WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
DEFENSE LOGISTICS AGENCY
AMERICA’S COMBAT LOGISTICS SUPPORT AGENCY
Quality Challenges
Associated with
Future Fuels
Rodney Fischer,
Defense Logistics Agency Energy
Chief of Quality Operations
May 2012
WARFIGHTER SUPPORT
STEWARDSHIP EXCELLENCE
WORKFORCE DEVELOPMENT
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Defense Logistics Agency Energy
In support of DLA’s mission, provide the Department
of Defense and other government agencies with
comprehensive energy solutions in the most
effective and efficient manner possible.
Mission:
Vision:
Values:
Warfighter-focused, globally responsive, fiscally
responsible supply chain leadership
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Warfighter needs guide us
Integrity defines us
Diversity strengthens us
Excellence inspires us
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
OVERVIEW
• Alternative fuels
• Specific quality concerns
• Some lessons learned
• Jet A conversion
• Particle counter field test
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Alternative Energy Drivers
• Energy independence
• Compliance with environmental regulations
• Reduce carbon footprint
• Minimize green house gas emissions
• Meet customer requirements
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
HRJ5 / HRJ8 / HRF76
Hydrotreated Renewable Fuels – The feedstock is defined
as esters or fatty acids, which have undergone deoxygenation
and subsequent hydroprocessing/isomerization into
hydrocarbon fuels. HR fuels that have been procured were
derived from camelina, algal, waste (yellow grease) oils and
tallows. HR fuels may be blended up to 50 percent with
conventional hydrocarbon fuels and meet JP8/JP5/F76
specification.
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
HR Quality Specifications
• HRJ5 – Procured to local specification
– To be added to next revision of MIL-DTL-5624
• HRJ8 – Procured to local specification
– Recently added as Appendix B of MIL-DTL-83133
• HRF76 – Procured to local specification
– To be added to MIL-DTL-16884 in 2013
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Storage Tank Prep to Receive
HRJ5 / HRJ8 / HRF76
• Mild caustic wash, if warranted, mild enough to not harm
epoxy coating
• No detergents
• After caustic minimum of two fresh water rinses validated
by pH comparison with the stock rinse water
• Tank and associated pumps and lines must be blown
completely dry. Nitrogen is preferable but air is
acceptable--if nitrogen used, no positive pressure need
be remaining inside compartment, however nitrogen
should not be purged with air after
• Offered tank requires inspection and acceptance by
government inspector
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Tank Truck Cleaning Procedures
HRJ5 / HRJ8 / HRF76
(Condensed Composite Table)
LAST PRODUCT CARRIED
PRODUCT CLEANING PROCESS
TO BE
LOADED
JP4, JET B, MOGAS, GASOHOL,
AVGAS, JP5, JP8, JET A/A1, F76,
MGO, JPTS – Other normal
hydrocarbon fuels
HR fuel
Hot water flush, steam, air blown,
nitrogen purge leaving 5 psi residual
pressure in tank compartments
Methanol, Ethanol, Isopropanol
HR fuel
Hot water flush, steam, air blown,
nitrogen purge leaving 5 psi residual
pressure in tank compartments
Ethylenediamine (EDA) (5),
HR fuel
Ethylamines (5), Hexamines (5),
Methylamines (5) – Other similar
-amines.
Caustic wash, Hot water flush, steam,
air blown, nitrogen purge leaving 5 psi
residual pressure in tank compartments
(1) When required, drain and empty includes the pump(s), filter(s), meter(s), and hose(s) as applicable.
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Fischer-Tropsch Synthesized
Paraffinic Kerosene
Fischer-Tropsch Synthesized Paraffinic Kerosene–
Hydrocarbon molecules in the fuel are synthesized from
hydrogen and carbon monoxide
– Fischer-Tropsch processes developed by Germans during
WW II to make gasoline from coal
– Modernized in South Africa by Sasol
• Feedstocks include
– Coal
– Biomass
– Natural gas
• Hydroprocessing/isomerization is the means of synthesis
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Storage Tank / Issue System
Fischer-Tropsch Synthesized Paraffinic Kerosene
• Refinery tankage must be dedicated to FT IPK
• Piping from FT process to storage tank must be
dedicated
– OR have the ability to be flushed so that there is minimal
product carryover
• Piping, manifold and pump from storage tank to container
loading point must be dedicated
– OR have the ability to be flushed so that there is minimal
product carryover
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Intermodal Container
Requirements for FTSPK
• Container must be stainless steel or aluminum intermodal
container
• Transport vessel must be steam cleaned and dry such
that no residue of the previous cargo is left on the interior
of the container including piping
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Alcohol to Jet
Alcohol to Jet – As the words imply jet fuel is derived
from alcohol. The alcohol has undergone a dehydration
process followed by oligomerization into jet fuel range
hydrocarbons and subsequently hydro-processed. The
current contract is for 11,000 gallons; 10,000 gallons of
the alcohol can come from any source and the remaining
1,000 gallons of alcohol had to come from the
fermentation of biomass.
R&D quantity awarded FOB destination to Wright-Pat
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Storage Tank / Issue System
Alcohol to Jet
• Refinery tankage must be dedicated to ATJ
• Piping from ATJ process to storage tank must be
dedicated
– Or have the ability to be flushed so that there is minimal
product carryover
• Piping, manifold and pump from storage tank to container
loading point must be dedicated
– Or have the ability to be flushed so that there is minimal
product carryover
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Intermodal Container
Requirements (ATJ)
• Container must be stainless steel or aluminum intermodal
container
• Transport vessel must be steam cleaned and dry such
that no residue of the previous cargo is left on the interior
of the container including piping
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Inspection Impact
• Increased surveillance of contractor receipt system,
storage tanks and issue system
• Increased surveillance of contractor intermodal
container/truck loading
• Site visits to receiving activities to assess ability to
receive and store the alternative fuel
• Increased customer assistance visits
• Inspection footprint will shrink after R&D phase
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Biodiesel/E85
• Biodiesel refers to vegetable oil or animal fat-based
diesel fuels consisting of long-chain alkyl esters
– Blend (B6 to B20) refers to biodiesel component
to conventional diesel fuel
– Biodiesel conforms to ASTM D6751
– The middle distillate diesel component in accordance
with ASTM D975
– FAME is biodiesel that is made from various animal
fats and tallow
• E85 is an abbreviation for an ethanol fuel blend of
up to 85 percent denatured ethanol fuel and
gasoline
– Procured against ASTM D5798
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Puerto Rico
• FAME contamination in marine gas oil
– Numerous U.S. Coast Guard Cutters affected
– FAME content: 3–20 percent
– FAME traced back to PR Main Distribution Terminal
• Currently, all delivery receipts are tested for FAME
contamination
• USCG established acceptable FAME limit: <1 percent
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
FAME Contamination
In Jet Fuel
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Emerging problem influenced by BioD mandates
Max allowed in jet fuel is five ppm
Move to allow 100 ppm progressing slowly
Euro pipe entry points require FAME-free cert.
• Protects aviation fuel in pipe from trail-back
• Introduced by transport conveyance not production
Quality Surveillance procedures adjusted to include EI
HM50 FAME last carried rules for vessels
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Washington, D.C.
• Winter conversion from ultra low sulfur diesel to B20
– Entire GSA diesel fleet affected to include all emergency
response vehicles
– B20 failed to meet specification in accordance with ASTM
D7467
– All nine dispensing locations experienced massive filter
plugging
• Currently, the District has suspended the use of
B20 pending further study
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Columbus Air Force Base, Miss.
• B20 vehicle filter plugging
– Bio-diesel component contained animal fat
– Source traced back to supplier
– Installation is in the process of flushing B20 from the
system
• Installation converted back to ULSD in-lieu-of
B20 until the bio-diesel component issues could
be resolved
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Fort Campbell, Ky
• E85 contained high concentrations of silicon
– Entire GSA Flex-fuel fleet affected
– All mechanical failures were post combustion
– Source of the silicon traced back to the motor
gasoline fraction
– Silicon levels ranged from 9 – 32 ppm
• Currently, the automotive industry does not have
a specification standard for silicon
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Lessons Learned
• E85 performs poorly in stationary equipment/vehicles
• E85 storage must be continually monitored for water
• Gasoline containing greater >10 percent ethanol is not
recommended for use in marine environments
• Bio-diesel has a very limited shelf (<four months?)
• Bio-diesel is NOT recommended for use in essential and
emergency response vehicles
• Bio-diesel is NOT recommended for marine use
• Both E85 and bio-diesel require an increased level of
monitoring and housekeeping to ensure serviceability
• FAME contamination in marine gas oil impacts vessel
operational readiness--current USCG limit < 1 percent
• ISO DMA 8217 and future F76 spec specifies 0.1 percent max
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
The Transition
JP8 to JET A
Why Switch?
• To increase the number of potential suppliers
• Lower cost
• Decrease time to receive / move to a location
• Increase flexibility in coverage
Differences in the fuel?
• JP8 is Jet A1 with specific additives
• Freeze point (Jet A1: -47C, Jet A: -40C)
• AO is optional in Jet A
• JP8 procured to MIL-DTL-83133/Jet A to ASTM D1655
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Commercial versus Military
Additives
• Additives (FSII, CI, SDA) – military customers will continue
to require additives in Jet A
• Additive injection will shift from refiner to defense fuel
support point
• If no intermediate DFSP is involved in shipment will require
the supplier to inject additives
• Installation of additive storage and injectors at DFSP
• Increased quality oversight of additive injection process
• Manage additive bulk inventories
• Reduced FSII injection ratios?
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
U.S. Army: expected completion 1st quarter fiscal 2013
• One year study, preparation for change
• All tanks and equipment must be marked for Jet A with
additives with accepted nomenclature
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
U.S. Navy:
Freeze Point Study:
• Determine any concerns changing to Jet A
• Expected completion: 1st quarter fiscal 2013
Peroxide Testing:
• DLA issued a joint Quality Assurance Advisory Pearl
Harbor, Puget Sound, San Pedro, Yorktown
• Test peroxide content via ASTM D3703
– Initial Jet A fill, every six months, for two years
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Future providers
• How will the supply chain differ?
• Current plans based on present award patterns
• Intermediate storage locations – do we need them all?
• Modes of transportation to be used?
• Pipeline shipments become fungible
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Example: Inland-East Jet A
• Fiscal 2011 (11-R-0061): Awarded 54,180,000 U.S. gallons
• Fiscal 2012 (12-R-0061):Requirements for 281,690,000 U.S.
gallons
• And so it begins….
Where:
• DFSP Charleston, S.C.– Charleston Air Force Base
• Laughlin Air Force Base, Dyess AFB, Lackland Air Force Base
• Ellsworth Air Force Base, Sheppard Air Force Base
• McEntire Air National Guard, Travis Field, Shaw Air Force Base
• DFSP Vancouver, Fairchild Air Force Base, Portland Air
National Guard, Kingsley Air National Guard
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Particle Counter
• Automatic Particle Counter has been a Report Only
requirement since Def Stan 91-91 Issue 6, 2008 and MILDTL-83133G Amend 1, 2011
• MIL-DTL-5624 will adapt automatic particle counters in
the newer version
• IP 564, IP 565 & IP 577 are approved methods
– These methods are based on the laser obscuration
technology
• No PC specification limits have been established
• MIL-DTL-83133G has note requesting PC results be
submitted to AFPA for data collection
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Benefits of PC Field Test
• Evaluate and map the particle/water contamination level
of aviation fuel throughout the Class IIIB supply chain
– Primarily at the DFSP and military bases
– Pipelines, delivery truck, storage tank, refueling vehicles, filter
separator, tactical dispensing equipment
– Identify critical contamination points, effectiveness of quality
assurance program, etc.
• Evaluate the efficiency and effectiveness of the filters
(separators, element change out), tank cleanliness, and
settling time
• Upon deployment to the field, it will provide immediate
results without being constrained by the limitations of the
visual and gravimetric method
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
DoD Fuel Supply Chain
PC Field Test
From the AF Presentation
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Program Details
PC Field Test
• DLA Energy funds and manages the program
• Participating members: DLA Energy, Air Force, Navy,
and Army
• Testing will be performed at 10 high volume sites
in the continental U.S. including aircraft carriers
using three approved testers
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DFSP Tampa
DFSP San Pedro
Dover AFB
Barksdale AFB
Holloman AFB
Whiteman AFB
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Patuxent River NAS
Jacksonville NAS
Camp Pendleton MCB
Hunter AAF
Rucker AAF
Navy Aircraft Carriers
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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP
Questions?
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