Case Studies

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NAMTEC Provides Nuclear Knowhow

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With over 1000 projects completed the Business Link Yorkshire Innovation Voucher scheme has proved to be a huge success. A wide spectrum of companies from both industry and academia have benefited, but now the scheme has been closed due to financial constraints.

One of the last of the scheme's projects was a recently completed collaboration between NAMTEC and a consortium of seven regional companies. A complete metallurgical assessment was carried out of the pumps and valves within a Generation 3+ nuclear power station (i.e. the Westinghouse AP1000 and Areva EPR models which will constitute the UK's nuclear new build). In addition to metallurgical issues, nuclear accreditation and certification were also examined in detail. Consortium members were also able to benefit from a visit by Martin Burnham, MD of Sheffield forging company IFA who have been involved in the UK's nuclear industry since the 1950s.

NAMTEC's Dr Richard Cindery, project leader for the consortium, commented "Through this detailed study of technical and market requirements we've successfully mapped a clear path for these companies that gives them a head start as they pursue opportunities in the civil nuclear supply chain".

 

Whilst the Business Link Yorkshire Innovation Voucher scheme has sadly been axed, money is still available to support innovative projects via the NAMTEC managed Innovation Fund.

This fund can provide up to 75% of projects costs for a wide range of product development and market access studies. For more details contact Richard at richard.cindery@namtec.co.uk

Marine Renewables

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Funded by the AEM Innovation Network, NAMTEC undertook a project which assisted seven regional SME's to gain early insight into this emerging sector, with the aim of identifying the strongest opportunities for manufacturing and providing the knowledge to help establish their presence in the supply chain. The seven participating SME�s represented a wide cross-section of world-leading technical expertise supporting marine renewables, ranging from bearings and transmissions to corrosion-resistant materials, castings and couplings.

The SME's were: Darron-SBO Ltd - FTL Seals Technology Ltd - KTN Couplings Ltd - Lancereal Ltd - Maher Ltd - Tinsley Bridge Ltd - Russell Ductile Castings Ltd

NAMTEC used its extensive knowledge of the power generation industry to identify front-runners for marine energy devices under development in Europe, from a complete portfolio of over 200 marine energy devices under development world wide. Key opportunities were identified in four manufacturing areas: castings; bearings; hydraulics; and fabrication. Cross-cutting trends which provided valuable insight into the sector were ascertained from direct correspondence with marine energy device developers, including methods for supplier selection, the materials selection process, suitable grades and quantities of materials, and the perceived relative strengths of UK manufacturing versus overseas. As a leading exponent of materials engineering knowledge transfer and an independent research and technology organisation, NAMTEC was able to access information from the supply chain which is otherwise difficult for a single organisation to achieve.

"The NAMTEC led project provided a very thorough technical and commercial evaluation of the sector. Completed very efficiently the report provides an excellent foundation from which we can carry out further meaningful marketing."
Nick Hampson, Lancereal Ltd

"This demanding and detailed project provided us with a sound basis for the development of this market opportunity. We have already made progress as a result and are in the process of tendering for new work. The collaborative approach to market research is undoubtedly cost and time effective."
Steve Wadsworth, Russell Ductile Castings Ltd

"The research carried out was of the highest order. The only work left for us to do is make use of information generated, and take our first steps into the marine renewables market."
Richard Rhodes, Darron-SBO Ltd

Ultimately the report delivered a list of key manufacturing areas, technical challenges and device developers which are potential customers for the participating companies, giving the participants valuable early insight into manufacturing opportunities in the emerging field of marine renewables.

Siemens VAI - Heat Treatment

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Siemens VAI are a global supplier of a range of full-line manufacturing systems. The company uses knowledge built up over several decades to focus on areas such as process optimization in plate mills helping metal producers to increase the performance of their plant and the quality of the product.

The Need

Siemens VAI uses knowledge built up over several decades to focus on areas such as process optimization in plate mills helping metal producers to increase the performance of their plant and the quality of the product. Siemens VAI needed a study In order to investigate further business opportunities.

The Solution

NAMTEC investigated the various methods of heat treatment available and the equipment required to perform the heat treatment in case. An assessment of the various processes and processing equipment was undertaken, suitability of each process to produce a particular set of properties was also indicated as well as advantages and drawbacks of each processing route in terms of energy efficiency and cost.

The Result

A detailed report was produced covering the different methods of heat treatment available, the properties which would be expected from finished material having undergone the various treatments and an explanation of why materials would be required in particular condition for a particular application. The report provided Siemens VAI sales and engineering teams with a better understanding of customer needs and requirements depending on the final application of rolled product from a particular mill.

Siemens VAI - Plate Cladding

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Siemens VAI are a global supplier of a range of full-line manufacturing systems. The company uses knowledge built up over several decades to focus on areas such as process optimization in plate mills helping metal producers to increase the performance of their plant and the quality of the product.

The Need

In response to a request from a customer and as part of a quotation for a new rolling mill, Siemens VAI needed to undertake a study into the process of steel plate cladding. The plate is usually formed and seam welded to produce pipe used in the transportation of oil or gas. The low alloy steel base material brings relatively high strength levels at low cost allied to established and well understood forming and fabrication technologies. The low alloy steel backing material usually has relatively poor corrosion resistance when in contact with the media requiring transportation. The thin, corrosion resistant alloy layer provides protection to the bulk, strength giving material.

The Solution

The technology team at NAMTEC undertook an in-depth technical study into the various methods by which steel plate can be clad. The study looked at the strengths and weaknesses of a range of techniques in terms of suitability for a range of materials over a range of sizes and shapes of finished components.

The Result

NAMTEC produced a detailed report covering methods for producing clad steel plate with a presentation of the findings to Siemens. The knowledge extracted from the report by the Siemens team gave rise to greater understanding of the processes and methodology of plate cladding. This information helped Siemens secure an order for a complete new rolling mill. The building of the new mill in turn helped Siemens to create 5 new positions within their organisation in the UK.

NAMTEC helps client avoid £2million in penalty payments

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The Client

NAMTEC's client company, who cannot be named for commercial reasons, manufactures wear-resistant ring bearings for subsea application in the Oil & Gas sector. Significant numbers of these ring assemblies had failed after only a few weeks in service, compared with a design life of over five years. NAMTEC's client was facing very high penalty charges if it could be proved that the rings were of sub-standard quality.

The Challenge

NAMTEC was asked to provide an independent, technical assessment of the reasons for failure. The client wanted to know whether the material specification and/or manufacturing processes were to blame or if the premature failures could be attributed to in-service conditions outside design specification. Several samples of unused and failed wear rings were supplied, with engineering drawings illustrating the position of the rings in the overall assembly.

NAMTEC's Approach

Samples of the failed wear rings were sent for metallographic, physical and chemical analysis to determine whether i) the rings had been manufactured from the correct alloys, ii) there had been any detrimental effects during fabrication & machining, iii) the components had been heat treated correctly. Samples were also examined for metallographic evidence of failure due to corrosion, galling or other material defects.

Benefits/Impact Delivered

The results of this detailed analysis showed clearly that the material composition, microstructure and hardness were all within specification. Some grain boundary oxidation was observed but this was an effect of abrasion damage rather than a cause. Non-uniform distribution of the wear pattern and the nature of the wear gave a strong indication that the premature failures were the result of axial forces outside the design specification for the wear ring components. Thus the failures had resulted from non-standard in-service conditions and not from inadequacies in the ring design, materials or manufacturing procedures. This has enabled NAMTEC's client to fend off claims for compensation estimated at between £1.5 and £2.0million.

Quotation from the client

The Technical Director commented that NAMTEC's pragmatic approach had identified the root cause of the failures in engineering terms. This contrasts with an earlier study by a university which had posed a number of scientific questions but provided few answers. Future supply of these wear ring components to a prestigious customer have been secured and a very expensive compensation claim has been avoided.

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