A more efficient alternative being used to maintain AEDC turbine engine test operations

  • Published
  • By Deidre Ortiz
  • AEDC/PA
ARNOLD AIR FORCE BASE, TENN. --  A conversion to using EcoSafe Hydraulic Fluid has improved operations for the Aeropropulsion Systems Test Facility (ASTF), which tests engines for the Department of Defense and commercial aircraft.

EcoSafe32 hydraulic fluid, a Polyalkylene Glycol (PAG) chemical fluid, is now being used to flush and fill the process air valve hydraulic systems at the ASTF C-Plant. Unlike the former petroleum-based fluid, EcoSafe is chemically incapable of producing varnish and sludge and instead acts as a mild detergent helping keep systems clean. Additionally, it is able to tolerate high concentrations (parts per million) of water and does not react with water.

As with all chemical fluids, national, state and regional guidelines are in place to prevent spills, and regular inspections of facilities are also mandatory.

The Environmental Quality office at AEDC noted that proper procedures are being followed to ensure that EcoSafe is not getting into the ground or the base's water supplies.

"The Eco-Safe 32 remains a hazardous material that must not be spilled onto the soil or released into any surface waters," Dennis Flatt said. "All releases [of hazardous material] at AEDC must be reported to the Operations Center and proper response measures taken."

Flatt added there are environmental guidelines the base must follow and environmental safety is a priority at AEDC because accidents can mean major cleanup and penalties.

"A release producing a visible sheen on water, if not controlled, violates the AEDC wastewater permit," he said. "Spills onto the soil or gravel generate contaminated soil requiring clean-up and is not permitted for disposal in our on-site landfill. Offsite disposal of this type of contaminated soil is managed as a 'special waste' permitted into special landfills by the Tennessee Department of Environment and Conservation. This disposal and cleanup cost exceeds $400 a ton for disposal alone."

David Lynn, ATA systems engineer for C-Plant, stated the switch to EcoSafe is benefitting the plant and is expected to help keep the system in satisfactory condition.

"We have seen a substantial reduction in the reported erratic valve operation, servo failures and burned out solenoid valves together with greatly reduced filter element replacement frequency," Lynn said. "This results in increased equipment uptime and availability."