Fuselage Paint Facility

Client: Spirit AeroSystems
Completion Date: 2012
Location: Lenexa, Kan.


Burns & McDonnell performed planning, design, engineering construction support and commissioning for the new Plant II 737 Fuselage Paint Facility, which contributes to increasing aircraft production rates to 42 aircraft per month.

The facility incorporated a new paint mix; paint storage; don/doff (hexavalent chrome) changing rooms; and mechanical and electrical equipment support rooms. The booth is approximately 43 feet wide by 214 feet long by 25 feet tall and includes a downflow exhaust trench system to provide an average of 100 feet per minute of downflow velocity within the 5-foot zone of influence around the aircraft fuselage. The new paint booth recirculates 75 percent of the paint air and exhausts 25,000 cubic feet per minute and must have a 36-inch exhaust duct, control isolation and bypass dampers, airflow monitoring stations, and a three-stage NESHAP-compatible filter house, exhaust fan, regenerative thermal oxidizer (RTO) and exhaust stack with emissions monitoring platform.

Direct digital controls (DDC) for the paint booth control panel allow the operators to select various modes of operation to allow the control system to automatically reset varying airflow and temperature/humidity set-point conditions for each of mode: prep, paint or cure. The elevated cure mode reduces cure times, reducing the overall turnaround time and allowing an increased production rate.

In addition to the paint booth systems, the utility systems had to be commissioned without disruption to existing operations. Utility systems included fire mains, industrial water, sanitary sewer, natural gas, domestic water, communications, 480-v, and a single-ended 12-kV switch gear. Also commissioned were two 350-ton water-cooled chillers that were integrated into the existing cooling tower condenser water system.

Commissioning services included development and execution of the commissioning plan, development and execution of pre-functional checklists, witness of startup, development and execution of functional performance tests, testing and balancing (TAB) verification, troubleshooting, retesting, deficiency tracking, and development of a final commissioning record and systems manual.