Replacement Of Main Aircraft Batteries In The

Hu-25 Aircraft Essay, Research Paper

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INTRODUCTION: HU-25 AIRCRAFT MAIN DC BATTERY REPLACEMENT

In todays aircraft it is essential we utilize the latest technology to eliminate costly maintenance procedures, safety concerns, and still maintain reliable performing equipment. The Tesla Dry-Cell battery is a candidate to replace the SAFT 2376 Nickel Cadmium (NICAD) battery presently utilized in the HU-25 aircraft. The Tesla Dry-Cell battery can meet all of the performance specifications of the SAFT 2376 NICAD battery. The Tesla battery also provides additional long term dollar savings, maintenance man hour savings, and safety benefits that are substantial enough to be considered as a viable replacement.

METHODOLOGY FOR EVALUATING THE TESLA DRY-CELL BATTERY

In evaluating the Tesla Dry-Cell Battery to determine if it is a suitable replacement for the SAFT 2376 NICAD battery I used several methods of gathering information. To determine if it met the performance specifications required I utilized Technical manuals on each respective battery. To determine if the Tesla battery will provide substantial savings in cost, maintenance man hour expenditures and areas of safety. I utilized the Federal Stock System price data base, Coast Guard (CG) Aircraft Computerized Maintenance System (ACMS), Material Safety Data Sheet (MSDS), and technical publication NAVAIR 17-15BAD-1, (1991) . I also utilized The Telsa Industries Inc. TI4676 Micro Power Unit technical publication, (1998).

STUDY 1

Method

Subjects. National Stock system prices for both the SAFT 2376 NICAD and Tesla Dry-Cell Battery. USCG HU-25 Prime Unit personnel for information on form and fit requirements to switch to the Tesla battery. Reviewed ACMS

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historical data base for replacement parts cost data on the SAFT 2376 NICAD battery. A Tesla Industries representative provided tesla battery overhaul costs data.

Battery Unit Item Cost

SAFT 2376 NICAD each $848.00

Tesla Dry-Cell each $3,300.00

Cost for Tesla upgrade installation each $0.00

Battery Unit Replacement parts cost

SAFT 2376 NICAD

Cells(19 per battery) each $361.00

Misc each $75.00

Tesla Dry-Cell

Parts (none)

Overhaul each $300.00

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STUDY 2

Method

Subjects. Reviewed CG ACMS data base for maintenance man hours expended on SAFT NICAD batteries. Researched Tesla TI4676 Micro Power Unit (MPU) Dry-Cell battery technical manual for testing and troubleshooting procedures.

Aviation Training Center Mobile, AL Man/Hour cost analysis

Aircraft Year Total Man/Hours Hourly Rate Total Man/Hour Costs

HU-25 1998 886 $16.00 $14,176.00

HU-25 1997 860 $16.00 $13,760.00

HU-25 1996 914 $16.00 $14,624.00

Tesla TI4676 MPU Dry-Cell battery is a maintenance free battery

STUDY 3

METHOD

Subjects. Reviewed SAFT 2376 NICAD battery and Tesla TI4676 MPU Dry-Cell MSDS specification sheets and technical manual for each respective battery.

NICAD BATTERY

1. Cadmimum & Cadmium Hydroxide

2. Nickel & Nickel Hydroxide

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3. Potassium Hydroxide or Sodium Hydroxide

4. Cobalt Hydroxide

TESLA DRY-CELL BATTERY

1. No Hazardous Material

MSDS for the NICAD battery see appendix A.

DISCUSSION

Description of Batteries

The SAFT 2376 NICAD battery has been used in the HU-25 aircraft since 1981. It has been a reliable and competent battery. The objective for replaceing the NICAD battery is not due to a failing component or lack of parts in stock system to maintain them. It is a matter of newer technology that will provide an equivalent performance while eliminating maintenance man/hour costs, hazardous material, and safety concerns.

The Tesla TI4676 Micro Power Unit (MPU) Dry-Cell battery meets all specifications required for HU-25 aircraft main battery operation and meets or exceeds all performance characteristics of the NICAD battery. See appendix A for TI4676 MPU output voltage and maximum output current charts.

Study 1 lists data to support short and long term costs related to converting to the Tesla Dry-Cell battery. The initial cost to purchase seventy Tesla Dry-Cell batteries to support the Coast Guards fleet of 24 HU-25 aircraft and supply

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units with spares equivalent to the number presently in the system. This data shows that the initial cost to make the conversion will be very expensive costing $231,000. Tesla Industries Inc. stated that the Coast Guard would not need to have as many spare batteries in the HU-25 fleet as they could guarantee that when we sent a battery out for overhaul we would receive a replacement within 48 hours. This would have to be looked into further, but may allow a small savings on the initial purchase. Replacement part costs are also a reacurring expense that was looked at to determine if the Tesla battery would be subject to high costs in this area. The data shows that in this area costs are comparable and perhaps slightly lower for the Tesla Dry-Cell battery. Th

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