Recent Projects
LANL TRP Project- Los Alamos, NM
On 8/17/09 as part of the 7-year, LANL TA-55 Reinvestment Project (TRP), JB Henderson received a task order to remove and replace a 27,000 lb, 41’ Air Cooled Chiller. The project seemed like many other projects JBH has completed throughout the years with one large exception…The 55 Factor that says to expect the unexpected! The new chiller had been delivered weeks prior in preparation for this day but was not within the work area due to a paperwork mix-up (The 55 Factor) and would have to be transported by JBH to the site from outside TA-55 just prior to installation.
The day began with our superintendent and the crew reviewing the day’s activities and capturing it all in their Pre-Task Plan. The highlight of the plan would be the six critical lifts that would take place in the next 12 hours. With pre-planning complete the crew went outside the fence to perform the first critical lift and was greeted by a LANL Quality Assurance representative who performed a surprise audit at the site of the lift. The JBH Crew and Crane Service passed this pop quiz with flying colors and the QA Auditor noted that our people were a model of safety and quality.
With the audit complete, the crew began transporting the chiller, crane, and a trailer load of rigging through the security areas to the worksite at TA-55. A few hours later the crew was set to remove the existing chiller and had identified these specific challenges: approximately 4” of clearance between a critical facility and the CUB that supports it, little room for the truck and crane to maneuver, and lastly (and most importantly) the Facility Operations Director and his entire staff were within the “cone of safety” of the pick and they would have to be evacuated each time the crane had a load in the air. With our superintendent coordinating all the variables, the pick went perfectly and the old chiller was loaded onto a truck strictly following the critical lift plan.
Crews now prepared to install the new chiller. The slab anchor bolts had to be preinstalled before setting the chiller. A dry fit was necessary, which meant the third critical lift of the day. The lift was completed and the exact anchor bolt locations were determined and piping dimensions verified. Everything was within an eighth of an inch but given The 55 Factor it was perfect.
The final placement of the chiller was ready, the crews were ready, the anchor bolts were ready…but the owner wasn’t ready. An occupant of the building was on an important phone call and could not be disturbed pushing the final install back about 2 hours. With all the extra time to plan, the lift went perfectly and the 24,000 lb unit was placed onto 24 anchor bolts without damage to a single bolt.
After six critical lifts, 12.5 hours, plenty of pre-planning, coordination, clarifications, anxious owners, and a few tense moments the project was complete and the facility received its new chiller.Bio Mass Boiler Installation- Colorado
JBH Colorado continues to add to the JBH resume, this time pioneering the installation of energy efficient systems. The team recently installed a Biomass boiler system at 9,953 ft. elevation for the Southpark Park and Recreation Center in Colorado. The JBH PM managed the installation of the boiler room built within a storage connex. The boiler will be used for heating pool water during the summer and for temperature control within the air handling units. Biomass is a biological material derived from living or recently living organisms. Generally, Biomass used to generate energy consists of plant-based material but can also run on animal and vegetable derived materials. The Southpark Park and Recreation center will use wood pellets obtained from local trees killed by beetles. By using this wood fuel, the boiler is a renewable energy source that releases no more Carbon Dioxide then the plant would have naturally released into the atmosphere and the center will save an approximate $40,000 annually in heating costs.
Fab 32 AWN Tank Set- Arizona
The JBH Rigging/Process Crew in Arizona was recognized for their exemplary execution of a very difficult Tank set within the Acid Waste Neutralization Pit at our microelectronics customer’s Ocotillo site in Arizona.
This effort was one in a series of modifications to the F-22/32 Acid Neutralization Systems that are being upgraded to support the new 1270 process. The 1270 process will be initiated at this site early 4th quarter. All work in this area is critical to the ongoing manufacturing processes in Fab-32. Current production revenue in this Fab is $ 1,000,000/ hour, 24 hours/day, 7 days/week. Any unscheduled interruptions to the Acid Neutralization System will shut this cash cow down!
The working conditions in the “PIT” are HOT with temperatures exceeding 120 degrees in July. It is extremely DANGEROUS due to all of the nasty chemicals being processed and neutralized here and space is limited. The 40’ tank shown in the photo required the reinforcement band be cut to enable a 1/2 inch clearance between the tank and existing structural steel before it could be lowered down. Once lowered, it went through a myriad of brittle, acid waste piping before resting on its pad.
The site owner and their construction manager recognized JBH for a flawless planning effort and a safe, perfect execution to this extremely risky work. This work was the last in a series of tank sets in the Pit. Previous work included a live tie-in to the acid waste system including an acid waste flow diversion work process that enabled F-32 to continue with production.
This is a great example of our company moving forward at a new site and gaining the confidence of the owner and construction manager. They have learned to trust JBH with their most critical work and consistently acknowledge our abilities. The JBH crew was given Home Depot gift cards for this project and recognized at the Construction Managers weekly safety meeting. CONGRATS TO THE CREW, JOB WELL DONE!
The Boeing Company Recognizes JBH for Work on the Advanced Tactical Laser (ATL) Aircraft
Pipe fabrication at JBH has expanded from commercial construction to high-tech cleanroom innovations and now to providing mechanical integration support to The Boeing Company. On June 8, 2009 Boeing presented a plaque to JBH that read; “In recognition and appreciation for your dedicated performance and service on the Advanced Tactical Laser Project.” On June 13, 2009, Boeing and the U.S. Air Force successfully fired a sharp-shooting laser from the Advanced Tactical Laser (ATL) Aircraft while it flew over White Sands Missile Range in Alamogordo, New Mexico.
Boeing describes the ATL Aircraft as a C-130H aircraft equipped with a chemical laser, a beam control system, sensors and weapon-system consoles. According to Gary Fitzmire, VP and Program Director of Boeing Directed Energy Systems ATL’s ultra-precision engagement capability will dramatically reduce collateral damage when hitting a target. Making this possible is a complex mechanical system facilitating the lasers release.
JBH has provided mechanical integration support to this system since 2005 through fabrication, installation and testing of the complex piping assemblies. The JBH team also provided design feasibility checks to Boeing engineers ensuring that the new systems could realistically be built. Once designed, the specifications for the piping system were given to JBH to construct.
The fabrication, assembly and installation of pipes ranging from 1/8” to 6” was performed at our on-site Pipe Fab Shop or installed directly onto the aircraft housed at Kirtland Air Force Base. Exclusive weld procedures were developed by our fab shop to meet the strict needs of the chemical laser support system.
Quality needs were significant because of chemical toxicity; each weld went through rigorous tests to prove its integrity. Weld procedures for the systems installation met classes A, B, and C of Aircraft Welding Spec D17.1. Orbital, Tig and Stick welding was performed on Stainless Steel, Monel and Hastelloy pipes by specially certified JBH pipefitters. Welds were tested based on the required class with Class A being held to the highest quality requirements. Class A welds were X-Rayed to identify gaps and non-conformance with specs. Class B and C welds were tested either pneumatically or hydrostatically using air-pressures up to 9,000 psi. Every weld was certified by a 3rd party before being integrated into the system.
The complex piping design, developed by Boeing’s highly skilled engineers, was brought to life by an educated and experienced JBH team of welders, pipefitters and sheet metal workers.
