MALS-40 OEF SMOKIN’ ACES

1. MALS-40 OEFSMOKIN’ ACES Maj Schweickart CWO4 LeBlanc GySgt Mrusek

2. Topics • Initial Challenges • Lessons Learned • Successes • Questions

3. From This

6. To This

7. Initial Challenges Developing a layout from inbound MF inventory & support posture Petitioning for land; joint approval requires CAD drawings Building relationships with external & adjacent commands Design a Marshalling plan for incoming MFs Prioritizing the build-up plan Executing the build-up (get it right the 1st time) Ensuring delivery/receipt of MFs & ancillary items

8. Lessons Learned Grounding Lack of Test Equipment (4-wire Ohmmeter i.e. TGRAA-A) Should be apart of 990 IMRL/SE British Engineers had one and performed initial tests on placement of 3 grounding rods and resistance exceeded 145 ohms Very arid climate, sand fine & dry Developed a grounding grid plan, based on existing and future capabilities, consisting of 72 grounding rods and tying it all in together with 2 awg bare wire Not every INU had grounding rods as per LIR Had to beg & borrowing from Brits, MWSS, Ordnance, KAF, etc to attain grounding rods No bare copper wire so after weeks of trying to get we attained jacketed wire from the Brits and proceeded to strip & uncoil over 2000’ of wire Once grounding grid was in place the Brit Engineers returned and conducted resistance checks and measurements were all less than .45 ohms

9. Land Preparation Need a hard or compacted somewhat level surface MWSS surveyed the land and placed stakes to mark We had a mountain of rock in place, but due to lack of MHE the priorities were diverted to FOB Dwyer and 2/3 of our rock was moved to the flightline AM2 matting project. Ended up having the remaining rock spread out, compacted and watered for ~2days. Result was not optimal, but acceptable. (impact fork lift options and MF support) MWSS delivered some rock a few months later

10. Grounding Grid Layout

11. Marshaling Area

12. CURRENT VANPAD LAYOUT

13. Door/Plug storage Removed all internal doors just like on the TAVB Utilized cut 4x4s to protect in between Stacked in piles of 10 and stored in CONEX boxes Returned bolts on MFs to avoid being misplaced

15. Tactical Quiet Generators Designed Power Grid to support redundancy Stack of (3) Generators side by side Generators wired in parallel to PDB This allowed for seemless switchovers while doing PMs Also planned for backups & paralleling in the event of an extra electrical load (capability growth) Fuel delivery worked out with MWSS Lack of fuel trucks limited runs, competing with the flightline before fuel farm set-up Without the availability of fuel storage devised a plan to use adjacent generators and fuel storage via the drain connection and supplied fuel line Working with contacts at MWSS attained fuel bladders Fittings to adapt fuel lines were not supplied with the 500gal bladders Utilizing the machine shop and fuel bladder plugs, milled and tapped IOT attach to generators High failure components DVRs ~6, Fuel probes~7, Main Contactors~9 Developed a repair procedure for the $2000.00 consumable contactors (see storyboard) and T/S procedures need to be improved

17. 200 KW TQG MAIN CONTACTOR The purpose of this is to show repair capability of a main contactor from a 200KW TQG. This item is currently listed by SM&R code as a consumable part. This is a high failure item which during this deployment has been ordered 7 times. It is possible to repair this asset and reduce generator down time while also saving in excess of $2,000 in the process. We have currently repaired 5 contactors. 1. Contact was “arc welded” together needed to pry apart 2. Carefully sand the contacts to remove carbon build-up 4. Connect 28VDC to –X2 & +X1 and check resistance across phases (should indicate <1 ohm) 3. Reassemble and check resistance across phases (should read open) 5. Mechanical adjustments can be made internally if still no continuity

18. Condition of Received MF’s Missing items IMRL Tools LIRs Internal items, i.e. chairs, desks, shoring kits, light diffusers, etc… Damaged SE & items that were not secured properly Miss wired Phases reversed Main CBs in INUs wired incorrectly Benches (AECTS, T-10 & MAG Particle)

19. ECU Repair Build proficiency Need a durable hand-cart type of device, that will roll over rough surfaces, jack up ECUs and move them in & out of place PEB establishment was invaluable At RIP/TOA has 52 RFI ECUs in storage containers

20. Double-wide panels ~70% of bolts were missing ~80% of bolts installed were stripped out Had to utilize tanker bar and sledge hammer to knock off heads IOT remove the panels Recommend a design that has the bolts going completely through beam with a nut, washers & lock washers inside

21. SMOKIN’ ACES

22. MERWS on van pad

23. MERWS as composite repair facility

24. Additional Successes • Compass Rose • Flightline Interdictions • Wiring team • A/F team • N2 servicing (On aircraft support) • F/L troubleshooting assistance • Calibration • MWSS F/L support • Local Manufacture • VMU support • Local Test Set Development • H-1 Indicators • EAPS T/S

25. Additional Items • Austere Packages • MF HQ packages, 1per Wing • Grounding Grid Packages 1 per Wing • Fuel Bladders • 990 PEB…

26. Questions?