Northrop Grumman Cast/Cure Pressure Skid

Team: Trevor Golding, Camden Gowans, David Rossberg, Tarick Piatt

Sponsor: Northrop Grumman Corporation

Project Definition

Northrop Grumman

Northrop Grumman casts and cures solid rocket motors at their Bacchus facility in Magna Utah. This cast/cure process can take up to 15 days and requires a high pressure air over water system. They currently don’t have an adequate back up system for total system failure.

Functional Requirements

  • Design a backup pressure system that can maintain up to 385 psi for 15 days during a rocket motors cast/cure process.
  • The designed system will need to be portable so it can be moved between eight different pit locations.
  • Remote communication with the facility control center during the entire cast/cure process.

Design Description

  • The skid design utilizes caster wheels to enable one operator to move the skid to different locations. The skid is also forklift compatible allowing it to quickly be moved across large distances.
  • The skid uses an air amplifier and control components connected to a programable logic controller to boost incoming plant air to various target pressures above 300 psi.
  • The skid is designed to operate in both a stand alone configuration as well as connected to Northrop Grumman's permanent systems using a series of 3 way ball valves and hoses. Operating while connected to the permanent systems allows for remote monitoring at the control center.
flow diagram
skid 1
skid 2

Performance Review

computer model
  • Ensured skid and castors could withstand weight of all required components including fully filled 40 gallon tank
  • Calibrated control system to deliver pressure to tank in under 10 minutes
  • Pressurized tank to 400 psi
  • Calculated tipping force for skid
  • Movable by one person

Conclusion

Significant Results:

  • Design successfully reaches pressures up to 400 psi
  • Design enables technicians to connect to existing pressure system by using each major component of the system individually or by using the design as a direct replacement for the entire pressure system.
  • Design supports autonomous pressure control.
  • Cast cure skid mobile pressure system may be controlled by a single operator.

Lessons Learned:

  • Pneumatic system design and operation
  • Design/ Fabrication/ Assembly processes
  • Teamwork

Recommended Future Work

  • Increase tank size to meet max water volume requirement to pressurize rocket motors
  • Baffling/ damping for amplifier input to provide more stable pressure readings