Facility upgrades complete ahead of schedule

  • Published
  • By Airman 1st Class Dan Gage
  • 90th Missile Wing Public Affairs
F. E. WARREN AIR FORCE BASE, Wyo. --  The Mighty Ninety completed the replacement of all diesel electric units in the missile fields with the replacement of the final unit at Launch Facility Echo-03 March 18 -- 20 months ahead of schedule.

The replacement of the final DEU at LF E-03 marks the completion of a $6.2 million project to replace 165 Allis-Chalmers engines with newer Cummins engines throughout the missile field.

"The Allis-Chalmers engines were relied on for nearly 50 years and proved a dependable piece of equipment," said Senior Master Sgt. Michael J. Kadrlik, 90th Missile Maintenance Squadron.

The engines came into service in 1961 and as they aged, maintenance became an issue, according to Sergeant Kadrlik. Many of the Allis-Chalmers engines have been rebuilt multiple times.

"The day was coming when we would no longer be able to repair this engine to sustain the ICBM force," he added.

In April 2003, the 90th Civil Engineer Squadron's Power Production Shop and the 90th Missile Maintenance Squadron's Facilities Maintenance Shop replaced the first diesel engine at Launch Facility Echo-08.

The new Cummins engine is an in-line, six-cylinder turbo-charged diesel-fueled unit that puts out 207 horsepower with about 361 ft-lbs of torque," Sergeant Kadrlik said. It requires little maintenance and is more fuel efficient than the Allis-Chalmers engine.

"Being a six cylinder," he added, "it's more powerful, runs smoother and picks up the site's electrical load better than the older engine. Additionally, parts will be available for the next 25 years, taking it well past 2030, which is the expected life of the Minuteman III weapon system."

After more than 600 hours of testing, including short cycle operations with repeated starts and stops, the Cummins engines were approved to provide back-up power to the nation's ICBM force.

On Dec. 20, 2005, the second generator was replaced at Launch Facility Kilo-03, marking the beginning of a rigorous replacement schedule.

"The program progressed, but with many delays," Sergeant Kadrlik said. "Issues like manpower shortages, higher priority work in the missile field, and higher headquarters inspections all contributed to slowing progress to a crawl at times."

DEU replacements were scheduled with whatever team was working that day, he added. However, higher priority work would come up in the field and the team would be diverted to these jobs.

To make the process more efficient, Master Sgt. Chad Hooks, 90th MMXS Facility Maintenance Section NCO in charge, and Tech. Sgt. Jeanette Boje, 90th MMXS Facility Maintenance Section assistant NCOIC, developed a dedicated team of six technicians and a team leader, who were assigned to replace generators in the missile field.

"The requirement set by higher headquarters was two generator replacements a month," Sergeant Kadrlik said. "By implementing the DEU team, we were able to replace two units per week."

"In September 2010, the FMS shop, using two DEU teams, replaced an amazing 12 units," he added.

As a result of their effort, the DEU team lead by Senior Airman Daryl Kroll, 90th MMXS, earned the 90th Missile Wing's team of the quarter, third quarter 2010.

"We encountered numerous challenges during the program," said Lt. Col. Trevor Flint, 90th MMXS commander. "Thanks to the leadership, technical expertise and commitment of outstanding Airmen like Sergeant Hooks and his DEU installation team, along with Jon Arnold, 90th MMXS, and his Corrosion Control Teams, the wing completed the install of all 150 LF and 15 missile alert facilities DEU 20 months ahead of schedule."

"As with any successful mission accomplishment," Colonel Flint added. "It was a true team effort across the 90th MMXS, the 90th Maintenance Group and the entire wing."

During the replacement of the engines, members of the corrosion control team worked to resurface the floors of the DEU units. These teams are made up of civilians, a work leader and two civilians. Larry Watters, Ronnie Monk, John Pierce and Carlos Hoschar make up the teams lead by William Wagoner and Frank Huff, all from 90th MMXS. Jonathan Arnold is the shop foreman, responsible for coordinating CCT teams with the FMS shop to provide smooth operations.

"More than 54,000 miles were driven along with more than 18,000 man-hours being dedicated to complete this phenomenal effort," Sergeant Kadrlik said. "A great number of these dispatches were two day trips with an overnight scheduled at a missile alert facility to save drive time."

"This team effort ensures that our venerable Minuteman III weapon system will continue to provide on alert sorties for our warfighter and credible strategic deterrence for our nation and allies," Colonel Flint said.