Jerad A. Ford
Research Scientist
fordj@battelle.org
(614) 424-3266
Painting Innovations
Increase Production
and Decrease Waste
at 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
Overview
Design:
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 OOALC/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)
Before
1200
Scheduled Moves
150
miles of travel
After
100
Scheduled Moves
30
miles of travel
Current Paths
With Proposed C-130 Repair Cell
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
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main and nose gear wheel wells
Sample of operating instruction for out-of-cycle painting
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
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 Fabrication
Plural Component Paint Dispensing Syst.
• Compiled baseline of material usage
• Reviewed COTS PCPDS (paint) equipment
• Completed downselect for wheel well and other
select applications
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Plural Component Paint Dispensing Syst.
• Graco ProMix Easy selected
Electronic 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 Fabrication
Plural 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 Fabrication
Portable Paint Booth and Env. Modules
• Worked directly with vendor to establish equipment
design, interfaces, filter requirements, etc.
Environmental
Control Module
Concept
NESHAP
1st stage
2nd stage
3rd stage
(12) 24x24x4”
Carbon Cells
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Portable Paint Booth and Env. Modules
Nose Landing
Gear Wheel
Well Booth
Concept
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Portable Paint Booth and Env. Modules
Main Landing
Gear Wheel
Well Concept
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Portable Paint Booth and Env. Modules
Main Landing Gear Booth
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Portable 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 Fabrication
Portable Paint Booth and Env. Modules
Environmental Control unit
BUSINESS SENSITIVE
Design, Downselect and Fabrication
Portable 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 Fabrication
Portable 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?
BUSINESS SENSITIVE