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 )