SAM team member and master builder Nathan Schmit spent the better part of January chasing leaks, patching, and running pressure tests in the Crew Quarters (40 foot shipping container) at SAM.
The leaks took on several forms, from punctured or torn aluminum tape to loose rivets in the original shipping container construction. Many of the leaks were audible, when in fact there were no trace sounds during prior pressurized tests and crewed missions. It was concluded that the daily expansion and contraction of the 40 foot container, which has an aluminum exterior and stainless interior, that new leaks had developed.
Using techniques applied in prior leak detection sessions, Nathan discovered a major leak behind the mini-split air conditioning system that invoked the need to pull the system from the wall, patch, caulk, and reattach. In so doing, we also moved the line-set from going straight out behind the head unit to first moving down along the interior wall, then out, through the wall. This gives us visibility and access to the interface, should it leak again.
Along the interface between the floor and rear wall Nathan poured over two gallons of clear epoxy resin to fill a series of leaks that were otherwise impossible to reach and patch, despite several attempts.
The subsequent pressure tests found leak rate increasing, not decreasing, which lead us to discover that once again, the patches on the lung had dry rotted.
