Fighter of Choice!

F-16 System Program Office

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F-16 Program Management TeamEnvironmental Program

Fighter of Choice!

F-16 Systems Group

Mary Wyderski F-16 Systems Group

Environmental Program Manager9 September 2005

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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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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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Questions ?Questions ?Questions ?