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.  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.

EELV LAUNCH FACILITY

Location: Space Launch Complex 6, Vandenberg AFB, California.

Customer: Boeing

Project consists of major mechanical modification of the ground support pressure systems at the existing Space Launch Complex 6.

Project includes 7,000 feet of vacuum jacketed liquid hydrogen and liquid oxygen piping, 45,000 feet of stainless steel unjacketed piping, 130,000 feet of stainless steel tubing, HVAC, plumbing, instrumentation and controls, and hydraulic systems which include the fixed umbilical tower system which consists of an 8 foot supply line with 1 1/2 inch wall thickness. The modifications facilitate launch of Boeing’s Delta IV rocket.

B-2 Test Stand Modification

Location: John C. Stennis Space Center, Mississippi.

Customer: NASA.

Project consists of major demolition of the B-2 Test Stand and modifications that included structural steel, cryogenic piping, process piping including oxygen, nitrogen, and hydraulic systems, instrumentation and electrical systems to support the testing of the Boeing Delta IV rocket engine.

MELTON VALLEY STORAGE TANK CAPACITY INCREASE

Location: Oak Ridge National Laboratory,Oak Ridge, Tennessee.

Customer: MK-Ferguson of Oak Ridge Company.
Project consisted of construction of a concrete structure lined with stainless steel. Six large stainless steel vessels, 100,000 gallons each, were installed with piping (nuclear grade), pumps, valves, HEPA filtration system, and controls. Work included placement of
7,000 cubic yards of concrete, 30,000 square feet of butt-welded stainless steel liner plate, placement of pumps, switch gear and fan units, fabrication and ‘installation of an all butt-welded, nuclear grade piping system, electrical power and instrumentation.

 

 

HIGH LEVEL WASTE TANK FARM REPLACEMENT

Location: Idaho National Engineering Laboratory 
Customer: MK-Ferguson Company
Project consisted of repair and replacement of high level radioactive waste piping systems. Existing piping systems were removed and replaced with secondarily contained stainless steel piping. Project included excavation of 3,000 cubic yards of highly radioactive soil and installation of 20,000 linear feet of stainless steel piping, modification of 23 existing valve boxes, and construction of one new valve box.

ENVIRONMENTAL HOT CELL EXPANSION

Location: Hanford Nuclear Reservation
Customer: Kaiser Engineers Hanford Company.
Project consisted of constructing a materials handling laboratory. The laboratory rooms were constructed of 9″ thick plate, lined with stainless steel (approximately 2,000,000 Ibs).Also included were all ventilation systems, with HEPA filtration, manipulator carts, and laboratory glove boxes.

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.

E-2 ULTRA HIGH PRESSURE SYSTEMS

Location: John C. Stennis Space Center, Mississippi.
Customer: NASA
Project consists of furnishing and installing ultra high pressure (15,000 psi) nitrogen, hydrogen and oxygen piping. Work included excavation for utilities, placement of concrete piers for tank and pipe supports, instrument and purge tubing, piping fabrication
and installation.

E-2 Test Stand Expansion to Support Vertical Engine Testing

Location: John C. Stennis Space Center, Mississippi
Customer: NASA
Project consists of mechanical modifications to cryogenic and process piping systems to facilitate testing of a vertical thrust engine.