, WPAFB, SBIR AF97-172

Humidity changes insulation resistanceHumidity changes insulation resistance

3

4

5

6

7

8

9

10

11

12

13

14

15

0 20 40 60 80 100

% Relative Humidity

10101010101010101010101010

Resistance in Ohms

PVC

Nylon

CH

P ra

nge

• Reduced insulating values can cause faulty signals in wiring harnesses.

• Navy/USMC aviation organizational level maintenance expends2 million man-hours each year to troubleshoot and repair corrosion-related aircraft wiring problems.

Mold and Bacteria attackMold and Bacteria attack

0

20

40

60

80

100

120

0 20 40 60 80 100% Relative Humidity

Tem

pera

ture

(ºF

)

3

21

0.1StartC

ontr

olle

d H

umid

ity P

rote

ctio

n

Values indicate growth rate in

millimeters per day

Cyclic maintenance is deferred--the “clock stops” in Sheltered CHP*

Cyclic maintenance is deferred--the “clock stops” in Sheltered CHP*

1. All Components are Protected2. Equipment Readily Available3. No Pre-or-Post Preservation Requirements

*Joint Service Manual for Storage & Materials Handling:• DoD 4145.19R• DLAM 4145.12• TM 38-400• MCO 4450-14• NAVSUP PUB 572• AFJMAN 23-210

OPNAVINST 4790.2

“All scheduled inspections may be deferred until the aircraft is removed from preservation.”

“Dehumidification is the preferred method of preservation.”

TECHNICAL MANUAL

MAINTENANCE INSTRUCTIONS(ORGANIZATIONAL ANDINTERMEDIATE LEVELS)

SUPPORT EQUIPMENTCLEANING,

PRESERVATION, ANDCORROSION CONTROL

NAVAIR 17-1-125

9-19. Level III Preservation Procedures-Dehumidification (0-

Indefinite).

TECHNICAL MANUAL

ORGANIZATIONAL,INTERMEDIATE AND

DEPOT MAINTENANCE

PRESERVATION OFNAVAL AIRCRAFT

NAVAIR 15-01-500

Chapter 6 - Environmental ControlSection IV - Dehumidification

Installation

Controlled Humidity ProtectionControlled Humidity Protection

Humidistat

Monitoring, Control, Data LoggingDesiccant Wheel Dehumidifier Process Cycle

30 to 40% RH

Desiccant Wheel DehumidifierDesiccant Wheel Dehumidifier

10% RH Air

Heater

Fan

8 rev per hourDesiccant W

heel

Humid Ambient Air

Damp AirFan

Humid Ambient Air

Process Air Cycle

Regeneration Air Cycle

Over 975 Controlled Humidity Protection Systems206 sites in 42 States and 9 overseas locations

Over 975 Controlled Humidity Protection Systems206 sites in 42 States and 9 overseas locations

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CurrentFuture

CHP Sites!

• Greece• Spain• Germany

• Japan• Bahrain• Qatar

• Guam• Puerto Rico• Virgin Islands

3,000,000 s.f. sheltered, and 3720 vehicles OP/individual CHP

Diurnal Relative Humidity (annual average)

30

40

50

60

70

80

90

1:00 4:00 7:00 10:00 13:00 16:00 19:00 22:00Time of Day

Per

cent

Rel

ativ

e H

umid

ity

Huntsville AL Ft. McPherson GA Ft. Campbell KY Ft. Bragg NC Ft. Hood TX

The “Clock Stops” on the Periodic Maintenance inspection cyclefor equipment in the Controlled Humidity Protection (CHP) range

Exponential corrosion rate above

50 %

Rel

ativ

eH

umid

ity

Equipment Dehumidification

Single Vehicle Dehumidification

Aircraft Dehumidification

Government confirms ten-year CHP8:1 ROI is conservative

Government confirms ten-year CHP8:1 ROI is conservative

DoD IG, Army CEAC, GAO DoD IG, Army CEAC, GAO -- analysis of CHP:analysis of CHP:•MTBF for electronics improved 30%•Maintenance times reduced up to 50%•ROI less than 1.5 years

DSMC guide to material acquisition:DSMC guide to material acquisition:“Reducing the effects of humiditycan reduce electronic failures 22%.”

Naval Air Systems Command EPNaval Air Systems Command EP--3 analysis:3 analysis:•Avionics reliability improved 25%•I-level labor reduced 40%•Depot level labor reduced 26%•ROI 6 to 9 months

• Equipment maintenance reduced by 80 %.• Hazmat and hazwaste reduced by 74 %.• Increased equipment availability.• Qualified Pollution Prevention Equipment

Program (PPEP) technology.• N45 funds CHP equipment and installation for

fleet units.

Navy Environmental Leadership Program: NAWC-AD Lakehurst NELP study results

Navy Environmental Leadership Program: NAWC-AD Lakehurst NELP study results

www.lakehurst.navy.mil\p2\docs\fr\265.htm www.lakehurst.navy.mil\p2\docs\fr\265.htm

• 392 items of Aviation Support Equipment1:-- 535 man-hours in normal conditions-- 8 man-hours on CHP (98% reduction)

• 201 items of Aviation Support Equipment2:-- $183,831 savings in first year-- 8-year savings of $1,624,530 projected

U.S. Marine Corpsannual Preventative Maintenance savings

U.S. Marine Corpsannual Preventative Maintenance savings

1MALS-292MALS-14

1/203 Air Defense Battalion, PATRIOTAlabama Army National Guard

1/203 Air Defense Battalion, PATRIOTAlabama Army National Guard

FY 1999 before CHP: $ 1,516,950FY 2000 after CHP: $ 1,024,21032 percent reduction in cost of

Electronic Components

Multiple Launch Rocket System (MLRS)Florida Army National Guard

Multiple Launch Rocket System (MLRS)Florida Army National Guard

• Top ten cost drivers (OSMIS) for battalion of 18 MLRS:from $ 413K in 1999 before CHPto < $ 92K in 2000 (78% reduction)

• Launcher LRU's accounted for over 50% of 1999 repair parts cost. There were zero demands for LRU's in 2000.

If these results were achieved for all 643 MLRS systems in the Army,

potential savings exceed$11 million per year.

Army National Guard Actual

$8,5

48,7

04

$9,8

49,0

20

$6,7

88,8

12

$7,6

94,9

63

$9,8

43,1

41

$3,4

35,1

27

$7,9

03,8

08

$8,9

52,0

44

$-

$50,000,000

$100,000,000

$150,000,000

$200,000,000

$250,000,000

1995 1996 1997 1998 1999 2000 2001 2002est

CHP Investment and Operations Maintenance Avoided

Army Reserve Potential

$-

$50,000,000

$100,000,000

$150,000,000

$200,000,000

$250,000,000

$300,000,000

$350,000,000

2003 2004 2005 2006 2007 2008 2009 2010 2011

CHP Investment and Operations Maintenance Savings

Brings 37 % of equipment up toFully Mission Capable “10/20” standard

and places on CHP

$340K

ARNG & USAR Cumulative

$-

$1,000,000,000

$2,000,000,000

$3,000,000,000

$4,000,000,000

$5,000,000,000

19

95

19

96

19

97

19

98

19

99

20

00

20

01

20

02

20

03

20

04

20

05

20

06

20

07

20

08

20

09

20

10

20

11

Maintenance Savings CHP Investment & Operations

!Mitigate the effects of reduced military manpower!Reduce maintenance backlogs!Reduces the logistics footprint!Compensate for the effects of OPTEMPO funding reductions!Enhance readiness by protecting FMC equipment!Enhance training, mobilization and deployment!Environmental no-brainer

Billions in savings await action Billions in savings await action

Capitalizing on Controlled Humidity Protectionthrough Asset Redistribution

Capitalizing on Controlled Humidity Protectionthrough Asset Redistribution

Web-based asset redistribution modeling optimizesresources to requirements: Reducing Logistics Footprint

and lowering Total Ownership Costs

REQUIRED

100% of personnel

100% of assets 50% of assets

50% of personnel

~ 30% of repair parts

50% of assetson CHP

THE CHP ADVANTAGE

100% of assets

50% of personnel

ACTUAL