Previous Facility Inspection and Recommendation.pdf

Previous Facility Inspection and Recommendation

TABLE OF CONTENTS

1. Investigate, Troubleshooting, and Findings

1.1 Site

1.2 Propane system

1.3 Nitrogen System

1.4 Water system

1.5 Electrical system

1.6 Airframe Mock Up

2. Recommendations and Activity Descriptions

2.1 Site

2.2 Propane system

2.3 Nitrogen System

2.4 Water system

2.5 Electrical system

2.6 Airframe Mock Up

1. Investigate, Troubleshooting, and Findings

1.1 Site

1.1.1 The site is of acceptable condition and ready to perform training exercises. However, the water conservation pond area (inside the fence) should have all brush and weeds removed from the area.

1.2 Propane system

1.2.1 The propane system was inspected and operated. The system is in satisfactory working condition with the exception of the low wing.

1.2.2 The low wing ground burner had minimal flow to the unit.

1.2.3 It was identified that the propane system had the regulators installed into the system. All regulators were in working condition.

1.3 Nitrogen System

1.3.1 Nitrogen pressure test was performed on the open and closed sides of the co-ax valves. The amount of Nitrogen pressure lost was minimal.

1.3.2 The Nitrogen actuation system to operate the propane valves is beginning to fail. It appears that the existing Nitrogen tubing is failing due to UV from the sun.

1.3.3 The emergency stop at the unloading station is malfunctioning. This switch actuates the air to perform the necessary duties of opening and closing propane valves.

1.4 Water System

1.4.1 The Outboard Rear and Inboard Rear Water Jackets were not discharging water.

Attachment 9 kees.negaard Typewritten Text (Sep 08)

1.4.2 The Wheel Well Water Jacket was not discharging water.

1.4.3 The water discharged from the water jackets was not used in a strategic manner to keep the igniters cool.

1.4.4 The Water Conservation Pond is full of Algae and plant growth that have the potential to restrict the water flow of the system throughout the water piping system or directly at the pump.

1.4.5 The drain pie for the weir has a restricted flow.

1.5 Electrical System

1.5.1 A dry igniter and pigtail Bench Test was performed test was performed and it was determined that all pigtails and igniters were functional.

1.5.2 Test were performed and it was determined that all transformers, switches, controls, and relays were in satisfactory operating condition.

1.5.3 Voltage Test were performed on the existing Ignition Cable which is not the cable required by AFCESA. The ignition cable failed and indicated major Voltage loss between the transformer and the ignition point.

1.5.6 The ground burner igniters were set to the proper elevation in relationship to the burn pit pool operating level.

1.6 Airframe Mock Up

1.6.1 The Airframe Mock Up did not have any engine cowlings on it.

1.6.2 There were no inspection doors for the APU and the Wheel Well igniter locations.

2. Recommendations and Activity Descriptions.

2.1 Site

2.1.1 The site is of acceptable condition and ready to perform training exercises. However, the water conservation pond area (inside the fence) should have all brush and weeds removed from the area. A crew needs to cut and remove most all vegetation from inside the fenced area of the Water Conservation Pond.

2.2 Propane system

2.2.1 The propane system was inspected and operated. The system is in satisfactory working condition with the exception of the low wing. The low wing ground burner had minimal flow to the burner unit. This is probably due to a faulty co-ax valve. The Co-Ax Valve should be replaced.

2.2.3 It was identified that the propane system had the regulators installed into the system. All regulators were in working condition. The regulators can be replaced with fixed orifice piping.

This activity is shown as an option in the attached cost analysis.

2.3 Nitrogen System

2.3.1 Nitrogen pressure test was performed on the open and closed sides of the co-ax valves. The mount of Nitrogen pressure lost was minimal.

2.3.2 The Nitrogen actuation system to operate the propane valves at the propane tank is beginning to fail. It appears that the existing Nitrogen tubing is failing due to UV from the sun. It is recommended that all of the lines and fittings are replaced.

2.3.3 The emergency stop at the unloading station for the propane tank is malfunctioning. This switch actuates the air to perform the necessary duties of opening and closing propane valves.

This switch should be replaced.

2.4 Water System

Attachment 9

2.4.1 The Outboard Rear and Inboard Rear Water Jackets were not discharging water. It is probable that the lines are plugged with debris that has gotten through the pump screen. The lines need to be hand excavated and disassembled until the problem is located.

2.4.2 The Wheel Well Water Jacket was not discharging water. It is probable that the lines are plugged with debris that has gotten through the pump screen. The lines need to be hand excavated and disassembled until the problem is located. Then reassembled.

2.4.3 The water discharged from the water jackets was not used in a strategic manner to keep the igniters cool. It is recommended that PT Flood jets are installed to achieve proper cooling methods. This will require welding a threaded coupler on the end of the existing water-jacket and setting a PT Flood jet at eleven locations.

2.4.4 The Water Conservation Pond is full of Algae and plant growth that have the potential to restrict the water flow of the system throughout the water piping system or directly at the pump. The liner should be hosed and pressure washed clean. When the pond is refilled, it should be treated so that the water is tinted to help prevent growth.

2.4.5 The drain pipe for the weir has a restricted flow. A high pressure water unit for performing sewer cleaning operations shall be employed to completely remove all debris within the drainage pipe between the weir and the water conservation pond.

2.5 Electrical System

2.5.1 A dry igniter and pigtail “Bench Test” was performed. It was determined that all pigtails and igniters were functional.

2.5.2 Test were performed and it was determined that all transformers, switches, controls, and relays were in satisfactory operating condition.

2.5.3 Voltage Test were performed on the existing Ignition Cable which is not the cable required by AFCESA. The ignition cable failed and indicated major Voltage loss between the transformer and the ignition point. The ignition cable needs replaced with MILSPEC ignition cable that has been proven in similar applications. It is recommended that the transformer cabinet with a heat shield is relocated to the edge of the burn pit near the front of the airframe mock up. This will reduce the amount of ignition cable that has to be replaced and will also assist in future repairs if necessary. Also, since the transformer will be closer and less ignition cable is used, there is less voltage drop and the igniters work better.

2.5.6 The ground burner igniters were not set to the proper elevation in relationship to the burn pit pool operating level. The ground burners need to be removed and the igniter boxes need to be adjusted to the proper elevation, and then replace the ground burners.

2.6 Airframe Mock Up

2.6.1 It was also identified that there are no engine cowlings on the aircraft engine pods. Instillation of “Engine Cowlings” are recommended at this facility. The engine cowlings will enable the trainees to obtain a direct water route to the engine burners and prevent the fire from being blown out of the engines.

This also reduces the amount of wind flow thru the engine itself, creating a safer, easier fire start. This feature is highly recommended for the tail engine. Because the tail engine is so high, it is very difficult to ignite because of the high wind speeds that exist.

2.6.2 There were no inspection doors for the APU and the Wheel Well igniter location. It is recommended that inspection doors are installed with some type of hinge action so that inspections and maintenance can easily be performed.