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Tinker's OC-ALC records F135 engine ‘firsts’

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TINKER AIR FORCE BASE, Okla. --  The Oklahoma City Air Logistics Complex recorded two 'firsts' recently.

The 76th Propulsion Maintenance Group and the 76th Software Maintenance Group along with support from partner Pratt and Whitney were the first engine repair depot to test an F135 engine, announced Corey Oltmann, Pacer Comet 4 project lead with the 555th Software Maintenance Squadron.

The F135 is an afterburning turbofan jet engine that powers the F-35 Lightning II fifth-generation single-engine joint strike fighter, which is replacing the F-16 Fighting Falcon. The F135 is "the most advanced U.S. fighter jet engine in existence today," Mr. Oltmann said.

On Aug. 27, the Oklahoma City team "were the first ones to run an F135 through a full-throttle test in a T-9 test cell anywhere in the world," according to Adam Giddens, 76th PMXG test cell program manager. The engine was subjected to an "acoustics survey" that measured decibel levels, to ensure that noise generated when the F135 was operated at all throttle levels would not damage the engine or equipment, or harm personnel. The results of the acoustics survey were positive, "meaning the team was able to proceed with F135 engine test inside the T-9 test cell," said Mr. Giddens.

Two T-9 test cells were recently re-located to Oklahoma City Air Logistics Complex from Aviano Air Base in Italy and Cannon Air Force Base in New Mexico Both test cells were reassembled northeast of Bldg. 9001 over the last year. The T-9 from Aviano Air Base will be used to test F108-100 engines and F101-102 engines after they're repaired by 76th PMXG mechanics in Bldg. 9001, according to Mason Hopkins, F135 Depot Activation Program Manager, 76th PMXG. The T-9 from Cannon AFB has been modified to enable testing of the F135 engine which will be overhauled by 76th PMXG mechanics in Bldg. 3001.

The F135 presented a unique set of challenges to standing up the testing capability. Engineers from the 76th SMXG developed test systems specifically for the F135 engine which included a unique test program sets consisting of hardware and software for the F135, Mr. Oltmann said.

For example, the engine communication protocol -- the way the test cell's computer equipment "talks" to the F135's internal computer -- is unique, Mr. Oltmann said. Using joint technical data developed by the F135's manufacturer, Pratt & Whitney, coupled with 'lessons learned' by P&W, Tinker's 76th SMXG successfully modified existing PC4 software to provide system functionality for that particular engine.

The F135 has "unique engine test support equipment that requires interface with the test cell, existing test cell equipment, and the Pacer Comet 4 engine test system," said Mr. Giddens. Mr. Giddens and a team of 76th PMXG engineers and production personnel "had the task of coordinating the efforts of the various entities involved in standing up the T-9s and F135 test capability as well as putting our own processes and equipment into place for the test cell to be operational and able to support the F135."

Pacer Comet 4 is a fully automated engine test system that utilizes software and hardware developed by 76th SMXG "that is necessary to read and control parameters on the engine and throughout the test facility," Mr. Oltmann said. It is a comprehensive upgrade of PC3, which is employed in the test cells in Bldgs. 3234 and 3703 for testing TF33, F108, F110, F101 and F117 engines with capability to test the F118 coming soon, Mr. Oltmann said.

"Because of the operator-friendly nature, supportability and reliability of the PC4 operating system, and in an effort to standardize engine test controls and engine test data acquisition across the OC-ALC, PC4 was the clear choice to be the operating system in the T-9 test cells," Mr. Giddens said.

The teams will continue conducting more tests "to qualify the engine, software, and support equipment in the test cell over the coming months," Mr. Giddens said. "We expect to be running production engines through the test cell by mid-2014," he added.
Besides Tinker AFB, PC4 also is in use at Edward AFB, has been installed at two Air National Guard locations, with a third planned for installation next year, Mr. Oltmann said. "We also have been funded to install PC4 at Whiteman AFB in 2014," he continued. "We are pushing to make PC4 the standard engine test system for the Air Force."

Three variants of the F135 engine are being manufactured: the Air Force F135-100, for conventional takeoffs and landings; the Navy F135-400, an aircraft carrier model; and the Marine Corps F135-600, for short takeoffs and vertical landings. Tinker will be able to test all three variants of the engine when full mission capability is reached sometime next year.

Tinker AFB will be the F135 engine depot for the Air Force. The Defense Department also plans to develop an F135 engine depot at Fleet Readiness Center Southeast, Naval Air Station Jacksonville, Fla., for the Navy. Fleet Readiness Center East at Marine Corps Air Station Cherry Point, N.C., will be the domestic lift system depot, and domestic F-35 airframe depots are planned for Hill AFB in Utah and at FRCE in North Carolina.

As the first F135 engine repair depot, the OC-ALC will be the first organization in the DOD to provide full depot-level test capability, Mr. Oltmann said, "a testament to the quality of individuals and work produced at the complex."