Neil Bednar – Some Interesting Career Projects in Engineering (Reverse chronological order)

1. 7-Pin I-Wire Penetrator System (ITT/BIW Connector Systems) – 2015

What is it?

The 7-Pin I-Wire Penetrator System is a wellhead penetrator and connector system that allows safe introduction of

seven instrumentation leads. It’s a 200°C, 5,000 psi rated instrumentation wire feedthrough that has a novel safety

feature, whereby internal pressure is visually indicated and removal is prevented.

What did I do?

I designed the device, specified the materials, built prototypes, performed testing, and worked with manufacturing to

specify the fabrication and assembly methods. I drove the project from ideation through a standard stage gate process

into final production preparation.

Biggest Challenges?

The biggest challenge was keeping the project moving through the gate process while product development protocols

changed mid-stream (new reporting requirements, introduction of SAP, new documentation processes, upgrade to

purchasing methods, etc.)

Greatest Rewards?

The greatest reward of this project was showing that a technology typically used for room temperature underwater

applications (glass-to-metal sealing) could be used for high temperature, hazardous locations.

2. Fast Fuel Sensor (Tyco Thermal Controls) – 2011

What is it?

The Fast Fuel Sensor is a leak detector- a conductive polymer film based device that changes resistance rapidly upon

exposure to hydrocarbon liquid. The mechanism is a physical swelling of the polymer matrix, which separates conductive

particles causing exponential electrical resistance change.

What did I do?

Coming in to the company I was tasked with redeveloping a sensor with major problems. The sensing film was too fragile

and deteriorated in the field even from simple freeze and thaw cycles. I reformulated the sensing film using a liquid

polymer instead of a semi-dissolvable silicone, modified the carbon loading and the fabrication process, made

modifications to the circuit board, eliminating soldered wires and adding a modular header. I produced full engineering

documentation through a three-stage gating process and managed all of the experimental testing. Final stages included

my bringing the assembly process in house from a vendor and working with operations and manufacturing to streamline

the process.

Biggest Challenges?

The biggest challenges were less technical, and more in recruiting other individuals over time to bring a process in-house

for which we were not initially well suited. I also had to design and build tooling, create processes, etc.

Greatest Rewards?

The greatest reward of this project was two-fold. I’m happy to know that I helped develop a technology that will be

deployed throughout the world to help detect and stop leaking fuel into the environment. Second, I learned a lot about

the capabilities of this technology for future applications.

3. Private Consulting Project for Big Horn Valve Company – 2007

What is it?

This particular Big Horn Valve model (stem-less) was designed for axial actuation, so by simple pushing or pulling the

valve could be opened or closed. This design feature was intended for space application such as orbital refueling or as a

quick-disconnect for ground based liquid hydrogen systems.

What did I do?

Under a NASA subcontract, I was hired by Big Horn Valve to design, fabricate, and operate a testing machine and

apparatus for measuring the flow rate of helium gas through an axially actuated valve, at cryogenic temperatures (77 K).

The machine had a load cell, LVDT (position sensor), and a cold sink for flowing liquid nitrogen, as well as a linear

actuator with maximum force of 750lbs. The testing in Wyoming was to prove the concept and function of the specialty

valve of their design. I also performed magnetic analysis using FEA (since the valve is actuated using magnets), and

designed all components with Solidworks.

Biggest Challenges?

The biggest challenges were documentation of progress per government requirements, though overall the project was

very positively motivating.

Greatest Rewards?

The greatest reward of this project was completing the project under my own supervision as a principal in a small

company. It was a side-job and a tremendous amount of fun. I enjoyed putting my work experience to use on my own.

4. BWXT High Voltage Current Lead Insulation – 1999

(Example not actual magnet)

What is it?

As part of a SMES project (Superconducting Magnetic Energy Storage) for BWX Technologies I had multiple

responsibilities. This particular SMES had a maximum safety design voltage of 90,000 V, and of course operated in a

vacuum at 77K. Design energy storage was in the neighborhood of 250 KJ.

What did I do?

I was primarily responsible for developing a novel low temperature electrical insulation scheme for oddly shaped, 25 ft.

long high-voltage current leads. I also modeled and designed an insulation scheme for high voltage current lead breaks

(where cryogen flowed but was insulated from ground). I did some thermal analysis, created manufacturing drawings,

ordered custom parts, fabricated components, managed a composite materials testing project to support the project,

and setup a small scale epoxy impregnation facility- training staff members.

Biggest Challenges?

The biggest challenge was satisfying the company’s safety department concerns while performing 90,000 volt insulation

breakdown tests. Also, as the project reached midway point, funding evaporated and it was eventually mothballed.

Greatest Rewards?

Seeing a large project move along on several different fronts was very satisfying. Coming up with solutions for unique

challenges was also enjoyable.

5. MINOS magnet design and structure - 1998

What is it?

MINOS is a neutrino detector with a near detector on the Fermilab campus, and a far detector half a mile underground

in a mine in Minnesota. There are three far detector modules which essentially form a massive magnet meant to steer

particles into a specific region of the steel in hope of weak interactions to produce photons which indirectly indicate the

presence of neutrinos. (There’s an arrow pointing to me in the first photo.)

What did I do?

Hired as a contract engineer, I designed the steel support structure for one of the near detector modules, which

weighed over 8,000 tons. After given some starting concepts by the physicists, I finalized the design and assembly

logistics of both the far detector magnet windings and the near detector magnet, which was a hollow, water cooled,

insulated, aluminum conduit seam welded and assembled in plate sections. The far detector utilized 1/0 building wire

and. I did some thermal analysis, all the structural steel design for the support structures, built an entire solid model in

SDRC CAD for dimensional tolerance checking, worked with technicians to build a scale mockup and thermal test, and

completed engineering drawings on initial plate designs.

Biggest Challenges?

The biggest challenge was simply that this was my first real job out of graduate school, so it was intimidating.

Greatest Rewards?

The greatest reward from this project was getting the opportunity to work on such a large device. The people I worked

with at Fermilab were also of the highest caliber of many places I have since been employed.