ASHE221058_Attachment 01_Pilot project lesson learned.pdf

U.S. AIR FORCE

31ST FIGHTER WING

31ST CIVIL ENGINEER SQUADRON

AVIANO AIR BASE, ITALY

1st GEN PAS DOOR REPAIR

ASHE 22-1041 PILOT PROJECT – LESSON LEARNED

1ST GEN PAS DOOR REPAIR REV.00

1 PILOT PROJECT DESCRIPTION - SOURCE OF ISSUE

1 PILOT PROJECT DESCRIPTION

The scope of prj. ASHE 22-1041 was to:

- Restore the operability of Z-2 [Bldg. 8010] 1st GEN PAS doors in Zulu Loop;

- Acquire know-how for the maintenance sequence of operations;

- Test the SOW for any optimization to be included in next projects;

1.1 SOURCE OF ISSUE

1st GEN PAS doors are manually operated. The doors are fully supported by 2 spherical roller bearings fitted on main hinges that are worn or broken due to poor lubrication, contamination, but mainly because they reached the expected end of life.

OLD NEW

REV.00 1ST GEN PAS DOOR REPAIR

2 SOURCE OF ISSUE - PILOT PROJECT DESCRIPTION

With increasing difficulties to move the doors by hand, the operators started to partially support the overall load with the use of the EMERGENCY spring rollers group. The high pressure of the rollers on the floor caused deep scratches that gradually reached 10 mm of depth or beyond.

OLD NEW

FLOOR SCRATCHES

3 PILOT PROJECT DESCRIPTION - LACK OF DOCUMENTATION

1.2 LACK OF DOCUMENTATION

This TAB-VEE generation was designed and built around 1969-1972 in most of USAFE installations. Shop drawings of each mechanical part of the main doors were not found in Aviano AB archives.

1.3 ITEM INCLUDED IN THE PILOT S.O.W.

Due to the unknown status of the existing components, it was decided to include a complete set of new parts (left and right hinge, 2x top support, 2x lower support and related sealings and steel covers) and to proceed with the restoring of existing hinges. Part of the SOW was to add lubricating holes and greasing points in lower and upper bearing support, to improve efficiency of re-lubrications.

NEW greasing point NEW greasing point

4 ITEM INCLUDED IN THE PILOT S.O.W. - PILOT PROJECT DESCRIPTION

New spherical roller bearings were supplied. All the connecting screws, washers, nuts that connect the lower and upper support to the casted frame and the screws that are connecting the hinges to the doors were supplied brand new.

It was discovered that the existing configuration could be improved. The shape of the lower machined pin of the hinges were updated and a new steel ring foreseen and supplied.

NEW STEEL RING

5 PILOT PROJECT DESCRIPTION - ITEM INCLUDED IN THE PILOT S.O.W.

Another critical phase of the project is represented by the handling and lifting operations and related cranes and operators. To move the doors the suitable crane should operate inside the shelter’s structure, with less than 1m of clearance from the door upper edge and the internal surface of the roof.

6 ITEM INCLUDED IN THE PILOT S.O.W. - PILOT PROJECT DESCRIPTION

7 PILOT PROJECT DESCRIPTION - ITEM INCLUDED IN THE PILOT S.O.W.

Two temporary carpentry structures were raised to support the doors during the reverse engineering and production of new parts. Now we can apply the same concept to support the doors during hinge replacements. We developed new drawings that we can share to external companies to have the same temporary structures.

8 ITEM INCLUDED IN THE PILOT S.O.W. - PILOT PROJECT DESCRIPTION

9 PILOT PROJECT DESCRIPTION - ITEM INCLUDED IN THE PILOT S.O.W.

10 ITEM INCLUDED IN THE PILOT S.O.W. - PILOT PROJECT DESCRIPTION

12 WORKING INSIDE AIRFIELD CHALLENGES - PILOT PROJECT DESCRIPTION

1.4 WORKING INSIDE AIRFIELD CHALLENGES

To have the possibility to start the job on time, it’s necessary to consider:

- To have a couple of stable military escorts of the User to be available during all the period of performance

- Required time to obtain base passes for all the external personnel;

- Required time to have the external personnel trained to guide vehicles inside the taxiway and obtain the Airfield Driving License;

- Required time to have the TERPS - TACW signed (2 months);

- That the site shall be fenced with short jerseys and lights according the airfield design guidelines, see UFC 3-260-04 chapter 8.6 SEE FOLLOWING SITE PLAN (coordinate with Airfield Management the eventual temporary shutdown of nearest shelters involved by the works)

13 PILOT PROJECT DESCRIPTION - WORKING INSIDE AIRFIELD CHALLENGES

23 LIST AND LOCATIONS OF 1ST GEN PAS IN ZULU

2 LIST AND LOCATIONS OF 1ST GEN PAS IN ZULU

Here below the overview and list of 1st GEN PAS in Zulu Loop. [Bldg. 7810 (Z-14) and 7850 (Z-15) are 1st GEN too but converted for other uses]