Cryogenics

B2 Test Stand Restoration and Modification

This project consisted on demolition and construction activities to adapt the B2 Test Stand to assist in NASA’s ongoing mission of sending a manned space flight to Mars.  The B2 Test Stand was originally constructed in the 1960’s as part of the space race to send a man to the moon.  Much of the piping that was originally installed had deteriorated over time, and as part of ICI’s scope had to be demolished and disposed of, much of which was coated in lead based paint and required extensive abatement activities (by others).  ICI fabricated the new piping at our facility in Idaho and shipped it to the project for installation by our field crew.  One of the major components of the project was the High Pressure Industrial Water system.  This included fabrication and installation of an extensive manifold system installed beneath the test stand to supply the flame bucket, which consisted of over a hundred 10” connections.  Due to its location, and limited access the installation required a tremendous amount of hand rigging of the piping into place, which included various sizes from 10” diameter piping up to 36” diameter.  The system also consisted of the main water supply to the stand which included a significant amount of 66” diameter piping, that due to its size and configuration was fabricated on site.  Other major components of the project were the installation of several systems of vacuum jacketed piping for cryogenic services of both liquid oxygen and liquid hydrogen.  ICI also fabricated and installed a substantial amount of stainless steel process piping to deliver and transport the various services needed for the shuttle engine, including helium, nitrogen, gaseous oxygen, gaseous hydrogen, and missile grade air.  The project required rigorous inspection and extensive quality control and assurance to produce a system that fulfilled the requirements of the space mission.  The project was incredibly unique and challenging, and ICI is extremely proud of the work that we performed, and to be part of such a historical project.

A3 Altitude Test Stand

Location: John C. Stennis Space Center, MS

Customer: Roy Anderson/NASA

Project consists of providing all mechanical labor and material to support the J-2X engine testing on A3 Test Sand. Piping includes stainless steel, cryogenic, and carbon steel systems to carry various fluids, include liquid hydrogen, liquid oxygen, nitrogen, and alcohol, from loading stations, over the ground, and 200+ feet up the test stand. ICI was also responsible for receiving, handling, and installation of 3 LOX vessels (321,000 lbs each), 9 Industrial Water vessels (290,000 lbs each), two Isopropyl Alcohol Tanks (260,000 lbs each), and 32 GN2 Bottles of 1000 cu. ft capacity each.

ICI was responsible for procurement, cryogenic cleaning, and installation of over 700 individual component, including various valves, filters, and expansion joints, as well as procurement and installation of stainless steel piping systems including high pressure and vacuum jacketed pipe to transport liquid hydrogen from associated barge docks to the test stand. In addition ICI was responsible for installation and handling of over $50 million in Government Furnished Equipment, including single valves costing over $100,000.

This job included strict quality control standards including radiographic inspection on the majority of welds.

TEST STAND 116

Location: Marshall Space Flight Center, Alabama.  
Customer: NASA
Project was for the construction of a new test facility which included providing and installing liquid hydrogen, liquid oxygen, and liquid methane cryogenic piping, ultra high pressure piping, hydraulic piping, high pressure water piping, tubing and components, structural steel, concrete, electrical, and controls.

RS-68 Modification for Dual Engine Testing

Location: John C. Stennis Space Center, Mississippi.

Customer: NASA

Project consists of major demolition of the B1 Test Stand and modifications to include steel, cryogenic piping, oxygen, nitrogen, hydraulic systems, etc, to allow for dual engine testing. Work included demolition of major structural members, piping, and electrical systems. New work included piping fabrication and installation, installation of vacuum jacketed piping systems, installation for purge and hydraulic tubing, placement of pumps, switch gear and overhead hoists, instrument and power wiring. This project was to support the testing of Boeing’s Delta 4 rocket engine.

COMPONENT TEST FACILITY

Location: John C. Stennis Space Center, Mississippi.
Customer: NASA
Project consisted of providing and installing cryogenic piping, ultra high pressure piping, hydraulic piping, high pressure water piping, tubing and components, cleaning and testing. Work included fabrication and installation of piping with wall thickness up to 6″, purge and hydraulic tubing, installation of 15,000 psi control valves, placement of high pressure gas tanks, and erection of flare stacks.

MODIFICATION TO S1C TEST STAND

Location: Marshall Space Flight Center, Alabama. 
Customer: NASA.
This project consisted of removal of the existing major engine thrust structure in the 230 ft. high S1C Engine Test Stand, modification of the structure and installation of the new thrust members and engine mounting gimbals within .010 tolerance. Supply and installation of cryogenic liquid hydrogen and oxygen systems, fire protection, high pressure hydraulic systems and all instrumentation was required for an operable liquid rocket engine test facility

INSTALATION OF ENGINE RUN SYSTEMS

Location: B-1 Engine Test Facility, National Space Test Laboratory, Mississippi.
Customer: NASA. .
This project required the installation and quality traceability for cryogenic test facility fueling fill systems and engine run systems complete with all instrumentation for an operable liquid rocket engine test facility.