SUPER FLIGHT LINE ELECTRICAL DISTRIBUTION SYSTEM (SFLEDS)

Revision Date: 9/01
Process Code: Navy and Marine Corps: ML-02-99; Air Force:  AC02, FA05; Army ELM
Usage: Navy - Medium; Marine Corps - Medium; Army - Medium; Air Force - High
Alternative for: Fuel-fired Mobile Electric Power Plants (MEPP)
Applicable EPCRA Targeted Constituents: N/A

Overview: The Super Flight Line Electrical Distribution System (SFLEDS) reduces emissions created by diesel engine-driven support equipment (SE) by replacing the existing engine-driven power supplies with host facility power and redistributing the conditioned power along the flight line.  SFLEDS converts and conditions 480V, 60 Hz, 3 phase host facility grid power to 120V, 60Hz, single phase output for low voltage equipment and 115V, 400 Hz, 3 phase for aircraft while still allowing outputs of 480V, 60 Hz, 3 phase for heady duty equipment.  Implementation of this system requires the routing of 480V, 60 Hz power cable from the host facility grid to the SFLEDS site.  SFLEDS configuration includes frequency converters, transformers, and electrical controls.

The Naval Air Warfare Center, Aircraft Division, Lakehurst, New Jersey is currently in the process of procuring a SFLEDS prototype for installation at the Naval Air Station North Island (NASNI), San Diego, California.  Installation is scheduled for October 1998.


Compliance Benefit: If the Super Flight Line Electrical Distribution System (SFLEDS is used in place of diesel engine-driven SE the facility will decrease exhaust emissions.  It may also decrease the need for a facility to obtain an air permit under 40 CFR 70 and 40 CFR 71.   In addition, less hazardous materials are used on site (i.e., diesel) so the possibility that the facility would met any of the reporting thresholds of SARA Title III (40 CFR300, 355, 370, and 372; and EO 12856) is decreased.  The decrease in the amount of oil stored on site may also drop the facility below threshold amounts for the requirement to develop and implement a Spill, Prevention, Control, and Countermeasure Plan under 40 CFR 112.  Other compliance issues associated with this technology include Energy Efficiency and Water Conservation at Federal Facilities - Executive Order 12902:  Additional electricity will be consumed with this technology.

The compliance benefits listed here are only meant to be used as a general guideline and are not meant to be strictly interpreted.   Actual compliance benefits will vary depending on the factors involved, e.g. the amount of workload involved.


Materials Compatibility:
There were no material compatibility issued identified.


Safety and Health: Proper design, operation, and maintenance of the equipment is required for its safe use.   Only trained personnel must perform installation of electrical systems.

Consult your local industrial health specialist, and your local health and safety personnel prior to implementing this technology.


Benefits:
  • Eliminates hydrocarbon and carbon monoxide emissions.
  • Reduces handling and use of hazardous and flammable materials on the flight line.


Disadvantages:
  • Can have high capital costs.
  • Requires operator training.


Economic Analysis: The cost elements for installing a SFLEDS at a site are provided below.

An updated cost analysis will be determined next year from the data collected during the SFLEDS prototype testing period of November 1998 to March 1999.

Note:  Associated costs used are very conservative estimates based on the installation of a SFLEDS prototype.  Actual costs for SFLEDS operation may be lower and will vary based on the equipment application.

Assumptions:

  • Estimated SFLEDS equipment cost:  $300,000
  • Estimated hours required for installation:  120 hours
  • Labor rate:  $30/hr
  • Installation cost:  $5,400
  • Diesel fuel cost:  $0.97/gal
  • Electricity:  $0.08/kw-hr
  • Hours for handling diesel:  5 hr/week or 260 hr/yr
  • No. of Mobile Electric Power Plants (MEPP) units in operation:  30 @ 12 hr/week
  • MEPP total hours of operation:  18,720 hr/yr
  • MEPP equipment rating:  118 hp or 88 kw
  • Estimated diesel usage for MEPP:  155,000 gal/yr

Waterjet Stripping Process

  • Maintenance: 20 hr/yr
  • Total labor requirement: $18,744/yr
  • Material costs: $0
  • Utilities costs: $262/yr electricity, $125/yr compressed air
  • Waste disposal and management costs: $1,570/yr plus $500 water permit every 5 years
  • Health and safety costs: $670/yr

Abrasive Blasting Process

  • Maintenance: 240 hr/yr
  • Total labor requirement: $25,344/yr
  • Material (abrasive and masking) costs: $75,330/yr
  • Utilities costs: $3,557/yr electricity, $371/yr water
  • Waste disposal and management costs: $7,358/yr plus $615 air permit every 5 years
  • Health and safety costs: $1,680/yr

Annual Operating Cost Comparison for SFLEDS and MEPP

  SFLEDS MEPP
Operational Costs:    
Labor: $0 $7,800
Diesel: $0 $150,000
Energy $131,800 $0
Total Recovered Income: $0 $0
Net Annual Cost/Benefit: -$131,800 -$158,200


Economic Analysis Summary

  • Annual Savings for SFLEDS:  $26,500
  • Capital Cost for Diversion Equipment/Process:  $305,400
  • Payback Period for Investment in Equipment/Process:  < 12 years

Click Here to view an Active Spreadsheet for this Economic Analysis and Enter Your Own Values. To return from the Active Spreadsheet, click the reverse arrow in the Tool Bar.


Approving Authority: Approval is controlled locally and should be implemented only after engineering approval has been granted.  Major claimant approval is not required.


NSN/MSDS: None Identified


Points of Contact: Navy:
Mr. Paul Durso, 1.1.7.1.6
Naval Air Warfare Center, Aircraft Division
Lakehurst, New Jersey 08733
Phone:  (732) 323-1932
Email:  dursop@navair.navy.mil

Mr. Jim Ambrosino
Naval Air Warfare Center, Aircraft Division
Lakehurst, New Jersey  08733
Phone:  (732) 323-7904
DSN:  624-7904
FAX:  (732) 323-4917
Email:  ambrosinoja@navair.navy.mil

Mr. Ed Bonnes
Staff Civil Engineer, Code 18E
NAS North Island
Navy Environmental Leadership Program
San Diego, CA  92135-7040
Phone:  (619) 524-6380
DSN:  524-6330
FAX:  (619) 524-6519
Email:  bonnes.ed.k@asw.cnrsw.navy.mil


Vendors: This is not meant to be a complete list, as there are other manufacturers of this type of equipment.

Frequency Converters:
Unitron, Inc.
10925 Miller Road
Dallas, TX  75238
Phone (800) 527-1279
or (214) 340-8600
FAX:  (214) 341-2099
URL:  http://www.unitroninc.com/

Transformers:
EGS Electrical Group
Sola/Hevi-Duty
7770 N. Frontage Road
Skokie, IL  60077
Phone:  (847) 763-665
FAX:  (847) 763-6652
URL:  http://www.sola-hevi-duty.com/

Controls:
Square D Company
A Scheider North American Company
15850 Crabbs Branch Way, Suite 210
Rockville, MD  20855-2622
Attn:  Chuck Hastings
Phone (301) 921-2064
or (888) 778-2733
FAX:  (301) 921-1977


Sources: Mr. Anthony Vendetti, Naval Air Warfare Center, Aircraft Division, Lakehurst, NJ, September 1998
Phone conversation with Unitron, Inc. representative, August 1998.
Phone conversation with EGS Electrical Group representative, August 1998.
Phone conversation with Chuck Hastings, Square D Co., August 1998.



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