By definition, our work produces turnkey solutions. That means our aim is to produce fit-for-purpose engineering that has been specifically designed to be deployed in a precise location. Although each solution leaves our workshop ready for the challenges ahead, actual deployment can be a complicated business and has to be as carefully considered as every other stage of the process.

Naturally, we provide complete documentation to cover both the specification and operation of our tools. We also liaise closely with our clients to define any training requirements and, following a detailed survey of the deployment site, we would normally provide detailed recommendations on the deployment process that would be appropriate to the precise location.

In some circumstances, we are also able to assign members of our staff to the deployment project if it’s felt that their skills are required. Like everything at Barrnon, each project is unique and we’ll do whatever is required to ensure it is a success.

Deployment

large_deployment.jpg

medium_deployment.jpg

small_deployment.jpg

thumbnail_deployment.jpg

deployment.jpg

From the moment we take on a design challenge, our work follows a rigorous process that has been fine-tuned to ensure success. Our in-house team covers a very broad range of engineering design and manufacturing specialisms and each member has the years of experience and technical know-how required to produce work of the highest quality.

## Problem solving, concepts and ideas

Everything begins with deep research, examining the challenge from a range of perspectives. This ‘blue sky thinking’ helps us identify innovative approaches while filtering out the probable from the impossible.

We also consider the technical requirements and explore existing technologies and standards that could impact on the design. We look at relevant country-specific requirements and draw together the detailed safety case that will frame the whole development while appointing a lead designer to co-ordinate the team.

We’ll then start **rapid prototyping**, using our **3D printing** capabilities to bench test ideas while sharing early-stage iterations in client workshops to gain feedback on design direction before down-selecting to one or two possible routes.

This gated design process optimises our due diligence while drawing on skills from across the company to ensure high levels of quality control. Key team members are encouraged to scrutinise and challenge each concept’s feasibility so that those that progress have a high chance of success.

## Detailed design and pre-production
Detailed design and pre-production Moving the concept into detailed **Computer Aided Design** (CAD) allows us to really put our ideas to the test. We’re able to create larger working models and prototypes while conducting detailed technical analysis and calculations to prove the engineering requirements, meet all applicable standards, complete stress tests and, most importantly, meet the client brief. We also workshop extensively at this phase to ensure client expectations are being met.

Finally, there’s a close collaboration between our design and manufacturing teams to sense-check proposals and complete accurate final drawings and documentation so that full-scale production can begin.

## Design verification
The final stage of our design process can be never ending. Our solutions are unique. So, we continually test and refine. We find ways to refine each design so that it’s even more successful, making the marginal gains that make all the difference. When you’re working in a field as important as nuclear decommissioning, for example, there’s no room for complacency.

Design

large_design.jpg

medium_design.jpg

small_design.jpg

thumbnail_design.jpg

design.jpg

As a rule, we build rugged, hard-wearing machines that are designed to withstand the most extreme conditions.

Our modular approach to design allows us to develop solutions that are both adaptable and easily maintained. This means that worn or damaged parts can be replaced – often by the machine itself. For example the robotic capabilities of the Barrnon Integrated Decommissioning System include routine maintenance tasks and the replacement of the many tools deployed by the system.

As part of the deployment of any of our turnkey solutions, we work closely to develop a bespoke maintenance plan that takes account of the precise requirements of the project to optimise the useful life of the equipment.

Maintenance

large_maintenance-2.jpg

medium_maintenance-2.jpg

small_maintenance-2.jpg

thumbnail_maintenance-2.jpg

maintenance-2.jpg

While big ideas are our stock-in-trade, our work is very much rooted in reality. Our highly experienced manufacturing team maximises the capabilities of our extensive and well-equipped production facilities to turn each of our designs into working prototypes for intensive testing as well as finished items that are ready to be deployed.

From reinforced steel containers capable of storing extremely dangerous radioactive waste to highly-complex, VR-controlled robotic ROVs that can remotely decommission nuclear cells, our staff can fabricate and assemble virtually anything from scratch.

## Realising each design
Every crucial element of our designs can be created in our workshop. We use a number of **different Computer Aided Manufacturing** techniques to produce component parts including **CNC machining, water jet** and **laser cutting** as well as 3D printing of various materials including stainless steel.

Maintaining a highly-skilled, in house production capability is a major commitment, but it’s an essential element of Barrnon’s success. Our design and production teams work closely together every day. This allows us to develop our ideas in a collaborative environment where each individual component can be analysed and tested until it works perfectly.

It also allows us to prototype rapidly, while assuring that quality always matches our own rigorous standards. We also have complete control over our work schedule and access to all the materials and equipment we need to build each innovative solution.

## Meeting the highest standards
Collectively, we have the necessary qualifications to meet any regional, national or international standards required including Nuclear Grade 2 fabrication, ISO 9001, SLM 4.06.02 and GS 3000.

Our **welding** is routinely inspected and verified using the relevant NDE procedures to suit client expectations and appropriate standards. We have **electrical, mechanical, hydraulic** and **robotic engineering** experts on site, working to all relevant industry standards. Of course, we can also bring in further specialisms when required. We have an extensive list of specialist partners who work with us whenever we feel we would benefit from expert support.

Every element of the solutions that we produce also has a full Lifetime Quality Record, detailing every aspect of its manufacture including any formal certification that’s required.

Production

large_welding.jpg

medium_welding.jpg

small_welding.jpg

thumbnail_welding.jpg

welding.jpg

Every project we take on is unique. Each has its own demands and complexities. Yet regardless of the challenge in hand, our approach is always the same. We take a structured, agile, collaborative and quality driven approach led by a qualified and experienced project manager who is responsible for coordinating our team and ensuring that the delivery requirements are met. Our project teams have clearly defined roles and responsibilities, helping to drive high performance and execution levels across the business.

Throughout the process, we maintain close relationships with our clients, holding workshops, updates and reviews while ensuring regular communication between stakeholders.

We understand the importance of key milestones and deadlines on projects and schedule every project in detail to ensure that these dates are visible, that progress is made and that timescales are maintained.

Compliance with required standards is built into our project management and design approaches. Across our teams, we have the necessary qualifications to meet any regional, national or international standards including Nuclear Grade 2 fabrication, ISO 9001, SLM 4.06.02 and GS 3000. We’re also currently working towards NQA 1 accreditation.

Project Management

large_project-management-2.jpg

medium_project-management-2.jpg

small_project-management-2.jpg

thumbnail_project-management-2.jpg

project-management-2.jpg

Much of our work is at the bleeding edge of **Research & Development** which means we have to build in meticulous testing at every stage. Our turnkey solutions are applied in some of the world’s most dangerous industrial environments so there is no room for error.

We use a wide variety of testing techniques. We use **3D printing** to fabricate temporary component parts that can be tested for fit and operational efficiency before machining the final element.

We produce extensive **test reports** where required – and test against regional, national and international standards.

We regularly create realistic test environments to put our solutions through their paces and we measure each test meticulously, putting the machinery we’ve created under extreme pressure.

For example, we built a replica of an irradiated cell to test the **Barrnon Integrated Decommissioning System**. We erected a **20m high testing rig**  to replicate the demands of potentially deploying and remotely operating our **Rotocutter** in former nuclear storage tanks in the USA.

![testing4.jpg](https://barrnon-website-images.s3.eu-west-1.amazonaws.com/testing4_f38f3990f9.jpg)

We also have a **140m2 pond** on-site for testing underwater and surface deployments, replicating the conditions that can be found in nuclear ‘ponds’.


Turning ‘impossible’ into turnkey solutions