On top with ICBM refurbishment

  • Published
  • By Hilltop Times staff
CLEARFIELD, Utah --  On Sept. 4, the successful completion of the Propulsion System Rocket Engine (PSRE) Life Extension Program (LEP) was celebrated at the Freeport Center, with many top representatives from the United States Air Force Intercontinental Ballistic Missile (ICBM) Systems Directorate, its Integrated Prime Contractor, Northrop Grumman, as well as the 309th Missile Maintenance Group in attendance.

The PSRE is an integral part of the Minuteman III ICBM. As the liquid-fueled post-boost upper stage of the Minuteman III, the PSRE provides on-demand precise impulse increments to the post-boost vehicle portion of the missile at altitudes above 300,000 feet to provide forward, pitch, yaw and roll control.

This program's importance to the Air Force's No. 1 critical priority -- ensuring excellence in its nuclear mission -- was emphasized in remarks at the celebration, as the LEP refurbished an important component in the nation's defense deterrence.

"Nothing got in the way to stop this team," said Col. Ryan Britton, director of the ICBM Systems Directorate. "This weapons system is operating better than at any time in the history of ICBM."

"The PSRE program is a great story of teamwork and determination both from the Program Office, from the missile maintenance group, from Northrop Grumman, but also from the maintainers up north at the missile bases. They were the ones that had to brave the heat, the frigid cold weather to get this program done," said Col. Andrew Healy, 309th MMXG commander. "This program had some setbacks and we overcame those to get it done, like Col. Britton said, 'Faster and better.'  "

The PSRE was originally built by Bell Aerospace in the 1960s with the first unit delivered to the Air Force in 1970. In early 2000, the ICBMSD Systems Directorate at Hill AFB began efforts to refurbish the entire operational PSRE fleet to extend service life beyond 2030.

With the help of Northrop Grumman and its subcontractor Aerojet Rocketdyne, this effort included an assessment of the units in the field and an identification of seven critical components for replacement to ensure reliable performance into the future.

The PSRE LEP engineering and manufacturing development program (EMD) began in January 2000 to build and qualify production facilities, test equipment, replacement materials, manufacturing processes and government technicians. EMD was complete in 2006 and included a successful transition into low rate product refurbishment in April 2004.

Trenton David, 581st Missile Maintenance Squadron flight chief, part of the Hill AFB team, explained that it took some time to get up to speed. "Extensive training was involved, including table-top and on-the-job training, as well as certification courses," David said.

In June 2005 the first field deployment of a fully refurbished PSRE occurred at Malmstrom AFB, Montana. Full rate production began in January 2006, highlighted by a successful flight test of a refurbished PSRE in February 2006.

The PSRE LEP was managed under a formal partnering agreement, established in September 2004, between the Ogden Air Logistics Center (ALC) and Northrop Grumman. Under this agreement Northrop Grumman and its subcontractor Aerojet Rocketdyne provided program management, engineering, test and operations support, and refurbishment kits. The 309th Missile Maintenance Group provided the refurbishment facilities at Hill AFB and technicians to disassemble, re-assemble, test transport and store refurbished PSREs. This partnership marked the first time in Air Force history where government employees worked in a contractor's facility, located at the Freeport Center in Clearfield.

The unique arrangement combined the advanced maintenance skills and experience of Hill AFB workers with contractor team expertise and replacement components developed by industry using the latest technology and manufacturing processes.

"The program has been very successful," said Jay Parkin, 581st MMXS director, as he looked forward to the completion of the final four PSREs. He had nothing but praise for his people. "There are people in this area who have worked there their entire career processing those engines. We have a very safe, conscientious workforce."

The entire Minuteman III operational flight of 558 PSREs was successfully refurbished, achieving full operational capability in September 2012. Refurbishment consisted of replacement of identified components as well as a full system-level inspection and checkout of the PSRE while at the Hill depot. The program also included completing system-level testing of nine PSREs. As part of this process, the PSREs were first dynamically tested at the Hill AFB Little Mountain Test Facility. Dynamic testing simulates flight environments and pre-conditions the PSRE for the test. Once that qualification was met the PSREs were shipped to
NASA's White Sands Test Facility in New Mexico for static fire testing. The testing, conducted at a simulated altitude of 80,000 feet confirmed the PSREs will operate as intended during flight.

The dedicated team successfully overcame a worldwide helium shortage when that element was required in the testing portion of the refurbishment. The 581st MXMS flight chief explained that engineers worked out a way to process components in such a way that they could be stored under tightly controlled conditions and then receive the required testing when supplies became available. An arrangement was worked out with helium suppliers and the Defense Logistics Agency for a steady supply of helium.

Maj. Naomi Franchetti, 581st MMXS operations officer reported that due to the program -- environmentally unacceptable materials and processes have ultimately been eliminated, replacements have been developed for unavailable materials and hardware reuse limits established.

Dennis Pulsipher, Air Force PSRE LEP Program manager said, "This has been a great program. To be able to work with professionals from industry, the 309th Maintenance Group, the Air Force and NASA to build a cohesive team that understands the requirements and value of this weapon system has been exciting. This team has overcome some huge challenges to deliver the warfighter a safe, reliable and cost effective PSRE that will help maintain our strategic nuclear deterrent well into the future."