PFC Projects

In more than thirty years of operation, PFC has performed thousands of jobs.  The following projects are highlighted to demonstrate the complexity and scope of our experience:

 

Hydrogen Fuel Station Testing and Precision Cleaning

General Physics / California

    

PFC, doing business as PCW in California, has performed extensive hydrostat testing and precision cleaning of state-of-the-art hydrogen fuel stations.  These facilities consist of a natural gas reformer, hydrogen compressor, hydrogen storage, and dual hose hydrogen dispensers along with all associated piping and valves.  PCW assisted General Physics in all stages of the projects to insure components were functionally tested and cleaned to strict requirements.  Because fuel cell components are sensitive to contaminants, PCW's precision cleaning was a critical factor during the hydrogen station construction.  

 

Compressed Gas Trailer Refurbishment

SGS / Kennedy Space Center

PFC maintained NASA’s fleet of compressed gas trailers at Kennedy Space Center for over 20 years.  This contract included remanufacturing and refurbishing 2 - 10 trailers and delivery systems for ultra-pure gases including hydrogen, helium, nitrogen and breathing air per year.  This effort started in 1974 and continued uninterrupted until 2003 as an SGS contract.  Specification refinements, engineering and as-built drawings, process development, etc., were supplied over and above the basic scope of work.  This resulted in hardware lifetimes double original design expectations, and reduction of maintenance requirements between refurbishment/retest cycles (5 years). Additionally, NASA KSC was granted a waiver to use 10-year retest cycles by the DOT.  This action was based on the efforts and processes employed by PFC, and resulted in a large Government cost savings.  This contract, employing Precision's facilities, processes and controls, was evaluated by representatives of the Federal Space Appropriations Committee and deemed the most cost effective contract ever reviewed.

 

Space Support Panel Assemblies

Lockheed Martin / Vandenberg AFB, CA & Cape Canaveral AFS, FL

Precision Fabricating & Cleaning Co., Inc. (PFC) performed this design / build project to fabricate and deliver control panels to Vandenberg Air Force Base and CCAFS in support of the EELV space program.

The contract involved all aspects of fabrication to consecutively process 42 panels from initial design, through fabrication, Hoffman box modifications, fit-up, tubing and component installation, testing, and delivery.  Each panel required individual custom mounting / placement of tubing, brackets and components. 

Panel materials included stainless steel, aluminum and carbon steel and components were precision cleaned within our facility. 

PFC was the prime contractor performed all work other than electrical work and insulation.  These panels ranged in size from desktop (2’ x 2’ x 2’) to 8’ x 7’ x 3’.  The panels were completed in two sets and were aggressively processed 21 at a time, almost concurrently, based on availability of customer furnished equipment

 

Mobile Service Tower (MST) Moveable Platforms

Washington Group International (WGI) / Kennedy Space Center, FL

This project included design, fabrication, corrosion control, and installation of 150 MST platforms and their associated control and hydraulic systems at SLC-37.  The platforms, of sizes ranging from 2’ x 4’ up to 15’ x 30’, are used to provide access to various classes of launch vehicles.  In order to assure proper operation, it was critical that all designs were compatible with vehicle interfaces and the structural components of the MST.  It was also critical to maintain all specified clearances and insure smooth operation at all stages of platform performance.  PFC completed the entire panel fabrication within 2 years.  PFC coordinated all aspects of this project between Boeing, Raytheon – Cape Canaveral, Raytheon – Denver, and the architects & engineers.

 

Launch Table

Washington Group International (WGI) / Kennedy Space Center, FL

PFC fabricated, assembled and delivered this massive 500-ton steel structure to launch complex 37 at Kennedy Space Center.  The transportation for this oversized (80’ x 40’ x 25’) item required special permitting for both ground and marine shipment from Georgia to Florida.  We installed and leveled the launch table in place while maintaining critical dimensions using a laser measurement system sensitive to 0.005 inch over 80 meters.  PFC also installed, assembled and tested hydraulic, cryogenic, pneumatic systems, and critical launch vehicle positioning hardware as an integral part of the table.  This included tubing, piping, and HVAC ductwork.  In addition, PFC installed electrical and control components for facility power and valve/equipment feedback.  We performed the entire finishing and corrosion control for the launch table, including specialized ablative coatings and high pressure / high strength grouting.  This critical launch support project was successfully performed on time and within budget, while meeting all of our customer’s requirements.

Cryogenic Test Skid

United Space Alliance (USA) / Kennedy Space Center, FL

This test skid is used to support testing of the LO2  (Type I) and LH2 (Type 2) 12-Inch Shutoff Prevalve Assembly.  The 12-Inch Prevalve is used in the space shuttle fuel oxidizer main engine feed systems to support propellant system chill down, control propellant flow, and facilitate propellant system dumping.  PFC designed, fabricated, cleaned, and tested the skid to USA specifications.  This project involved the creation of AutoCAD fabrication and as-built drawings, extensive integration of electrical and controls components, cryogenic testing of the system, and mass spectrometer helium leak detection. PFC coordinated closely with USA project engineers to insure the delivery of a fully functional test skid meeting all of our customer’s criteria.

Universal Coolant Transport System (UCTS)

United Space Alliance / Kennedy Space Center, FL

Precision manufactured two Universal Coolant Transporter Systems (UCTS), which included fully performing the fabrication, corrosion control, assembly, integration of GFE, cleaning, testing, and delivery services for successful completion of this contract.  This was a highly technical and complex project that required close interaction with USA personnel.  These units are still in work, but are undergoing final punchlist and acceptance testing.  They are expected to be delivered ahead of schedule.

PFC Customers

PFC satisfied customers include: