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Fighter of Choice!
F-16 System Program Office
1
F-16 Program Management TeamEnvironmental Program
Fighter of Choice!
F-16 Systems Group
Mary Wyderski F-16 Systems Group
Environmental Program Manager9 September 2005
2
Overview
• F-16 Program
• F-16 Environmental Program Network / Charter
• F-16 Environmental Working Group
• F-16 Environmental Program Management Team (PMT)
• F-16 Environmental PMT Initiatives
3
Overview
F-16 Program
• F-16 Environmental Program Network / Charter
• F-16 Environmental Working Group
• F-16 Environmental Program Management Team (PMT)
• F-16 Environmental PMT Initiatives
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F-16 Key Players
F-16 PROGRAM
PARTNERSHIP
Aircraft CompositionCFE GFE65% 35% ($ Ratio)75% 25% (Item Ratio)
Over 4000 Aircraft Built24 Countries10 Major Blocks
Edwards AFB416 FLTS
508th Fighter Sustainment Group -DepotLanding Gear, Photo,Avionics, Structures,Weapons/Air Munitions, Trainers & Simulators,Pneumatics, Hydraulics,Electro/Mechanical SE,Flight Controls
F16 SG508 FSG F16SG
Major Contractors /SubsGeneral Electric (OH) Engine
Litton (OR) APX-109Lockheed Martin Corp.
LM Aero (TX)Fairchild Sys (NY)Elect Def Sys (NY)
Luminescent Sys (NY) NVISNorthrop GrummanESSD (MD) RADAR
Pratt & Whitney (CT) EngineSymetrics (FL) IDM
Eglin AFB53 Wg/46TW
Oklahoma City-ALCEngines, Aircraft & Engine Accessories, Aircraft Harness/Cable
ASCTraining Sys
TucsonAMARCAATC
Nellis AFB422 TES LM Aero
Prime ContractorCFE
Warner Robins-ALCLANTIRN, Common AvionicsECM, Life Support,Power Conditioning Equip,Generators, ATE
DLA (HQ)Inventory Mgt
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Overview
• F-16 Program
F-16 Environmental Program Network / Charter
• F-16 Environmental Working Group
• F-16 Environmental Program Management Team (PMT)
• F-16 Environmental PMT Initiatives
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F-16 Environmental Network
• Charter
• To create an environmental assistance resource infrastructure for F-16 users, maintainers and other weapon system stakeholders
• Enviromental points of contact from each Major Command to represent and coordinate activities for users
• Purpose
• To create a forum to ensure processing of information is timely,complete, and consistent, from the Program Management Team to Users and vice versa.
• Environmental Working Group provides avenue to address concerns of the Network
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Overview
• F-16 Program
• F-16 Environmental Program Network / Charter
F-16 Environmental Working Group (EWG)
• F-16 Environmental Program Management Team (PMT)
• F-16 Environmental PMT Initiatives
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F-16 Environmental Working Group
F-16 Environmental
Team
HQ ACC
HQ
AETC
HQ ANG
Lockheed
OO
-ALC
Depo
t
HQ
USA
FE
HQ
PAC
AF
HQ
AFRC
Portugal
User
Use
r
User
User
User
ProducerDepot Maint.
User
User
User
Netherlands
User
User
Belgium
EPG
s
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F-16 Environmental Working Group (EWG)
• F-16 EWG meets annually in various locations
• 2005 EWG held 17-19 May at Nellis AFB, Nevada
• 26 participants, representing F-16 Systems and Sustainment Groups, depot, using commands and bases, LM Aero, Portugal, Netherlands, F-15 weapon system
• Primary objective: Crossfeed of information by F-16 stakeholders to share common issues and solutions
• F-16 EWG conducts telecon annually Nov–Dec timeframe
– 2005 telecon to be held October 2005
• 2006 EWG to be held February 2006 at Shaw Air Force Base, South Carolina
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F-16 Environmental Working Group (EWG) (cont.)
Sample of Agenda Items from May 2005 EWG
• Nellis Air Force Base Tour
• F-16 Program Management Team Initiatives
• F-16 Propulsion Environmental Initiatives
• LM Aero Environmental Projects and F-16 Tech Order Initiatives
• Lead Free Solder
• Boeing Lead Free Electronics & Beryllium Project Update
• F-16 Environmental Issues Update
• OSHA Chromium Standard Update
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F-16 Environmental Working Group (EWG) (cont.)
Sample of Agenda Items from May 2005 EWG (cont)
• Gaseous Oxygen Cart Cleaning System Update
• Hill AFB & Shaw AFB & Nellis AFB Environmental Initiatives
• Royal Netherlands Air Force
• Hazardous Waste Compaction
• Crashed F-16 Disposition Process
• JP-8 Toxicology Study Results
• Cross-Feed/Lessons Learned, etc
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Overview
• F-16 Program
• F-16 Environmental Program Network / Charter
• F-16 Environmental Working Group
F-16 Environmental Program Management Team (PMT)
• F-16 Environmental PMT Initiatives
F-16 Environmental Program Management Team (PMT)
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• Team Members:
• F-16 Systems Group, F-16 SG/EN
• Mary Wyderski
• “Acquisition” Environmental Program Management
• F-16 Sustainment Group, 508 FSG/GFFBS
• Paul Hoth
• “Sustainment” Environmental Program Management
• Lockheed Martin Aeronautics (LM Aero), Jerry Brown
• Provide guidance/advice to F-16 users, maintainers, stakeholders
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Overview
• F-16 Program
• F-16 Environmental Program Network / Charter
• F-16 Environmental Working Group
• F-16 Environmental Program Management Team (PMT)
F-16 Environmental PMT Initiatives
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F-16 Environmental Team Initiatives
• Programmatic Environmental, Safety and Health Evaluation (PESHE)
• Hazardous Material Reduction Program
• Seeking continued LM Aero Environmental, Safety and Health (ESH) support
• Disposal, Deactivation and Demilitarization Plan
• Pollution prevention initiatives
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F-16 Programmatic Environmental, Safety And Health Evaluation
•l Programmatic Environmental, Safety and Health Evaluation (PESHE) document
• Prepared / maintained by F-16 Environmental Team
• Provides guidance for management of ESH program with focus on five primary areas
• Environmental compliance
• Hazardous Material Management
• Pollution Prevention
• National Environmental Policy Act (NEPA)
• Occupational Safety and Health Five primary areas
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F-16 Programmatic Environmental, Safety And Health Evaluation (cont.)
• Additional details of PESHE
• Provides guidance for entire life cycle of F-16 weapon system - production through disposal
• Focuses on risk assessment for decision making
• Provides guidance for environmental program enhancements
• Describes Environmental Working Group, Network and Monitoring System
• Environmental Monitoring System helps to ensure ESH is considered through all phases of weapon system
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Hazardous Material Reduction Program Hazardous Material Reduction Program
• Accomplished by LM Aero, funded by F-16 Systems Group • Began July 1996, ended February 2002
• Goal - identify, test, and qualify substitutes for hazardous • F-16 manufacturing processes• F-16 maintenance and repair procedures
• Driven by U.S. Department of Defense requirement to reduce hazardous materials• Ozone Depleting Compounds (ODCs)
• Hazardous Air Pollutants (HAPs)
• Volatile Organic Compounds (VOCs)
• High vapor pressure solvents
• Low permissible emission limit (PEL) materials
Hazardous Material Reduction Program (cont)
Tasks
Hazardous Material Reduction Program (cont)
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TasksNonchromated SealantsNonchromated CoatingsMiscellaneous Solvents Cadmium Plating
Replacement High VOC Coatings
Replacement Dot Stencil InkDepainting
Solid Film Lubricant Nonchromated DeoxidizersNonchromated Prebond EtchantNonchromated Conversion CoatingPrimer for FMS-3049HazMats & Obsolete Materials
in Technical Orders
Following tasks not yet completed:
F-16 Hazardous Material Database
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Hazardous Material Reduction Program (cont)
Hazardous Material Reduction Program (cont)
• Hazardous material replacements in Technical Orders
• LM Aero identified alternative maintenance chemicals for F-16 • Cleaners• Lubricants
• Adhesives
• Pretreatments
• Coatings
• Specialty Products
• Also, worked cancelled specifications and obsolete chemicals
• Over 500 materials, 30,000 applications, 1682 Technical Orders effected
Hazardous Material Reduction Program (cont)
Hazardous Material Reduction Program (cont)
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• Hazardous material replacements in Technical Orders (cont)
• Replacements added to Technical Orders during digitization of Organizational level books• Completed October, 2004
• Recommendations also made for most of Intermediate and Depot level books• No incorporation funding available• If digitization effort occurs, will try to incorporate then
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Hazardous Material Reduction Program (cont)
Hazardous Material Reduction Program (cont)
• Hazardous material replacements in TechnicalOrders (cont)• Replacement strategy
• Attempt to select replacements that will offer maximum flexibility to the field
• e.g. ability to select solvent that best meets location’s need
• Attempt to reference materials already in use when possible
• desire to minimize required specialty chemicals
• Do not change chemical if technology has not yet arrived
• e.g. nonchromated primers
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Hazardous Material Reduction ProgramRelated Projects and Needs (cont)
• Nonchromated flex primer for F-16 outer mold line
• Nonchromated reactivation primer for ballistic liner coating
• Low volatile organic compound fuel tank coating
• Nitrile phenolic primer
• Non-lead solid film lubricants
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LM Aero Environmental, Safety and Health Support
• F-16 Environmental Team is seeking continued LM Aero Environmental, Safety, and Health support
• Including sustainment of Technical Order and hazardous material databases developed under Hazardous Material Reduction Program
• Hazardous material database needed for safe disposal and crash recovery investigations
• Technical Order database useful for hazardous material replacement implementation
• F-16 Sustainment Group recently secured funds for further completion of hazardous materials database
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F-16 Disposal, Deactivation, and Demilitarization Plan
• Disposal, Deactivation, and Demilitarization Plan is being prepared by F-16 Sustainment Group
• Provide guidance for safe and economical disposal of F-16 aircraft and components.
• Hazardous materials database will be part of plan
• Database also useful for crash recovery investigations and clean up actions
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F-16 Pollution Prevention Initiatives
• F-16 Environmental team maintains involvement/cognizance of pollution prevention initiatives managed by several organizations:
• Joint Group for Pollution Prevention (JG-PP)
• Air Force Research Laboratory (AFRL)
• ASC/ENVV (Pollution Prevention Branch)
• Air Force Petroleum Office (DET 3, WR-ALC/AFFT)
• AF Plant #4 Integrated Product Team
• Environmental Security Technology Certification Program
• Other weapon system programs
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F-16 Pollution Prevention Initiatives
• Monitoring Hydrazine replacement efforts • Hydrazine is used to start F-16 Emergency Power Unit
• Hydrazine is one of the top three F-16 ESH hazards• Carcinogen
• Considered extremely Hazardous Substance under U.S. Environmental Regulation
• Continually a User top concern item
• Past efforts to identify a replacement have been unsuccessful
• F-16 Environmental Team continually seeks a cost effective replacement
F-16 Pollution Prevention Initiatives (cont)
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• Monitoring Hydrazine replacement efforts (cont)
• Small Business Innovative Research proposal activity• Phase I effort yielded potential replacement
• Phase II effort kickoff meeting 17 Nov 04• Develop / demonstrate components of an environmentally
benign system for Emergency Power Unit
• Develop detailed plan for prototype and identify potential infrastructure issues
• Pending favorable results, F-16 Environmental Team would seek funding:
• Program for system integration and qualification
• Retrofit by USAF and potentially all F-16 users.
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General Arrangement
Nitrogen Bottle
Hydrazine Tank
Nitrogen Valve
Fuel Control ValveTurbine Power Unit
Bleed Air Control Valve
Turbine Exhaust (underside)
Ground Service Connector (underside)
Controller (underside)
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F-16 Pollution Prevention Initiatives (cont.)
• Pollution Prevention Projects managed by F-16 Environmental Team
•• MultiMulti--Weapon System/Environmentally Compliant Weapon System/Environmentally Compliant TopcoatTopcoat
•• Environmentally Friendly Alternative for Specialty Environmentally Friendly Alternative for Specialty CoatingCoating
Environmentally Compliant Environmentally Compliant TopcoatTopcoat
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• Develop/operationally evaluate environmentally friendly topcoat • Funded by HQ AFMC/CEVV
• Benefits• Hazardous waste reduction • Volatile Organic Compound (VOC) / Hazardous Air Pollutant
(VOC/HAP) emissions reduction • Reduced labor costs
• Phase I – Develop Zero VOC topcoat system • LM Aero effort, September 2002-2003 • Two coatings were downselected for a Field Service Evaluation
• Phase II – Field Service Evaluation • Apply to two F-16 aircraft and evaluate over 18-month period
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Environmentally Friendly Environmentally Friendly Specialty CoatingSpecialty Coating
• Develop/operationally evaluate an environmentally friendly coating • Funded by HQ AFMC/CEVV and DoD ESTCP • Benefits
• Hazardous waste reduction • VOC/HAP emissions reduction • Reduced labor costs
• Phase I – Develop zero VOC specialty coating system• LM Aero effort, September 2002 – March 2004 • Two coatings were chosen for a Field Service Evaluation
• Phase II – Field Service Evaluation• Apply to two F-16 aircraft and evaluate over 18 month period
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Environmentally Friendly Topcoat and Environmentally Friendly Topcoat and Specialty CoatingsSpecialty Coatings
Program Benefits
• Fully Qualified Material System Enables USAF to Meet Increasingly Stringent EPA Regulations by Significantly Reducing the Volatile Organic Content (VOC) and Hazardous Air Pollutants (HAPs) Emissions at Air Force Plant 4 and OO-ALC Depot
• Reduced cost and maintenance time
• Improved performance
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Field Service Evaluation - Topcoat and Specialty Coating
•• Phase II – conduct Field Service Evaluation (FSE)
• Objective - Evaluate durability and maintainability of coatings
• Two F-16 aircraft from Spangdahlem Air Base, Germany, coated March – April 2004 at depot
• One with low-VOC specialty coating, one with zero VOC specialty coating
• One with low-VOC topcoat, one with zero VOC topcoat
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Field Service Evaluation - Topcoat and Specialty Coating
• FSE for F-16 aircraft coatings underway at Spangdahlem Air Base, Germany, through October 2005
• Feedback positive regarding durability, maintainability, and cleanability
• Feedback positive regarding application processes by depot
• Second six-month inspection performed by Lockheed and Air Force at Spangdahlem AB on 11 May 2005
• Final inspection will be performed in October – November 2005
• Coatings are doing very well
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