HomeNewsArticle Display

AFLCMC personnel travel to Brazil for test cell correlation

  • Published
  • By Kimberly Woodruff
  • Staff Writer
TINKER AIR FORCE BASE, Okla. --  Four members of the Air Force Life Cycle Management Center Propulsion Sustainment Division recently traveled to Brazil to conduct an in-country review and perform a "test cell correlation" on a J85 engine for the "Forca Aerea Brasileira," also known as Brazilian air force.

The four are part of the AFLCMC/LPS International Engine Management Program at Tinker Air Force Base.

The IEMP is comprised of 44 nations, with Brazil having the third largest J85 engine fleet in the program.  The IEMP's purpose is to provide logistics support to global partners in the community after procurement of U.S. military engines.  It links IEMP member countries, the United States Air Force and Department of Defense civilians to use their knowledge base and expertise aiding in resolution of safety and reliability issues.  Member countries may request a once per year in-country review which provides program, engineering and technical guidance and support.

Back in 2011, the J85 Engine IEMP team traveled to Brazil to perform an annual ICR.  During that visit, the FAB requested a "test cell correlation" in which test cell experts compare the Brazilian engine performance to that of a standard engine. Because contracting out the effort would have been too expensive to complete, it was put on hold.

In 2014, the U.S. Air Force made a "J85 Gold Plated Engine," a standard engine, available to foreign military customers for comparison.  The release encouraged the FAB to again request the test cell correlation using the Gold Plated Engine.

"Having the test cell correlation ensures the instruments used to perform operational checks on the FAB J85 engine are working correctly and ensures the safety and health of the J85 engine fleet," said Jason Compton, J85 Engine technical adviser.

This year, the J85 Engine IEMP team traveled to Brazil for the annual in-country review.  Seizing an economical savings opportunity, AFLCMC officials decided to do the ICR and test cell correlation simultaneously. The J85 team of experts traveled on this first-time-ever J85 engine correlation event to monitor the critical process steps and to provide key team/customer support.    

"Since members of the IEMP team were previously scheduled for the annual FAB ICR visit, we were able to plan the correlation in conjunction with the visit," said Luis Camacho, J85 Program manager. "By combining these efforts, we were able to further cost savings."

Mr. Camacho said the contractor cost would have been in excess of $300,000; however, because of their IEMP membership, the FAB only needed to fund transportation of the Gold Plated Engine, approximately $10,000. That resulted in an overall cost avoidance of more than a quarter of a million dollars.

Rafael Ramos, the FAB point of contact at Wright Patterson Air Force Base, Ohio, coordinated the transportation with an "Air-Ride Truck" to protect the engine from bumps in the road. 

Mr. Ramos' office engaged the Brazilian Aeronautical Commission in Washington to look for a way to move the engine between Tinker AFB and Sao Paulo in the most economical way possible. The commission realized that they had a contract with a transport company and could exercise that option for the move. 

"Our office got all the specifications such as weight and cube from the IEMP as well as any specific requirement like an air ride," Mr. Ramos said. "Our office then coordinated with the BACW, the IEMP, as well as the transport company to move the engine and kept track to ensure that there (were) no glitches and that this opportunity would not be wasted." 

The BACW took the lead once all parameters were met and arranged for the movement.  The move was done in two stages: one from Tinker to Rio de Janeiro and then by organic airlift (C-130) from Rio to Sao Paulo.

On July 27, the engine began its travel to Brazil from Tinker AFB.  It arrived at "Parque de Material Aeronautico de Sao Paulo" on Aug. 10.  Ricky Wooden, lead J85
Correlation engineer, traveled to Brazil with the IEMP team to perform the test cell correlation.  He is an Air Force expert for the J85 engine with many years of experience and outstanding knowledge on the procedures for correlating engine test cell benches.  In addition, Will Garza, J85 Engine technical adviser and technical expert in the J85 engine test cell operations, also accompanied Mr. Wooden to provide support for the test cell correlation process.  They conducted the test and ensured the process was completed in accordance with Air Force standards.

"Once the correlation was completed the technicians were very pleased, and confident, that the work that had been performed was affirmed by the correlation, not only the engine performance but the safety of the engine," Mr. Ramos said. "Needless to say, they feel extremely confident of the condition of the engines and their future fine tuning of engines to bring these to peak efficiency. The engine folks also feel very confident because of their contribution to the complete update/modernization of the F-5 aircraft,  first line of defense and expected to continue to be the 'fighter work horse' for many years to come." 

Mr. Compton said the professionalism and maintenance capability of the FAB in Brazil was outstanding and very impressive. 

"Their crew did what we suggested with no questions," he said, "and they had the capability to get it set up to do everything with little involvement from us."

Mr. Ramos said the IEMP contribution was really significant as they had the information, pricing and suggestions to get the job done. 

"In these days of belt tightening, any and all actions that benefit our allies is always most welcome," he said. "In the case of Brazil, this was a quantum leap in capability with minimal expense. The Brazilian armed forces, just like the U.S. armed forces, are suffering from sequestration, at a much higher rate and any savings are well received and applied somewhere else to support the fleet."

During the week, the IEMP team performed four successful engine runs on the FAB's test cell and minor adjustments were made.  In the end, the J85 engine FAB test cell passed the performance correlation with flying colors.

The IEMP provides a voice to foreign military customers through the U.S. Air Force and the original engine manufacturer.  Membership into the IEMP is a minimum of three years.  As an IEMP member, countries -- who are allies to the United States --share equally in the engine Component Improvement Program costs with other member countries, thus giving all members full benefits through partial funding while ensuring the health and safety of their fleet.

"The proactive stand taken by the IEMP, and all the engine and transportation folks at Tinker AFB, made a big difference in getting the engine to Brazil and accomplishing the correlation," Mr. Ramos said. "Without their positive outlook and 'can-do' attitude this effort would never have come to fruition."