Force Protection from Corrosion

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Force Protection from Corrosion a proven 81 ROI
solution
Jim Martin LOGIS-TECH Andy Shelter Munters US
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Atmospheric Corrosion is the most prevalent form
of corrosion for weapon systems and military
equipment
Prevention always costs lt correction.
You can modify the equipment or change the
atmosphere
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Above 50 Relative Humidity (RH) the rate of
corrosion is exponential1
In the U.S. the Relative Humidity exceeds 50
RH over 90 of the time.
1 Vernon, W. H. J. (1926). Second experimental
report to the Atmospheric Research Committee,
British Non-ferrous metals Research Association.
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Controlled Humidity Protection (CHP)
30 to 40 RH
Humidistat
Monitoring, Control, Data Logging
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Desiccant Wheel Dehumidifier
Process Air Cycle
Humid Ambient Air
10 RH Air
Damp Air
Humid Ambient Air
Regeneration Air Cycle
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Common solution to common problems

• Mitigate the effects of reduced military manpower
• Reduce maintenance backlogs
• Reduces the logistics footprint
• Compensate for the effects of OPTEMPO funding
  reductions
• Enhance readiness by protecting FMC equipment
• Enhance training, mobilization and deployment
• Environmental no-brainer

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Corroded Compressor Blades
Comparison of both engines of a twin-engine
aircraft. DH Operational Dehumidification
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H-3 Sea King Compressor Blades
Present only Operational Dehumidification
Past washes and gas path cleaner
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22 of electronic failures are caused by humidity
induced corrosion1
even in MILSPEC conformal-coated hermetically
sealed parts3
1DSMC Guide to Material Acquisition
2Sandia National Laboratories
3USAF, WPAFB, SBIR AF97-172
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Humidity changes insulation resistance

• Reduced insulating values can cause faulty
  signals in wiring harnesses.
• Navy/USMC aviation organizational level
  maintenance expends
• 2 million man-hours each year to troubleshoot
  and repair corrosion-related aircraft wiring
  problems.

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Fungi Corrode 2024 T-6 Aluminum

• Fungi food sources
• CPCs (lanolin-based coatings).
• Hydraulic fluid film.
• Require RH gt 65, 68 - 104 degree F.

• During dehumidification fungi are
• not growing,
• not producing acids,
• not causing corrosion.

D. M. Lavoie, B. J. Little, R. I. Ray, D. R.
Hart, P. A. Wagner, Microfungal Degradation of
Polyurethane Paint and Corrosion of Aluminum
Alloy in Military Helicopters, Proceedings of
the Corrosion NACExpo 1997, (Houston, TX
National Association of Corrosion Engineers
(NACE), 1997), p 218/2.
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Cyclic maintenance is deferred-- the clock
stops in Sheltered CHP

• Joint Service Manual for Storage Materials
  Handling
• DoD 4145.19R
• DLAM 4145.12
• TM 38-400
• MCO 4450-14
• NAVSUP PUB 572
• AFJMAN 23-210

• All Components are Protected
• Equipment Readily Available
• No Pre-or-Post Preservation Requirements

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Aircraft protected from Ambient Humidity
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Aircraft protected from Ambient Humidity
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AGE, SE, WHE and high-value components protected
from Ambient Humidity
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CHP for all operational aircraft types

• Installed directly on or adjacent to the flight
  line
• Unlimited access to each aircraft
• Full aircraft and systems protection

Army PEO AviationDesign work for new OH-58 CHP
shelters in Hawaii begins in April
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Government confirms ten-year CHP 81 ROI is
conservative

• DoD IG, Army CEAC, GAO - analysis of CHP
• MTBF for electronics improved 30
• Maintenance times reduced up to 50

• ARNG - analysis of 8-year CHP fielding
• Confirmed Readiness Stabilizer
• Proven Total Corrosion Prevention

• Naval Air Systems Command EP-3 analysis
• Avionics reliability improved 25
• I-level labor reduced 40
• Depot level labor reduced 26

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Science meets the real world
Avg Annual Avionics Humidity Annual Base
Lo - Hi Cost/MC-130H

• Kadena 67 - 80 450,000
• Hurlburt 62 - 86 400,000
• Mildenhall 65 - 82 350,000
• Kirtland 28 - 59 250,000
• AMARC 23 - 53 reference only

AFSOC calculated they could save 4,000,000 per
year on MC-130H avionics
Based on 26 MTBF improvement (Navy IG
study), not including CLS savings or O/I man-hour
savings. AFSOC spent gt 19M on C-130 avionics in
FY00.
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NAVAIR AGE/SE/WHE results

• Stored equipment maintenance reduced by 80 .
• Hazmat and hazwaste reduced by 74 .
• Increased equipment availability.
• Qualified Pollution Prevention Equipment
  Program (PPEP) technology.

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U.S. Marine Corps AGE/SE/WHE annual Preventative
Maintenance savings

• 392 items of Aviation Support Equipment1
• -- 535 man-hours in normal conditions
• -- 8 man-hours on CHP (98 reduction)
• 201 items of Aviation Support Equipment2
• -- 183,831 savings in first year
• -- 8-year savings of 1,624,530 projected

1MALS-29 2MALS-14
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1/203 Air Defense Battalion, PATRIOT Alabama Army
National Guard
FY 1999 before CHP 1,516,950 FY 2000 after
CHP 1,024,210 32 percent reduction in cost of
Electronic Components
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European Operational Aircraft CHP

• Sweden uses Dynamic Dehumidification on all
  operational aircraft
• 26 improvement in avionics MTBF
• 5 improvement in availability
• Costs recovered in 6 months
• German Tornado Sea King squadrons use Dynamic
  Dehumidification
• Avionics failures reduced 45
• Engine maintenance significantly reduced.
• UK Australian Air Forces Navy experiencing
  similar results.

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The Clock Stops on the Periodic Maintenance
inspection cycle for equipment in the Controlled
Humidity Protection (CHP) range
Joint Service Manual for Storage Materials
Handling DoD 4145.19R, DLAM 4145.12, TM 38-400,
AFJMAN 23-210. Section VII, page 3-35 to
3-40 OPNAVINST 4790.2 VOL I 12.1.16, NAVAIR
15-01-500 Paragraph 6-16, NAVAIR 17-1-125
Paragraph 9-20
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Over 975 Controlled Humidity Equipment systems at
206 sites in 42 States and 11 overseas locations
3,000,000 s.f. sheltered CHP and 3720 vehicles
OP/SVESS
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Exponential corrosion rate above 50 RH
Corrosion suppressed 30-40 RH
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LOGIS-TECH 703-921-1038 Frank
Travis ftravis_at_logis-tech.com Jim
Martin jmartin_at_logis-tech.com Munters
US 610-690-4455 Andy Shelter andy_shelter_at_munters.
com GS00F0040M 817-978-8608 GSA
Advantage, 5-year Ms. Cheryl Goff N68335-01-D-009
6 732-323-2103 Navy, 2-year IDIQ Mr. Tom Hill