A Satellite in Hot Water

Jason Wyckoff Space Coast Launch Services

ABSTRACT

A critical satellite processing facility that Space Coast Launch Services is contracted to maintain had an issue with the hot water feeding the HVAC environmental control. The predictive maintenance team helped the technicians to determine the source of the leak using thermography. The infrared findings saved approximately $250,000 and hundreds of man hours, eliminating the need to dig up a 30-foot berm and the entire pipeline area. This quick repair resulted in the continued environmental control of a $300 million GPS satellite and no launch schedule delay, which would have been extremely detrimental to the contract both financially and politically. In addition, if the environment of the satellite goes out of specification and allows condensation to form, the satellite may have to go through a major re-build and cleaning process requiring thousands of man-hours and millions of dollars to complete.

The predictive maintenance team has implemented the same technique for all of our chilled and hot water pipes. We are monitoring the condition of the submerged pipes and above ground pipes, as well as the condition of the insulation and leak detection. By doing this, we are improving the efficiency and reliability of the environmental control systems at the facilities we maintain.

INTRODUCTION

The condition of underground and above ground insulated chilled and hot water pipes can be monitored with the use of IR. Using IR to detect hot or chilled water leaks results in a more efficient HVAC system, as well as less energy consumption and a more reliable system. Inspecting every connection along a water pipe would be time consuming and may not lend itself to detecting the leak.

LOAD MEASUREMENT

Figure 1 is the IR image of the hot water supply and return pipes providing the Satellite Processing Facility with hot water. Evidence of a suspected leak is visible in the images; note the pooling of hot water near the hot water supply pipe.

Figure 1. Thermogram/photo pair showing hot water supply and return pipes.

Figure 2 is the IR image from 35 feet above the area providing a clear image of what is going on and identifying the potential source of the leak.

Figure 2. Thermogram/photo pair showing hot water supply and return pipes as viewed from 35 feet above.

Figure 3 shows an IR image of the leak area with the rainbow palette allowing us to view the probable source of the leak more easily.

Figure 3. Thermogram/photo pair showing hot water supply and return pipes as viewed from 35 feet above.

The predictive maintenance team directed the dig crew to the area most likely to contain the broken section of pipe. They replaced the broken section without digging up the burm or any excess area.

SUMMARY

Although there was a leak, IR proved to be a cost effective method to detect the source and direct the dig team where to unearth the faulty connection. At our facilities located in Cape Canaveral, Florida, we are implementing an IR program that encompasses electrical equipment and rotating equipment. The IR program also now includes monitoring the condition of chilled and hot water pipes above ground, underground, and insulated.

ACKNOWLEDGEMENTS

The authors wish to thank the Infrared Training Center at FLIR Systems, Inc. for the opportunity to publish this paper. We are also grateful for the support from the Space Coast Launch Services’ operations and maintenance personnel who provided additional data and information for this paper. Special thanks to the RCM team.

ABOUT THE AUTHOR

Jason Wyckoff is a Level I Certified Vibration Analyst and a Level II Certified Thermographer. He has reduced downtime downtime and cost by 60% for electrical predictive maintenance programs by performing infrared analysis. Wyckoff has extensive experience in predictive maintenance and reliability engineering and holds a BS in Mathematics: Engineering Physics from the University of Central Florida.

Predictive Maintenance

• Vibration analysis Level 1 Certified
• o Reduced downtime on rotating equipment performing condition based monitoring
• Level II Thermographer Certified

o Reduced downtime and cost by 60% on electrical PMs performing Infrared Analysis

• Laser Alignment, Ultrasound, Oil Analysis, Motor Circuit Analysis Reliability Centered Maintenance Trainer/Facilitator Reliability engineering (nearly ten years of experience) University of Central Florida (UCF), BS - Mathematics: Engineering Physics (ECD 5/2010) Reliability Centered Maintenance
• Reliability Centered Maintenance (RCM) analysis on critical equipment
• Developing a Predictive Maintenance program using the following technologies:
1. o Ultra Sound
2. o Oil Analysis
3. o Vibration Analysis, also proficient in Laser Alignment
4. o Infrared Analysis
• Reliability/Risk Management Analysis for each Expendable Launch Vehicle Reliability Engineering
• Developed a Reliability Program for NASA EELV Safety & Mission Assurance
• Failure Modes and Effects Analyses/Failure Modes, Effects, and Criticality Analyses
• Performed, Fault Tree Analyses, Criticality Assessments, Safety Hazard Analysis
• Calculated/predicted reliability parameters including AO, DO, MTBF, MTTR, etc.
• Developed/managed risk management program Systems Engineering
• Trends Analysis for critical equipment improving reliability and maximize availability
• Part of Integrated Product Teams (IPTs) of projects managing reliability requirements
• Managed DMSMS issues resolving obsolescence concerns improving space lift launch range

availability Trained personnel

• PdM technologies IR and Vibration Analysis
• Reliability Centered Maintenance methodology and facilitating.

• Reliability Engineering uses and applications Software Proficiency

o RCM Toolkit, MAXIMO database (CMMS), Agile, Crystal Report Writer, Enshare Emonitor,

FLIR Report Writer, RELEX Reliability Suite, Microsoft Office Professional Employers Systems Engineering Tech – Space Coast Launch Services (SCLS) (08/2004 – Present) Consulting Reliability Engineer Aerotek/SAIC ELVIS Contract (12/2005 – 04/2005) Consulting Reliability Engineer - RAM Analysis Inc. (01/1998 – Present) Systems Engineer - ITT Industries - Systems Division (10/2001 to 05/2004) Electronic Warfare Systems Maintenance Technician – U.S. Army (01/1998 to 08/2001)