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Tinker project could save millions in fuel costs

  • Published
  • By Brandice J. O'Brien
  • Tinker Public Affairs
TINKER AIR FORCE BASE, Okla. --  Armed with everything but a cape and mask, the Propulsion Environmental Working Group here is actively striving to "green" the engine community. Comprised of Department of Defense personnel and academic and industry partners since 1991, the group identifies opportunities for environmental improvements. One such project is the Engine Water Wash initiative.

The goal of the Engine Water Wash initiative is to qualify an environmentally acceptable closed loop on-wing engine cleaning system. This effort is under way and could potentially save the Air Force millions of gallons of fuel -- as well as millions of dollars -- over the lifecycle of the engine fleet.

"In today's fiscally-constrained environment, and with our high operations tempo, the potential for any kind of savings is of interest," said Capt. Adam Langborgh, Oklahoma City Air Logistics Center Aerospace Sustainment Directorate Propulsion Sustainment Division water wash initiative program lead. "When the Air Force became aware of such a procedure, we were very eager to investigate it."

The project studies the effects of washing an engine's core compressor while it is on the aircraft. In the past, the Air Force standard engine wash techniques did not result in a comprehensive wash beyond the fan blades, the captain said. As a result, the engine core developed inefficiencies such as debris build-up, which impedes air flow and results in higher engine-gauge temperatures.

By cleaning the core compressor, build-up is eliminated; air can penetrate through, resulting in a lower engine-gauge temperature and higher fuel efficiency.

Two engine types are being tested for this initiative. They are the TF39, which powers the C-5 Galaxy, and the F108, which powers the KC-135 Stratotanker. Applicability of other engines is being investigated for a follow-on effort.

The PEWG was introduced to the water-wash concept in 2008 through the Navy and commercial airlines, which had already tested, proven and institutionalized the concept.

"The need for us to adopt this procedure wasn't as visible," Captain Langborgh said. "The Navy deals with a constantly corrosive environment with the salt water. The airline industry flies millions of miles each year and if they can get a fuel savings, then they're going to do what they can to get that fuel savings."

The PEWG is working with several contractors to see who is able to prove the concept. The testing element of the phase is expected to be finished in April 2012, with a final report of finding due June 2012.

"This is a no-brainer. Industry has done and has proved the benefits of washing the core," the captain said. "Even if we save 1 percent of fuel over the course of a year with the whole fleet in our current operations, 1 percent of a huge number is still a huge number."

The PEWG resides within the Propulsion Directorate under the direction of OC-ALC Vice Commander Col. Evan Miller and Lois Lum, Propulsion Support and Staff Office chief. Currently, there are approximately 30 projects in work. Once implemented, the projects not only improve the environment but often result in decreased cost and improved depot turn times, said Deborah Faulkner, PEWG program manager.

"The group's goal is to bring on processes that have been proven in industry so the cost is minimal compared to some acquisition programs," Ms. Faulkner said. "Within today's fiscally-constrained environment, ensuring return on investment and timely implementation is key to success."