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Trade revealed reuse of existing ductwork was lowest cost but risk was high to clean the ductwork, adapt to modern clean room air flow protocol and energy efficiency due to ductwork location above ceiling.
New ductwork was selected even though higher in cost risk was the over-riding factor. Retrospect – Correct decision was made as existing ductwork was grossly contaminated and contained asbestos mastic.
Design requirements specified oil filled transformers. Vendor quotes revealed higher cost and longer lead time than dry wound transformers. Dry wound transformers operate at higher temperatures, and have lower output ratings.
Load study revealed dry transformers will adequately support IOZ and have suitable reserve with cooling fan option installed.
Cost savings exceeded $100K by selecting dry wound transformers.
Completed substation Installation New Dry Wound Transformers
Cost estimates for ESD flooring greatly exceeded budget allocated for floor.
Team challenged requirement for ESD flooring and revealed no vehicle or program requirement existed for the capability. Revised FDC requirement and specifications to delete the ESD capability. Estimated cost avoidance is $300K
Design required standard gypsum board 5/8 inch thick. Roof water leakage was apparent and occurring when schedule mandated installation of the ceiling material. Questions on table as to the suitability of existing ceiling suspension system for holding weight of the gypsum board.
Team revised gypsum board to ½ inch thick and water resistant fiberglass backing rather than paper backing.
Water leaks continued for a year after ceiling installation; due to the revised material selection no gypsum board was required to be replaced.
Reduction of material thickness reduced overall ceiling weight and enabled utilization of existing suspension system without modification.
Design required elevators 9 (West) and 11(integration cell) to be rated for personnel use. Elevator 9 was to be rated for a 30K pound lifting capability. Significant cost and infrastructure is added when elevators are “man rated” rather than used only for material.
Team challenged requirement to man rate and found no need for personnel to ride on the elevators. Orion had no requirement to maintain a 30K pound lifting capability. Specification was revised to delete the man rating and reduce lifting capability to 15K pounds.
Original specification pricing greatly exceeded available budget; revised requirements enabled installation within budget limitiation.
Original concept and baseline reutilized existing O&C tank farm for high pressure gas storage. Evaluation of the existing tanks revealed in poor condition and out of certification. Cost and risk was elevated.
Performed commodity use study which revealed the validation vehicle manufacturing and testing could be completed using portable tube bank supplies.
Revised engineering to provide connections to tube banks yet maintain growth capability to reconnect to refurbished tank farm in future.
Handrails for Integration Cell
Team located useable aluminum hand rails at the LC-40 MST. MST was being taken down and hand rail became available.
Recovered Aluminum hand rail salvaged from the Titan IV program was used for railing at the O&C IOZ integration cell saving approximately $20K.
IOZ ceilings were in poor shape. Sampling prior to repair revealed asbestos in taping compound used during original installation.
Could not qualify drywall contractor to work on asbestos containing materials and could not find asbestos mitigating contractor to work on drywall.
Resolved to remove entire 50,000 square feet of ceiling material and replace with new. Retrospect – ended up being the right decision as continuing roof water leaks would have demanded significant additional removal and replacement. New material used was resistant to water.
Use of Mobile Platform and Aerial Lift to perform Asbestos Ceiling Demolition New Ceiling Gypsum Installation Ceiling Installed Ceiling Access
Minimal work baselined on East and West vertical bay doors.
Deeper investigation revealed significant defects and degeneration in the doors and supporting systems. Substantial effort required to replace pneumatics, control system, seals, counterweights, cables, and drive systems.
Overall door retrofit effort split between baseline and follow-on scopes.
Door retrofit effort completed within schedule and budget limitations.
Counterweight Corrosion Repair Door Operator Drive Shives Cable Reels