Process Improvement Saves $25K Published Aug. 6, 2012 By Consetta Woosley AEDC/PA Arnold Air Force Base, Tenn. -- Nathan Lister doesn't just sit on ideas - he takes action. Lister, a test engineer in the High Temperature Lab (HTL) area of ATA's Integrated Test and Evaluation Department, took the initiative to improve a process that will result in a cost savings of $25,500. "The idea had been discussed by our test team, but I wanted to take it and run with it," Lister said. The initial idea was to improve the process of hydrostatic testing such that the segments used in the modules of the arcs heater can be initially tested at operational pressures. "The segments used in the HTL facility are purchased off-base and are required to go through an acceptance test upon arrival at AEDC," Lister said. "The acceptance test includes hydrostatic testing of each individual segment. Since the segments are not supported (uncompressed) they cannot be hydrostatically tested at operational pressures without being damaged." Due to the inability to hydrostatically test the segments at operational pressures, the segments periodically leak during pre-operation water flow checks. When this happens, the module and segments must be removed from the heater and another one installed, costing many hours of work. "The idea was really not mine," Lister said, "Our entire team threw the idea around, but I decided to follow through and design something that might work." Lister designed a hand-operated hydraulic press to compress and support the segments just like they would be when installed into the HTL heater. This would allow the segments and modules to be hydrostatically tested at equal to or higher pressures than those used during operation. Another advantage of the hydro press is that it allows for a whole module of segments to be tested at the same time rather than the current process of testing them individually. Furthermore, the hydro press has the capability to pull a vacuum on the modules while the water passages are being hydrostatically tested, a capability that previously did not exist. "Using the hydro press will reduce the time it takes to hydrostatically test segments, reduce the number of leaks found after installations, reduce the need for heater tear down and ultimately save money," Lister said. Lister began design of the hydro press in January of this year with a projected completion date of late August. "This whole process has been a great learning experience for me," Lister said."It is exciting seeing my design materialize, but it took a lot more people than me to make all this happen. I sought inputs from many people, so it really is a group effort. I just put everyone's ideas into action." Kevin Thompson, lead engineer for the HTL facility said, "The ability to check segments at operating pressures will not only aid in the acceptance of new segments, but will also allow us to better evaluate used segments during routine maintenance. Nathan's positive attitude and easy-going personality make him a pleasure to work with and his technical abilities and work ethic are outstanding." Lister was a co-op with ATA in the HTL area in 2007 and was later hired in 2009 after graduating from Tennessee Technological University with a bachelor of science degree in mechanical engineering. Lister currently resides in Murfreesboro, Tenn., and plans to complete his master's degree in mechanical engineering from the University of Tennessee Space Institute (UTSI) in 2013.