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NOAA P-3 Service Life Extension Program

The maintenance team of the NOAA Aircraft Operations Center services the engine of a NOAA WP-3D Orion.

NOAA is the government’s premier science research agency, providing the nation with critical information that impacts the daily lives of millions of American citizens. The public uses the weather report to govern their daily lives, plan accordingly for travel, alert them when imminent danger is approaching as well as for various other reasons. Instrumental to the investigation of tropical cyclones are NOAA’s two Lockheed WP-3D Orion aircraft, best known as “Hurricane Hunters.”   

Operated by the NOAA Marine and Aviation Operations, these aircraft and NOAA’s Gulfstream IV-SP jet are vital research and surveillance tools that study tropical storms and hurricanes along with a variety of other events for NOAA. The P-3 aircraft have served NOAA well since they were built in 1975 and 1976 respectively. They have flown in over 180 hurricanes as well as logged more than 21,000 flight hours. These aircraft are equipped with highly specialized avionic systems, sensors and other equipment that allow them to gather vital and specific data; such as wind speed and storm trajectory as they fly into hurricanes as well as fly in the surrounding areas of storms.  

The P-3 aircraft have surveyed some of the most impactful storms and events in U.S. history. For example, NOAA aircraft gathered data prior to Hurricane Sandy reaching land that provided National Weather Service forecasters with valuable information about the storm's intensity and direction. Emergency managers later used these forecasts to guide evacuation plans and resource deployment for citizens in the New York City and New Jersey area. The P-3 aircraft not only monitor hurricanes, but participate in a wide variety of national and international meteorological, oceanographic and environmental research missions; for example, air quality study, satellite wind verification, and Jetstream research.

With the P-3 Service Life Extension Program that is currently underway these highly specialized aircraft will be receiving upgrades that will amplify their mission capabilities, extend their geographical reach and improve their fuel efficiency. These aircraft have served NOAA well over the course of their service life; however, these upgrades are necessary and will allow them to continue performing their duties for 15 to 20 years to come.  Improvements will focus on the P-3s’ engines, wings and avionics systems.  These improvements will also save the government significant dollars in the long run in lower maintenance and fuel costs.

The overall performance of the P-3s will be enhanced through engine upgrades. NOAA has been working with an aircraft engine manufacturer by the name of Rolls-Royce which will be supplying the aircraft with the new T-56 Series 3.5 Enhancement Package which will be installed in 10 engines (four for each aircraft, and two additional spares).  This enhancement package will result in lower engine maintenance costs in the future and an anticipated fuel savings of nearly 10 percent.  

This improved fuel efficiency not only saves cost, but also allows for extended flight time to gather data that is essential to storm research and forecast prediction as well as reach greater distances in flight up to 300 miles.  According to Cmdr. Devin Brakob, “The upgraded Series 3.5 engines on the NOAA planes will not only allow us to save money on fuel costs but will enable us to reach further out for scientific data.  From flying further north in the North Atlantic during our annual Ocean Winds project to exploring out further from Hawaii and the West Coast during Pacific Ocean projects like Atmospheric Rivers and Winter Storms our reach will be extended.” The engine upgrade phase of the project was completed in March 2016.

The life of the Hurricane Hunters will also be extended by the scheduled upgrades to the wings.  NOAA is working in conjunction with the United States Navy Air Systems Command in Patuxent River, Md. to provide its planes with newly refurbished wings made from newer corrosion resistant materials. These wings were built by L-3 Systems in Waco, Texas through an existing Navy P-3 sustainment contract.  This portion of the project will extend the service life of the two aircraft by 15,000 flight hours and out to 2030 and beyond.  Over the next 15 to 20 years the revitalized wings will also significantly reduce maintenance costs as a result of the corrosion resistance of the new wings. The actual wing installation will take place at the United States Navy Fleet Readiness Center in Jacksonville, Fla. from March 2015 to June 2016 for one P-3 and February 2017 to May of 2018 for the other.

The third and final phase includes upgrades to the avionics systems of the two P-3 aircraft. The tail Doppler, nose radar, and the lower fuselage radar located on the belly of the aircraft will all be replaced with new and improved models. This will increase the data collection capability of the Hurricane Hunters allowing for more accurate as well as more detailed forecasts.   

According to Alan Goldstein, chief of science and engineering at the NOAA Aircraft Operations Center, the project will, “include an upgraded multifunction display to provide better radar and flight path information, ADS-B (Automatic Dependent Surveillance- Broadcast) to help track other aircraft in the vicinity, a software upgrade to the internal communication system to improve cockpit voice channels, and a modern nose radar system with advanced wind shear and turbulence detection.”  

These aircraft will be given extended life through the replacement of the engine display gauges, autopilot system, and electrical power conversion system. Since their installment, simplified technology has been developed that is even more reliable and manufacturers have committed to their long term production.  Cmdr. Brakob says, “The Avionics Refresh will bring most of the remaining original avionics from when the plane was built up to current technology. It will strengthen both the electrical and electronic infrastructure to allow more flexibility for the scientists in the type and number of sensors they can use onboard the NOAA P-3.” 

In addition, the cockpit renovation will construct a more modern appearance including all flight gauges and devices being embedded into the instrument panel behind a glass top along with numerous analog and digital upgrades. The renovation will not only improve situational awareness, but will also enhance the aesthetics of the cockpit. This portion of the upgrades is currently underway and is scheduled to conclude in 2018. 

This Service Life Extension Program has been carefully planned to ensure that the survey of storms will not lack in any capacity.  At all times during this project, NOAA will have a fully capable P-3 at the ready. In addition, the NOAA Gulfstream-IV along with the 53rd Weather Reconnaissance Squadron of the U.S. Air Force will also continue to track and survey hurricanes and other storms.  This project will not only yield dividends of financial nature in the future as well as improve storm survey capability; it will allow the agency to collaborate with the U.S. Navy as well as the U.S. Air Force and bring some of the brightest minds in the country together to produce the best results.