US Space Force / Boeing AEOS Dome Modernization EPC Project, Maui, HI

Project JRC played a pivotal role in the AEOS Dome Modernization project for the US Space Force and Boeing, a $3.5M+, 3-year endeavor located in Maui, HI. Serving through Controlled Fluids Inc. as the Principal Engineer of Record and Lead Project Manager, Project JRC spearheaded significant hydraulic and control system upgrades for the telescope roof actuation. The project involved installing eight 16 ft hydraulic cylinders with specialized mounting hardware, demanding a unique approach to buckling analysis. This included non-typical calculations and Non-Linear FEA, with findings successfully presented and defended to Boeing Engineering Buckling Experts.

Notable aspects of the project included the installation of three PLC Control Cabinets equipped with Delta Motion Controllers, all at the challenging elevation of 10,060 ft in Haleakala National Park, Haleakala Crater. Effective coordination with National Park Rangers and Space Force Civil Engineers was crucial for the crane operations. Project JRC's involvement spanned from the bid phase, determining project requirements, cost, and scheduling, to creating and implementing a comprehensive Project Management Plan with an Integrated Master Schedule.

Further contributions encompassed preparing the Controls and Hydraulic Cylinder Replacement Plan, incorporating environmental considerations like spill plans and solid waste management. The team also developed the System Integration Test Plan and the System Acceptance Test Plan. A full Risk Assessment, including FMEA, was conducted, leading to a thorough Risk and Mitigation Plan. Throughout the project, Project JRC facilitated critical Project Status Reviews, Critical Design Reviews, and Ship Readiness Reviews. The project culminated in the successful on-site installation of the control system and hydraulics, showcasing Project JRC's expertise in managing and executing highly specialized and technically demanding projects.

• Role: Principal Engineer of Record and Lead Project Manager.

• Project Scope: Hydraulic and Control System Upgrades for telescope roof actuation.

• Key Components:

• 8 x 16 ft Hydraulic Cylinders with specialized mounting hardware.

• Unique Buckling Analysis with Non-Linear FEA.

• 3 PLC Control Cabinets with Delta Motion Controllers.

• Installation Challenges:

• High-altitude work at 10,060 ft in Haleakala National Park.

• Coordination with National Park Rangers and Space Force Civil Engineers.

• Project Management:

• Bid phase participation, project requirement analysis, cost and scheduling.

• Developed Project Management Plan with Integrated Master Schedule.

• Prepared Controls and Hydraulic Cylinder Replacement Plan.

• System Integration and Acceptance Test Plans.

• Comprehensive Risk Assessment with FMEA and Mitigation Plan.

• Facilitated critical project reviews and on-site installations.