Ultra Fast Closure Valve Systems
Sandia National Laboratories (SNL) awarded Raytheon Ktech a contract to design, procure, manufacture, and test ultrafast closure valve systems (UCVSs) for experiments on hazardous and radioactive materials
(Figure 1). The UCVS is one of three major components to protect personnel and facilities. The UCVS is an explosively driven valve designed to provide an airtight, robust closure that can withstand severe impulse loads. Over the last eight years, Raytheon Ktech has designed and fielded over 70 UCVSs at SNL and at the Nevada Test Site. Raytheon Ktech has developed similar designs on containment systems for Lawrence Livermore National Laboratory’s JASPER Gun
(Figure 2), located at the Nevada Test Site.
Figure 1. UCVS being assembled for fielding
on Sandia’s Z- Accelerator Isentropic
Compression Experiments |
Raytheon Ktech followed stringent production disciplines based on the Department of Energy’s (DOE’s) quality processes to assure that UCVS produced by Raytheon Ktech met all design requirements. We developed a set of production documents, including a manufacturing plan, procurement specifications, receiving inspection, drawings, and assembly instructions. Raytheon Ktech follows the Quality Assurance (QA) Requirements set forth in DOE order 10 CFR 830.120 governing safety in a DOE nuclear facility, management, performance, and assessment. Raytheon Ktech also developed a set of procedures for assembling, shipping, storing, installing, operating, and venting the system following 10 CFR 830.120. Our quality plans are periodically audited both internally (Raytheon Ktech) and externally (SNL), and undergo an internal management review.
Recognizing that Raytheon Ktech’s performance is only as good as its vendors, Raytheon Ktech only approves vendors that are ISO certified or have an internal QA plan, as well, and we assure the vendors remain qualified after a significant change in management or key fabrication personnel. In addition, Raytheon Ktech has systems in place to prevent counterfeit items from entering the manufacturing process.
Figure 2. UCV installed in front of the
catcher chamber on the Jasper Gun
|
SNL approved the initial UCVS design Raytheon Ktech provided, and the design plan performed well during testing runs; however, as the task load increased, the components were no longer performing at the level of proficiency Raytheon Ktech requires. The close working relationship Raytheon Ktech maintained with the testing facility revealed the source of the performance problem, and Raytheon Ktech responded by encouraging SNL to revamp the system, even though the initial switches met the contract requirements. A subtask was added to the contract’s scope, and the schedule was extended accordingly.
As work progressed, Raytheon Ktech staff realized that the customer’s costs could be significantly reduced without sacrificing quality or UCVS performance by switching the containment housing from billet to forging. When discharged, the housing contains explosives, so it must perform without fail. The change meant pioneering a new manufacturing process and finding a qualified vendor capable of meeting the material and design requirements within the timeframe established by the contract. Raytheon Ktech personnel rapidly became familiar with the process and maintained excellent communication with a noted forging company that we eventually selected. As a result, Raytheon Ktech was able to improve the UCVSs, expedite manufacturing time, add value to the product, and realize cost savings amounting to between $1.5K and $2K per unit for the customer. We accomplished all within the established timeline, resulting in a 10% to 13% savings per unit which was passed on to our customer.
