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Darchem Engineering Nuclear Systems
BECBC DWG Sector Group – 19th March 2014
• AGENDA • The meeting will be chaired by Ivan Baldwin -Nuvia • Welcome from the Chair. • Welcome from Phil Vaughan, Director of Nuclear Systems at Darchem. • Around the room introductions • Apologies • Host Presentation : Darchem Engineering • Update from Sellafield inc current commercial opportunities • Update from LLWR inc current commercial opportunities • Updates from group members on new opportunities / new technologies / feedback from
events: • The next meeting will be on 11 June Hosted by ARUP Venue TBA • Any other business • Lunch will kindly be provided by Darchem Engineering and provides an excellent
opportunity to further network. • Factory Tour – PPE: Safety Glasses will be required
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Safety Share
Agenda
1. Darchem Engineering
2. Capabilities
3. Nuclear Industry and Markets
5. Conclusion
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Esterline Background
Annual sales of over $2Bn Total of over 12,000 employees worldwide
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Sales turnover £80m Personnel Employed 850 Quality Approvals BS EN ISO 9001:2008 AS9100 Environmental Standard ISO 14001 Safety Management ISO 18001 Energy Management ISO 50001
Company Data
Darchem Engineering
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Customers by Market Segment
Customers by Market Segment
Aerospace
Energy
Naval and Marine
Automotive
Darchem Engineering
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Darchem Engineering
Insulation Systems (Gloucester)
ALAN SHEFFIELD
VP Finance
JIM LOVE
VP Sales and Marketing
ANDY BRAGG
Managing Director
WILLIAM MEIJER
Nuclear Systems
PHILIP VAUGHAN
Purchasing
DEREK SMITH
Technical Services
GARY JOBLING
Human Resources
SHIRLEY WILSON
I.T.
IAN CLARK
Accounts
SANDRA MORRIS
Commercial
MICHAEL AYRES
Insulation Systems (Stillington)
MICHAEL
JUILLERAT
Thermal Protection
GEOFF BUTLER
Aerostructures
PATRICK COWAN
Turbine Structures
ANDREW TAYLOR
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Insulation Systems
Darchem Engineering
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Providing a range of high specification insulation systems for the aerospace, land based gas turbine and performance car markets.
- increasing engine temperatures
- increasing use of composites for weight savings
Customers - Airframe manufacturers (Boeing, Airbus , Spirit Aerosystems, BAE SYSTEMS,GKN, Aerospatiale, Augusta Westland, Volvo)
- Engine manufacturers (Rolls-Royce, Rolls-Royce Deutschland, Siemens)
- Nacelle and Accessory manufacturers (Shorts, Goodrich, Honeywell, Dunlop)
Insulation Systems
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Boeing 737
Insulation Systems
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Yellow Vehicles (Helping to achieve TIER 4 emissions regulations)
Insulation Systems
High Performance Vehicles (Specialist thermal management )
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Testing
Insulation Systems
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Aerostructures Darchem Engineering
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The Aerostructures business unit has unrivalled expertise in the design and manufacture of aerospace gas turbine exhaust systems modules and is a major force in the development and manufacture of aerospace components which are subject to extremes of temperature.
Customers - Airframe manufacturers (BAE SYSTEMS, Airbus, Augusta Westland, GKN, Gamesa)
- Engine manufacturers (Rolls-Royce, Rolls-Royce Deutschland, Pratt and Whitney, MTU, ITP )
- Nacelle and Accessory manufacturers (Shorts, Dowty)
Aerostructures
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• Titanium Ram Air exhaust system
• Titanium insulation on wing ducts
• High temperature APU exhaust system
• Fan blade membranes on Trent 900
• Insulation system on Trent 900
• High temperature components on GP 7200
Aerostructures
Airbus A380
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Gulfstream jets
Aerostructures
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Rotary Wing
Aerostructures
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Turbulence Control Screens
Aerostructures
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Flow Straighteners
Aerostructures
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Specialist Fabrications
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Specialist Fabrications
Specialist Fabrications provides expertise in the design and manufacture of high temperature fabricated structures for the gas turbine and chemical processes markets.
Marine - increasing new build and refurbishment of gas turbine powered vessels
Land - increasing power industry requirements
Customers - Prime contractors (BAE Systems, Rolls- Royce, Navantia and Siemens, )
- second tier specialist contractors
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• Gas turbine intakes and exhausts • Exhaust fabrications for the diesel engines • Hanger deck fire curtains • Exhaust plume cooling • Passive fire protection systems
Queen Elizabeth Aircraft Carriers Specialist Fabrications
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Intake and Exhaust systems
Specialist Fabrications
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Industrial Gas Turbine Fabrications
Specialist Fabrications
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Folding Fire Barrier Doors
Specialist Fabrications
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Thermal Protection
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Thermal Protection
For the Oil, Gas and Petrochemical industries, Darchem designs and manufactures bespoke passive fire protection systems for onshore and offshore installations
Market trends - increasing safety awareness
- increasing environmental regulations
Customers - Shell, BP and EPC’s
- International valve and actuator customer base.
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Darmatt Thermal Protection
FPSO’s
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Darshield
Thermal Protection
Agenda
1. Darchem Engineering
2. Capabilities
3. Nuclear Industry and Markets
5. Conclusion
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Design
Skills Thermal analysis - Temperature distribution, heat flow, transient etc F.E Analysis - Shock, thermal, pseudoplastic etc Computational Fluid Dynamics - Fluid flow etc Acoustic - Silencing etc Codes - ASME VIII, PD5500-2000,ASME III,NES312
Design Software Model & Draught - Inventor, Mechanical Desktop, AutoCAD, Catia Finite Element Analysis - UGS Femap with NX Nastran, Altair Hypermesh Comp. Fluid Dynamics - ESI CADalyser Other - MathCAD - PM2000( lay flat development software) - Various in-house developed programmes for specific applications
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Manufacture
Profiling - Laser, Robotic 3D
Forming - Pressing, Folding
Welding - MIG, TIG, Resistance, Laser, Sub arc
Materials - Stainless Steel, High Nickel Alloys, Titanium,
Super Duplex
- Plate, Sheet, Foil
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Installation
• New sites
• Operational plant (Radiation Classified workers)
• Site passports ( adding new nuclear passport)
• Risk analysis
• Use of local contractors worldwide
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Project Management
• Long term over years
• Short term, fast track in weeks
• Sub-contract management worldwide
• Radiation management
• Risk assessment
• Focus on customer reporting and communication
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Quality
• ISO 9001 : 2008 , ISO 18001 • Nadcap X-ray facility • Ultrasonic, MPI, Helium leak testing • Computer aided measuring equipment
• Documentation safety management system in accordance with • Site passports • Risk assessments
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People
• 70 Engineers many with experience of the Nuclear Industry
• 160 welders, platers and sheet metal workers of which 40% have
worked on nuclear contracts
• 32 Classified Radiation workers
• Apprentice scheme and ongoing learning
• Quality and safety culture
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Nuclear Fabrications Factory
• 57,000 sq ft facility build • 20 tonne crane – 11M under hook • Completion in Jan 2014
Agenda
1. Darchem Engineering
2. Capabilities
3. Nuclear Industry and Markets
5. Conclusion
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History
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•Major player in 70’s and 80’s with very large contracts for lining interior of AGR pressure vessel • 45 Years in Nuclear Industry in high end thermal insulation and precision fabrications • 170 Reactors (plus nuclear processing plant) • 18 Countries • Magnox, AGR, THTR, PFR, BWR, PWR reactors • New build and fast track repair/replacement projects
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Overview - The Products
• Darmet ( and encapsulated fibre) thermal insulation
• KM1 – cable tray fire protection ( made in Korea) • Pool liners • Tanks and other fabrications
• Custom designed unique stainless steel fabrications • Honeycomb impact energy
absorbers
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Reflective Metal Insulation Systems
• On over 140 reactors worldwide • In service for over 30 years • All stainless steel • Extensively tested as a system • Can be rapidly removable • Both new build and retrofit • Can be recycled
Applications
New build – all of containment vessels and pipework
PLIM & PLEX – plant replacement and GSI 191 (replacement of fibre with RMI )
Decommissioning – pipework and vessels
Defence - submarines
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Passive Fire Protection Systems
• 3 hours fire protection • Extensively tested
ASTM E119,ASTM E1027 ASTM E136 etc
• Removable when needed
KM1 – cable tray passive fire protection systems
Darmatt flexible wrap passive fire protection systems
Applications New Build – small areas of high risk
PLIM & PLEX – reviews of fire risk
Decommissioning – small areas of high risk
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Impact Energy Absorbers
• Design and manufacture • Honeycomb crushes evenly
and precisely • Stainless steel • Can be progressive crush
Applications New Build – pipe whip restraints
Waste – transport protection
Decommissioning – safe movement
Fuel – impact limiters
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Custom Designed Unique Fabrications
• Focus on stainless steel • Complexity sought • Trial assembled • Tested as components and as a
system when required • Appreciation of working in a
radioactive environment • Work with the customer to optimise
the fabrication method • Able to support installation and
commissioning
Applications
Decommissioning – new unique plant
Sludge retrieval
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Pool Liners & Tanks
• Darchem system • Design, manufacture and
installation • Panels made in factory • Fully testable before concrete
pouring • “Kit” approach reduces site time • Sizewell ponds have never leaked
Applications New Build – reactor & fuel pools, sumps, tanks
Decommissioning - tanks
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Waste Containers
• Mechanical design and manufacture
• Dedicated manufacturing cells for cost minimisation
• Stainless steel, duplex, boronated stainless steel, high nickel alloy,
Applications New Build for fuel storage racks
Waste for drums and boxes
Defence for specialist containers
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Ventilation Ducts & Double Wall Pipes
Ventilation Ducting
Double wall pipes
• stainless steel • high integrity • complete system supply • mechanical and flow design • full NDT by radiography and helium leak testing
Applications New Build – containment, drain pipes
PLIM & PLEX - improvements
Decommissioning – radioactive liquid transfer lines
Waste – storage facilities
Agenda
1. Darchem Engineering
2. Capabilities
3. Nuclear Industry and Markets
5. Conclusion
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Conclusion
over 45 years ongoing experience in the nuclear industry
world class products and services ensure low risk to customers
solid design, manufacture, quality and safety with a skilled workforce provides a right first time supply
able to both manufacturing engineer and productionise products ( application of lean)
prepared to invest in plant and equipment to achieve long term goals ( office in Westlakes and New Factory )