The Challenge
Sierra Nevada Corporation (SNC) faced a critical need to significantly expand its testing capabilities for a new, patented engine. This expansion was crucial for the development and validation of next-generation propulsion technology, including their VORTEX® rocket engine, intended for NASA, the U.S. Air Force (USAF), and commercial launch companies. To meet this demand, SNC sought to undertake a comprehensive restoration and renovation of its existing facilities and site at the Badger Army Ammunition Depot campus, alongside the ambitious plan to construct an entirely new test cell. The project demanded a partner with deep expertise in complex facility integration and custom control solutions, given the precision and scale required for advanced rocket engine tests. This new rocket engine test facility would be a cornerstone of their innovation.
The Solution
SNC engaged ACS, leveraging ACS’ proven track record in delivering integrated industrial solutions. Through a meticulously planned phased approach, ACS managed the entire site renovation and expansion, delivering a fully integrated, state-of-the-art rocket engine test facility. This comprehensive solution encompassed engineering and building custom controls solutions tailored to the unique demands of rocket engine testing.
- Integrated facility modernization: ACS undertook a complete upgrade of the existing testing facilities, infrastructure, controls, and test equipment across the site. This involved a detailed assessment and remediation phase to prepare the site for advanced operations, including specialized areas for rocket fuel testing.
- New test cell design and construction: A cornerstone of the project was the design and management of the construction of an entirely new, purpose-built test cell. This new cell was engineered to accommodate the specific requirements of SNC’s patented engine technology, including the flexibility to test in both vertical and horizontal positions. This expansion significantly boosted their capacity for rocket engine tests.
- Advanced control and monitoring systems: ACS designed and implemented a sophisticated remote control room, connected via CCTV and PLC communications. This system provides operators with precise control over test parameters and real-time monitoring of engine performance, ensuring safety and data integrity. The solution also included a fuel farm upgrade, crucial for efficient rocket fuel testing, and an underground sound suppression and cooling system, critical for managing the intense conditions of rocket engine testing.
- Local collaboration and turnkey delivery: ACS collaborated with over 40 Wisconsin companies, including design professionals and material suppliers, underscoring a commitment to local economic partnership. The project was executed as a phased turnkey delivery, covering everything from initial site evaluation and remediation to civil, architectural/structural, mechanical, electrical, and plumbing design engineering, alongside process piping modeling and coordination, and complete controls system design, fabrication, and installation, all contributing to a world-class rocket engine test facility.
The Outcome
ACS successfully delivered a robust and fully integrated testing complex that significantly enhanced SNC’s engine development capabilities. The upgraded facilities and the new test cell provide the necessary infrastructure for rigorous rocket engine tests of next-generation propulsion systems, as demonstrated by the public test-fire of the VORTEX® rocket engine. This project has empowered SNC to advance its patented engine technology, serving critical needs for NASA, the USAF, and commercial space ventures, while ensuring operational precision, safety, and efficiency in all aspects of rocket fuel testing and engine validation.
Key Features
- Ability to test vertical and horizontal positions and multiple fuels, supporting diverse rocket fuel testing needs
- Fuel farm upgrade
- Underground sound suppression system and cooling system
- Remote control room is connected via CCTV and PLC communications
ACS Services
- Phased turnkey project delivery including site evaluation and remediation
- Civil, architectural/structural, mechanical, electrical, and plumbing design engineering
- Process piping modeling and coordination
- Controls including PLC panel design, fabrication, and installation
