Innovative method used to fabricate and install equipment at C-Plant

  • Published
  • By Deidre Ortiz
  • AEDC/PA
ARNOLD AIR FORCE BASE, Tenn. --  By implementing an innovative method for refurbishing the lower header ducts of one of the C-Plant heaters at the AEDC Engine Test Facility at Arnold Air Force Base, craft crews were able to finish the project 7.5 weeks ahead of schedule and achieve a cost savings of over $195,000.

According to Jeff Tate, Technology/Manufacturing planner and scheduler at Arnold, the original drawings for replacing the lower header ducts for the heater were the ones used for the initial assembly of the heater.

“In the original design, the upper and lower header assemblies with tubes were fabricated and installed in 135-inch long sections prior to the installation of the south heater wall,” he said. “But the removal and reinstallation of the south heater wall for this refurbishment process was determined to be too costly and time consuming, so we found an alternate method for installing the header duct assemblies.”

Using the existing drawings, Tate said his team at the Model and Machine Shop worked with the Design team to modify the drawings and come up with a way to make the job cheaper and more efficient.

“We wanted to develop the most productive and cost efficient method to fabricate and install two 50-inch diameter by 93-feet long replacement lower header ducts on the heater at C-Plant, so measurements were taken to determine the maximum duct lengths installable,” he said.

The existing header ducts were demolished by cutting them into four pieces each to verify that they could also be installed at the same length.

“Auto CAD (computer-aided design) was used to plan the best ways to cut, form and weld the ducts into these installable lengths,” Tate said. “The Design Team was then briefed and the group agreed to move forward with the new plan.”

In comparing this refurbishment project to when the heater duct was original installed, it is estimated that demolition cost was reduced by almost 30 percent due to fewer cuts being made to remove the larger sections.

“Waste was also reduced because the guys were able to cut and fabricate wider duct sections to match forming roll limits,” Tate added. “The number of welds needed were reduced as well, estimating at almost 29 percent less in labor and weld consumable costs.”

The Technology Innovations Branch staff at Arnold is constantly working to create competencies, and at the same time, ensures that its employees are recognized as the driving force behind these advances.

“Our Technology Innovations Branch is focused on cultivating the portfolio of our innovation pursuits,” said David Miller, Technology Development Group manager. “As part of leadership's commitment to cultivating new technical competencies, we are also recognizing the innovators who are accomplishing our mission during their daily work.”

If you have ideas on how to perform work more efficiently or how to reduce risk, the Technical Innovations Branch managers want to hear about it. Please contact the Arnold Technical Innovations Branch at 454-7491.