FRCSW Earns FY 2017 SECNAV Platinum Level Energy Award

Fleet Readiness Center Southwest (FRCSW) has earned the Secretary of the Navy’s (SECNAV) Fiscal Year (FY) 2017 Energy and Water Management Platinum Level Award for FY 2016 environmental accomplishments.

Presented annually and divided into 15 major categories (10 shore and five ship) the SECNAV award is the highest level of recognition within the Navy’s energy programs.

FRCSW’s efforts recognized by the “Platinum” level category designate “… an outstanding energy program and an exceptional year for energy project execution.”

Three shore-based commands, including Marine Corps Air Station Miramar, and four ships joined FRCSW in the “Platinum” level of accomplishment.

One measure of a successful energy conservation program is by meeting compliance with executive order 13423 (EO 13423). Signed in January 2007, EO 13423 directs federal agencies to improve energy efficiencies by reducing water consumption, electricity usage and greenhouse gases by three percent per year.

The new executive order 13693, Planning for Federal Sustainability in the Next Decade, started in the beginning of FY16 which created the new baseline of FY15 and a yearly energy reduction of 2.5% moving forward to FY2025.

Investing more than $42 million in energy reduction projects since FY 2012 to FY 2016, FRCSW managed a 28 percent reduction in energy consumption, and a drop in energy intensity by 32.91 British Thermal Units (MMBTU)/thousand square feet (KSF) MMBTU/KSF.

MMBTU is an energy measurement for steam, electricity or natural gas.

During the same fiscal four-year period, water consumption was reduced by 21.7 percent, and water intensity by 2.48 thousand gallons (KGAL/KSF).

FRCSW uses an index of energy consumption called “energy intensity,” which is based on BTUs, vice industrial floor space.

A similar index, called “water intensity” is used to measure thousands of gallons of water instead of industrial square feet.

The command’s Building Energy Monitor (BEM) Program promotes energy awareness not only on the work floor, but throughout all levels of management.

FRCSW has 12 BEMs who monitor energy systems in their respective buildings.

Metering data is graphed and distributed to FRCSW managers and BEMs monthly.

Funding for FRCSW’s energy programs originate through various sources including utility Energy Service Contracts (UESC) and Energy Savings Performance Contracts (ESPC).

Authorized by the Energy Policy Act of 1992, UESCs are a limited-source contract between a federal agency and its serving utility for energy and water efficiency improvements and demand-reduction services.

An ESPC enables federal agencies to partnership with energy service companies to achieve reduction goals or create improvements to existing energy systems.

FRCSW has a current $24 million ESPC that targeted LED lighting retrofits in nine buildings, decentralization of compressed air, HVAC retrofits to two different calibrations labs, zero-bleed cooling towers, and water conservation steam mixing valves at multiple wash racks.

The contract also includes operations and maintenance of the equipment installed for 14 years which will help sustain the equipment to its maximum lifespan.

Furthermore, the command is forming a second ESPC to decentralize all buildings from base steam. Steam boilers will be used for industrial process buildings, while the remaining buildings will be converted from steam to heating hot water boilers, gas fired unit heaters, or heat pumps.

Natural gas will be supplied by a new Navy-owned gas main.

In other cost saving initiatives, FRCSW disabled steam to roof top air handlers in Building 472 resulting in approximately $500,000 in annual savings, and by reducing winter irrigation at Building C-100 more than $6,800 will be saved annually.







FRCSW Selects Hollie Shaw for Nov 2017 Golden Wrench Award

                                                                                   Fleet Readiness Center Southwest Commanding Officer Capt. Craig Owen presents the November 2017 Golden Wrench Award to technical data writer Hollie Shaw. Shaw was recognized with the award for her work within the F/A-18 and EA-18G Technical Data Team where she identified all technical publication deficiency reports on more than 1,200 Naval Air Technical manuals, including their status within the process and the required engineering. She completed the task in days — well ahead of the anticipated schedule —- enabling the technical data team to formally incorporate hundreds of backlogged technical publication deficiency reports which are currently being delivered to the Fleet.

DRIFT NDI Method Used to Evaluate MV-22 Wing

Materials engineer technician Steve Pacheco uses the DRIFT portable spectrometer to determine if the wing of a legacy F/A-18 sustained any heat damage. DRIFT is a Non-destructive Inspection (NDI) tool that detects chemical changes to composite materials that have been exposed to excessive heat. Photo by Jim Markle


An assignment to access the integrity of an MV-22 Osprey wing at Marine Corps Air Station (MCAS) New River in North Carolina earlier this year resulted in the validation of a non-destructive inspection (NDI) method that stands to save the Navy and Marine Corps millions of dollars in maintenance and repairs to the primarily composite-based airframe.
“The Diffuse Reflectance Infrared Fourier Transform (DRIFT) is a portable spectrometer that can determine if a composite is heat damaged. We developed it to serve that purpose,” said Naval Air Systems Command (NAVAIR) materials engineer Justin Massey.
“It was originally invented for geological surveys, then we (modified) it with the help of Boeing to determine chemical changes in composite materials to find out if they are heat damaged or not.”
The handheld DRIFT detects chemical changes, such as those induced by heat, to composites on a molecular level. Weaken or damaged composites typically result in cracks or de-laminates to the component.
“Boeing initially developed DRIFT for its 787 platform. Our team lead, Ed Harris, came up with the idea of developing it for the F/A-18. The development period was from 2012-2015, and it was officially adopted as an inspection method by NAVAIR in 2015 where it has been used on the F/A-18,” Massey said.
The DRIFT NDI procedure was qualified by Fleet Readiness Center Southwest (FRCSW) in 2015 to detect heat damage in F/A-18 composites using an Agilent Flexscan 4200 spectrometer.
The following year, a national team that included staff from FRCSW, FRC Southeast, FRC East, and Naval Air Warfare Center Aircraft Division (NAWCAD) was assembled to modify the DRIFT NDI for use on other airframes, including the V-22 Osprey.
“With the national team, we took this technology and developed it for the V-22. It usually takes about two to three years to do something like this, but we got it done in two months to be able to inspect the V-22 wing (at MCAS New River),” Massey said.
“The wing was thermally damaged from an engine fire, and there was no inspection technique to determine if it could be saved or not.”
Massey and NAVAIR materials engineer technician Steve Pacheco were joined by FRC East materials engineers Rob Thompson and Andrea Boxell, and with the help of the materials group and Fleet Support Team at Cherry Point, completed inspections and assessments on the V-22 wing after two days.
“This was a onetime deal in that we got authorized through their program office,” Pacheco said. “It was an emergency because the aircraft was taking up an entire hangar bay, so they needed to know if they could fix it and fly it again, or part it out.”
The wing was recoverable, saving approximately $10-$12 million in replacement costs.
“We’ve already saved about $20 million in aircraft parts over the past few years,” Pacheco said.
The DRIFT spectrometer cost about $60,000, and development costs were approximately $400,000.
“Composites are high value assets, and the return on investment is relatively quick on this kind of technology,” Massey noted.
“Prior to the development of DRIFT, visual inspections and standard NDI methods were used on composite parts. Generally, if the paint showed any discoloration, it was the removal and replacement of the part under analysis. Which is what would have happened on this V-22,” Massey said.
“We’re currently the only branch in the military that can detect heat damage on composites,” he said. “We see this use expanding to every aircraft that has composites. People have reached out to us from the Air Force, to the Army and the prime contractors. Everyone has caught wind of this and wants to know how to get this for their aircraft.”
A joint project by Massey, Thompson and Boxell entitled “The Use of DRIFT for Composite Heat Damage Evaluation of the V-22 Wing,” was submitted to the 2017 DOD Maintenance Innovation Challenge. It is one of six finalists from a field of 77 submissions. A winner will be selected at the DOD Maintenance Symposium in Salt Lake City Dec. 5.




FRCSW Employee earns Navy Meritorious Civilian Service Award

Fleet Readiness Center Southwest (FRCSW) Commanding Officer Capt. Craig Owen presents the Navy Meritorious Civilian Service Award to FRCSW Director of Human Resources Ashley Smith Oct. 27 in the boards area of Building 94. Smith was recognized for her leadership in implementing the Special Salary Rate program which targeted recruitment remedies of occupational series difficult to fill and retain in the San Diego area. Further, she was instrumental in leading the support and implementation of Advanced Skills Management, a web-based application designed to enhance the quality and efficiency of the command’s training programs. Photo by Scott Janes

FRCSW Teammates Recognized for Quick Actions

Fleet Readiness Center Southwest Commanding Officer Capt. Craig Owen presents Special Act Awards Oct. 27 to Manuel Perez-Preve (top) and Richard Daoedsjah for their swift actions Oct. 19 in administering the Heimlich maneuver to co-worker Louis Lonero, who was choking. Lonero was transported to Sharp Hospital in Coronado where he was evaluated and later released. Photo by Scott Janes