Significant refurbishment of BAE Systems Autoclave

AIC Group today announced that it had completed the significant and full refurbishment of BAE Systems’ 5.5m x 14m autoclave. This has added an expected 10+ years to the life of the machine which has been heavily used since it was installed in the early 1990s. The refurbishment has improved the performance of the autoclave, and with the installation of inverter driven motors where applicable this has resulted in lower energy usage. The heating system was replaced to enhance the performance of the autoclave together with a new uprated water-cooling system which will deliver a significant increase in cooling capability. Further improvements and efficiencies are achieved by introducing AIC’s AMCS – Autoclave Management and Control System, a unique software and hardware system which improves control with ease of operation. A team of 10 highly skilled professionals spent in excess of 10,000 engineer-hours over a period of seven months on site. The company deployed engineers of all types: civil; control; instrument; design and project. These were supported by electricians, pipe-fitters, welders, painters, cleaners and labourers. Coordination was carried out by a tightly-knit group of BAE Systems and AIC project managers. Importantly the project was delivered on time and within budget. Tim Denison, AIC’s operations director, said: “This was a huge project. We had to combine our technical engineering skills with organisational and project management capabilities. We are pleased that BAe Systems now has an efficient autoclave that will last for years to come, and that this project was delivered on time and within budget.” Ben Gregory, Senior Facilities Engineer, commented: “Having a fully operational suite of autoclaves is essential to ensure the Carbon Fibre business can deliver on its workload. AIC first provided a full detailed condition report on the plant then were selected as part of the competitive tender to complete the refurbishment works. They provided and delivered a cost-effective solution when compared to a new system with the same specification requirements. The end result has been an autoclave with a higher than original specification and coupled with the new AMCS control system it will see the autoclave continue to run for another 10 years with improved efficiency and control. “Throughout this major refurbishment project AIC were on hand to listen to our concerns and on a number of occasions were able to modify the agreed specification at short notice for the ultimate benefit of the project. AIC were able to act as the Principle Contractor on the project so from a client point of view they were able to manage all site operations including the health and safety, scheduling and the use of sub-contractors with minimal client interaction which helped with the autoclave being handed back to the customer on time and on budget. As part of the contract, AIC ensured that the autoclave is now fully compliant with all current EU safety legislation. The refurbishment extended to support systems, including: pressurisation; depressurisation; vacuum; thermocouple; and loading. AIC up-rated the motor for air circulation, heat transfer and temperature uniformity. It also updated the infrastructure, with new foundations, gangways and gantries. These have enabled maintenance engineers to gain better and safer access to the equipment. Before working on the machine, AIC conducted a full condition survey. This highlighted areas where the autoclave system needed to be refurbished, producing revised heating and cooling requirements, and detailing the components that needed to be upgraded.