Category Archives: Thermo-slider

THERMOCOAX, part of the new space propulsion technology of the key occidental Geosatellite makers.

THERMOCOAX equips with magnetic coils and heating systems to make the platform more reliable and 25 years service life.

The Challenge

Space platform request magnetic coils to produce the thruster of the engine to travel to final orbit and then keep the satellite on the orbit during all his life.

The customer system was looking for component withstand high temperature and long reliability (25 years).

Heating system is used to avoid the engine to rech too low temperature. By this, the engines are fully operational at full power when activated.

These systems need to be fully proven by strict tests and qualifications program. Heavy document have to be provide for a full traceability of the components and production.

The Solution

Based on our homemade mineral insulated cable and our high level of engineering, production and quality management, we design and produce dedicated final systems ready to be mounted on the propulsion system.

 

Choosing electrical propulsion increases the service life of the satellite, means more value for the OEM and more service for the satellite operator.

In pratice, electrical propulsion saves 10 to 15% of volume replaced by payload used for datas that the operator sell to his customers.

 

Fusion reactors : THERMOCOAX cabling solutions in the heart of ITER reactor

THERMOCOAX is committed to develop solutions for new nuclear reactor technologies. We are proud to have been elected as the Mineral Insulated Cable supplier for the ITER project in the frame of  F4E (Fusion For Energy) and ITER international call for tender.

THERMOCOAX will provide Cabling  systems for ITER Vacuum Vessel where harshest conditions are met. We greatly value this contribution to the FUSION reactor technology.

Click here to get the whole article.

 

Nuclear fusion

1.    FUSION: Advantages and CO2 reduction in energy production.

Fusion is a physical principle during which two nuclei combine to generate energy.

For a peaceful application, electricity would be generated through a reactor generating heat, which would then be transferred in a loop to activate a turbine.

There would be numerous advantages of this technology: CO2 free electricity production, minimal waste compared to FISSION reactors, unlimited “raw material” coming from the sea and intrinsic safety. If problems occur, switch off the reactor.

2.    Basic principle

Fusion is the process that occurs in the core of the Sun and stars. When we see light and feel warmth, this is the result of fusion reactions: hydrogen nuclei collide, fuse into heavier helium atoms and release considerable amounts of energy in the process. Fusion is the main source of life in the Universe. To reach an appropriate environmental condition at which the reaction can occur, different vacuum chambers have been developed with Tokamak reactors.

3.    TOKAMAK reactors

A Tokamak reactor is a vessel which uses a strong magnetic field to contain a plasma and ultimately produce a net energy output. It is shaped like a “donut”.

Tokamak stands for the Russian acronym of toroidal chamber with magnetic coils. This scientific device was initially conceptualised in the 1950s in Russia and built in several countries in the 1970s. The most powerful of them being built in UK, the Joint European Torus (JET).

In the 1980s the idea of an international project called ITER (International Thermonuclear Experimental Reactor) was proposed by Russia to the USA.

4.    ITER

ITER (“The Way” in Latin) is designed to demonstrate the scientific and technological feasibility of fusion energy. ITER is a large-scale scientific experiment that aims to demonstrate the possibility of producing commercial energy from fusion. It is the culmination of sixty years of fusion research, carried out on hundreds of devices all over the world.

ITER is also a unique international collaboration bringing together China, the European Union, India, Japan, Korea, Russia and the United States – seven Members (35 nations).

The ITER Members have a shared responsibility to design, build and operate the ITER installation. Following the establishment of the ITER Organisation and a preparatory site, a unanimous decision was made in 2005 whereby the ITER Members chose a site in the South of France suggested by the European Union.

© ITER Organisation

 

  • A giant device weighing 23,000 tonnes. A fusion energy generating 500 MW of output power.
  • The World’s largest vacuum vessel, heavier than the Eiffel tower.
  • A plasma temperature of 150 million °C, x 10 the core temperature of the sun.
  • And when less than 10 metres away, there is a magnet temperature of -269°C (4K°).

5.   ALTERNATIVE TECHNOLOGIES

Nowadays multiple initiatives are receiving funding. Some new projects have been launched in the US, in the UK and in China. Plasma is a question of density. To increase plasma density and release more energy than  required in order to initiate the plasma, some compression techniques are combined to magnetic confinement. The future reactor will be more compact, simpler, more stable and cheaper.

6.    THERMOCOAX INVOLVEMENT

THERMOCOAX fully supports FUSION technology. Over the years and through projects like JET, we have accumulated experience and developed specific solutions for the FUSION reactor.

THERMOCOAX technology -Mineral Insulated cable- is ideal for harsh environments with fluctuating temperatures, high levels of radiation, a high vacuum or a high magnetic field.

THX can offer solutions such as:

CABLING: In-vessel cabling, penetration feedthrough

SENSORS: Temperature and magnetic field measurement

HEATING: Backing of small items or massive pieces of steel forming the vacuum vessel

Our integrated nuclear department (engineering, qualification, quality assurance, production) coordinated by our project department develops bespoke solutions, in which norms and regulations play a critical role.

 

 

Anticipate today on future nuclear supply chain standards to maintain highest requirement in term of safety culture, quality and competitiveness.

WNE will be coming up mid 2020. We are actively preparing our stand booth to warmely welcome you. While waiting for this great event, let’s share with you our paper on ISO 19443 and Skills & Knowledge Management. We had the pleasure to be part of the nominees’ list for the 2018 WNE award.

In an effort to be ready at the time of the implementation of this new standard, THERMOCOAX puts the emphasis overs the last three years on Skills & Knowledge Management.

How do we put it in practice? Hereafter a brief description of the organization we put in place.

COMEX commitment: On the supervision of the CEO, Mr Patrice GUILLON – Quality director- and Mme Michèle CHAUMONT -HR director- are promoting Skills & Knowledge management in the Group Management Manual. Nuclear business unit is related to our French entity THERMOCOAX SAS only but this Skills & Knowledge Management is considered at a group level.

Click here

From the beginning (integration of news staff), recruiting process defines clearly what are the responsibilities and Authorities.

Project after project, THERMOCOAX has developed proprietary solutions mainly based on our MI cable technology. To make them available to the engineering staff, Manufacturing skills are identified and listed. Mentoring of the engineering department new comers associated with training “on the field” in all workshop allows a comprehension of technics and their implementation difficulties and limits. An expert senior engineer is made available to ensure a smooth implementation of existing Manufacturing skills and their implementation in new designs.

 

Each COMEX member proposes through a yearly assessment and a CEO approval trainings to managers who in return are doing the same with their N-1.

 

On a yearly basis and based on specialized questionnaires on individual competencies so that competencies matrix can be updated and training plan defined accordingly. On an individual level, very specific skills and knowledge but also processes are followed individually through internal tolls developed on ACCESS & Excel.

In order to capitalise and materialize THERMOCOAX key Know How, the technical director is in charge of the definition of the core competencies of THERMOCOAX. This document has been initiated at the time of a very specific project where THERMOCOAX took a significant role in the development of a Post Fukushima sensor along with CEA / AREVA/ IRSN ( “Investissement d’avenir “ supported by French Government).

 

At a technician and operator levels, procedure are made to be directly understood; a picture being far more comprehensible than a long description. Both cumulated they facilitate operators comprehensions.

 

 

Under the responsibility of the technical director, it is the duty of the R&D department to anticipate on future requirement in term of Know Why and – through partnership with universities, research institutes (For instance: CNRT for advance material dielectric behaviour, SCK-CEN for In Core simulation related to Neutron sensors) to launch survey on fundamental knowledge on specific topics declared to be strategic and turn them into new technologies.

 

 

As a recognition of our expertise based on specialized technological components, THERMOCOAX has been entrusted of several Transfer Of Technology (TOT) by reputable companies like AREVA or GE.

 

 The nuclear safety culture is a fundamental part of our training cycle. All the actions launched by the Management demonstrate a firm commitment in this culture so that every individual understands its total responsibility in the nuclear safety.

 

Competitiveness On the basis of our identification of the knowledge and skills of our staff, we have in hand powerful tools to meet the most demanding requirements of our customers. Our methods of qualification of personnel directly related to the matrices of competences demonstrated their efficiency and their completeness. They are a means of effective differentiation for the selection of our company through the demonstration of our mastery of our know-how.

Inconel 625 signal transmission solutions for high-pressure applications

THERMOCOAX is used to meeting the highest standards, with more than 60 years’ experience in the nuclear and aviation industries.

We are able to manufacture and weld various materials in-house.

We had the opportunity to work with Inconel 625 to ensure the requirements were met for deep-sea in terms of pressure, tightness, and reliability.

We worked on a transmission cables solution, including feedthroughs and mechanical parts.

The main focus of the solution was the sealing at the welds.

We used our internal welding and testing capabilities to develop a multi-conductor solution for signal transmission. We now offer signal transmission solutions for up to 8 conductors.

THERMOCOAX internal capabilities:

  • Welding capabilities: TIG, plasma, laser
  • Testing capabilities: FPI, X-ray, ESS, macrography, penetrant testing level 4

 

THERMOCOAX mineral-insulated cables are able to operate when subject to 300 bars of pressure (when 3,000m/10,000ft under water) for 30 years.

They have been subject to up to 450 bars of pressure during the qualification process.

Our solution is compliant with ASME BPVC Section IX.

 The THERMOCOAX mineral-insulated cable is an alternative to polymer-based power and control cable systems :

– Suitable for high temperatures/high pressures
– Not thermally degradable
– Not susceptible to fluid getting into the sheath
Easier to connect and interface with other equipment: no need for pressure- adaption devices.

         => Lower CAPEX, longer lifetime

Our mineral-insulated cable solutions can be used in critical environments for electrical power and control.

One use is for subsea equipment.

For example :

– Pumping systems
– Transformers
– Heating systems
– Power supplies for control systems
– Valves
– Sensing devices
– Metering devices
– Blowout preventers

 

THERMOCOAX works with a permanent improvement strategy in terms of:

  • Design
  • Manufacturing process
  • Cost reduction

 

 We adapt to customers’ specific requests.

THERMOCOAX is fully established in the US and supplies ASIA directly.

Thermal chucks and pedestals for ALD deposition processes

Thermal chucks for front-end wafer processes have demanding specifications and require constant improvement and innovation.

We are working closely with our OEM customers on improving our thermal chuck specifications to reduce the manufacturing deposition cycle time, to increase the yield in wafer production, and to be able to work with new precursors.

Temperatre uniformity across the surface of the chuck is always our first priority when we design a new chuck.

To achieve the uniformity our customers want, we custom design the chucks, from the heating cable to the plate material.

We are able to do this because we design and manufacture our own Mineral Insulated Cables inhouse. We adapt the internal structure of the cables to ensure the best quality when it comes to the finished product’s temperature uniformity, while conforming to the maximum temperature restrictions, with multiple heating zones.

The temperature control on the surface of the chuck is important for the process. We use fast response time thermocouples on different areas of the plate. At the prototyping phase,  we use more precise solutions to guarantee the temperature is uniform across the surface of the chuck and to control the gradient between the different heating zones.

Detailed thermal analysis is used for ensuring temperature uniformity across the wafer.

The transfer of heat between the chuck and the wafer affects the temperature uniformity and the wafer’s temperature requirements.

We offer several texturing solutions that improve this parameter.

The mechanical support is also important, including the design of the plate and the material used.

Our in-house high precision machining capabilities are a real asset at the prototyping phase and then for high-volume manufacturing.

Specific heat treatments and coatings can be used to meet high expectations and demanding specifications from our customers.

Our thermal chucks are used in ultra high vacuum and corrosive enviroments. The choice of the material and the welding process used for the encapsulation plates and for fixing the mineral insulated cable to the plate is essential.

The material means it requires to be cleaned less frequently on manufacturing . The welding process guarantees that there is no outgassing of the material in the deposition chamber.

 

FROM PROTOTYPING TO HIGH-VOLUME MANUFACTURING

We design and manufacture the chucks in-house and control the dimensions with high-performing tridimensional CMM control facilities.

 

 

THERMOCOAX  metal chucks are available in stainless steel, Inconel or a special alloy offering high dimensional stability.

  • diameters of up to 450mm (18″).
  • up to 7 state of the art separate heating zones
  • Maximum temperatures of up to 900°C.

The temperature of each heating zone is controlled independently.

We meet the requirements of the SEMICON market in terms of repeatability, temperature uniformity, production control, quality monitoring and COPY EXACT for high-volume manufacturing.

We adapt the feedthrough by offering customised bushings and flanges.

The following are also optional:

  • A cooling channel
  • A gas line
  • Vacuum wafer sucking
  • Anti-slice grooving

THERMOCOAX is constantly striving to improve in the following areas:

  • Design
  • Manufacturing process
  • Cost reduction

  

We are highly adaptable to customers’ specific requests

THERMOCOAX has a full-scale presence in the US and supplies ASIA directly.

 

 

HAF 604 certification’s extension

THERMOCOAX is serving the civil nuclear Chinese market for more than 20 years as an authorized exporter for safety related components for nuclear power plant.

We are proud to announce that our HAF 604 certification has been extended by the National Nuclear Safety Administration (NNSA) of People’s Republic of China) till 2022.

This certification initially issued in 2011 has been extended to additional product categories so that THERMOCOAX can now cover a wide range of I&C solutions in term of design and manufacturing of safety related CABLING and SENSORS for InCore and ExCore application.

THERMOCOAX will strengthen its position by providing more cabling for new reactor type like HUALONG, EPR or upgrade solutions for Gen 2 Nuclear Power plant.

作为核电站安全相关部件的授权出口商,THERMOCOAX在中国民用核市场服务了20多年。我们自豪地宣布,我们的HAF604认证已由中华人民共和国国家核安全局(NNSA)延长至2022年。2011年发布的这一认证已扩展到其他产品类别, Thermocoax现在可以在设计和制造用于堆芯和堆芯应用的安全相关电缆和传感器方面涵盖广泛的I&C解决方案。

Thermocoax将通过为华龙、EPR等新型反应堆或2代核电站升级解决方案提供更多电缆来巩固其地位。

 

HAF 604 certification
Copy of the HAF 604 certification

THERMOCOAX is now part of the SPIRAX-SARCO ENGINEERING PLC GROUP

Spirax-Sarco Engineering plc, which specializes in the control and efficient use of steam, and in peristaltic pumping and associated fluid path technologies, is pleased to announce the completion of the acquisition of Thermocoax, details of which were announced on May 13th 2019.

Nicholas Anderson, Group Chief Executive of Spirax Sarco, said:

« We have developed an exciting strategy for Thermocoax, which will sit within the electrical process heating business of our Group, which was created in 2017 with the acquisition of Chromalox in the United States. Our goal is to elevate the position of both brands in their markets by combining the potential of Thermocoax with that of Chromalox, while strengthening the Thermocoax brand worldwide. »

About Spirax Sarco

Spirax‐Sarco Engineering plc is a thermal energy management and niche pumping specialist. It comprises three world‐leading businesses: Steam Specialties, for the control and management of steam; Chromalox, for electrical thermal energy solutions; and Watson-Marlow, for peristaltic pumping and associated fluid path technologies. The Steam Specialties business and Chromalox provide a broad range of fluid control and electrical process heating products, engineered packages, site services and systems expertise for a diverse range of industrial and institutional customers.  Both businesses help their end users to improve production efficiency, meet their environmental sustainability targets, improve product quality and enhance the safety of their operations.  Watson‐Marlow Fluid Technology Group offers the ideal solution for a wide variety of demanding fluid path applications with highly accurate, controllable and virtually maintenance free pumps and associated technologies.

The Group is headquartered in Cheltenham, UK, has strategically located manufacturing plants around the world and employs over 7,800 people, of whom over 1,600 are direct sales and service engineers.  Its shares have been listed on the London Stock Exchange since 1959 (symbol: SPX) and it is a constituent of the FTSE 100 index.

Further information can be found at www.spiraxsarcoengineering.com

 

Visit us at Le Bourget Trade show (June 17-21, 2019), Hall 2B, Booth D40

The Latest Innovative Solutions for Temperature Measurement Sensors Heating Systems

 

 

Thermocoax Pedigree

For 25 years, THERMOCOAX has been a leading global figure in designing, developing and manufacturing heating systems for the Aerospace market.

We provide solutions for:

– Ground applications:

  • R&D programs in collaboration with institutes
  • Ground test equipment

-Flying models:

  • On board satellites, 50- & 100-volt communications satellites, low orbit constellations, long range space probes
  • On board planes, helicopters

– Defense

  • Armored Vehicles
  • On board fighters, long range missiles
  • Submarines

 

Our solutions include:

  • Heating systems for space propulsion, satellite heating management, shape-memory devices
  • Anti-icing system for pitot tubes, AoA tubing, Ta tubing, drain masts
  • Bleed Air Overheat and fire detection systems
  • Brake temperature monitoring system
  • Engine temperature measuring system
  • Oil and fuel temperature measuring system
  • Heating solutions for composite industries (curing, shaping, bonding…)

 

Heated Waste Water Drain Mast

To remove unnecessary weight, the greywater from the washbasins is ejected outside the plane.

Most airplanes are equipped with two drain masts, one at the front and one at the rear near the washbasins.

 

  • Heritage:
    • Falcon Jet : F900, F2000, F7X
    • A220, Ejet1&2

 

  • Technology with self-regulation or equipped with switches
  • Resin shell
  • Power: from 28 volts to 115 volts
  • Power dissipation: from 20 watts to 250 watts
  • RTCA/DO160

 

 

Brake Temperature Monitoring System

The brake thermocouple gives the brake temperature in real time and can be transformed into a “hot brake” alert for the pilot when the value goes over a predetermined temperature threshold.

It provides the cockpit with important information regarding the temperature of the right and left brakes. If the difference is too great, asymmetric brake friction can occur, leading to difficulties in maintaining constant heading and keeping speed under control.

Thanks to this system, the pilot receives a clear “Go/Don’t Go” message for the takeoff authorization. The brake thermocouple indicates that if an emergency brake needs to be carried out during the takeoff operation, the brake will have its full efficiency so that it can stop the aircraft on time for the safety of all passengers.

 

     

 

  • Heritage:
    • Airbus 350
    • Embraer E-jet
  • Soon to be available for:
    • IRKUT MC21
    • Mitsubishi MRJ
    • COMAC C919
    • Eurofighter
  • K type thermocouple
  • Class1
  • Dielectric 500V
  • Ø5 up to 4.75mm
  • RTCA/DO160

 

Heating System for Space Propulsion

Electrical and chemical thrusters are small rocket engines used for orbit raising as well as attitude, trajectory and orbit control for satellites and spacecraft

The main purpose of pre-heating thrusters is to improve their performance at startup and to increase the lifetime of their components.

 

 

Heritage:

  • E3000 100volts
  • Prisma
  • Smart 1
  • Planet constellation
  • Many more

 

  • 100mN to 400 Newton thrust
  • 3 to 100 watts under 28 to 55 volts
  • Redundancy made with 2 heating loops
  • Dielectric 500 volt
  • Up to 1600°C

 

SMA heater

In order to accomplish their mission, spacecrafts require a variety of mechanisms whose typical functions are designed for deployment, articulation, positioning and displacement operations.

However, pyrotechnic separation nuts, paraffin actuators and certain other devices are no longer compatible with satellite requirements due to shock wave generation and potential contamination risks.

Non-pyrotechnic devices make use of SMA technology and are equipped with internal heating elements, offering slow and smooth responses, cleanliness and good vibration & shock resistance.

 

-Application:

  • Single one-time use Valve
  • Hold Down & Release Mechanism

 

  • Data:
  • Cable Ø1 mm 28VDC
  • 2 to 10 watts

 

  • Cable Ø5mm, 28volts:
    • 30 watts with 1 loop activated
    • 60 watts with 2 loops activated

 

Test List for Qualification Program

THERMOCOAX manages and conducts the qualification test programs in accordance with our customer’s specification.

Our engineers design the QTP for customer approval prior to running the test.

Most of the tests (thermal, humidity, electrical, etc.) are performed in HERMOCOAX’s labs.

Tests requiring heavy equipment (vibration, acceleration, shocks etc.) are subcontracted to external laboratories or supported by our customers with the complete propulsion system.

  • List of possible Qualification Test:
  • Vibration
  • Acceleration
  • Mechanical shock
  • Pyrotechnic shock
  • Helium leak
  • Burn-in
  • Humidity
  • Hot Firing
  • Electrical cycling
  • Thermal cycling
  • Lead attachment
  • Dielectric
  • Destructive physical analysis
  • X-ray examination

 

THERMOCOAX is a major competitor for onboard heating solutions for electrical heating systems and is proud to be a part of challenging international space programs.

THERMOCOAX focuses on high quality heating products for maximum stability and repeatability during operation. For 20 years we have understood our customers’ challenges to manufacture spacecrafts to create a better life for human beings.

Extensive new constellation programs are currently in construction.

THERMOCOAX is now ready to support the market with highly reliable and efficient heating elements.

 

 

THERMOCOAX Nuclear department : 2018 highlights

DISCOMS project: a happy ending with promising results.

Following the FUKUSHIMA disaster, the French government decided to allocate some of its budget  to stimulate R&D in the field of nuclear safety and radiation protection.

investir l'avenir logo

The DISCOMS (DIstributed Sensing for COrium Monitoring & Safety) project aims at developing an innovative under-vessel remote monitoring instrumentation to improve NPPs safety in operation.

A team of reputable Research Institutes, universities and Industrial companies was formed to address the development of a remote monitoring solution able to improve the safety of Nuclear Power Plants and strengthen the third containment barrier in case of a severe accident with a reactor breakthrough and corium release.

Long-length Self Powered Nuclear Detectors have been developed to identify the reactor core debris progression, the erosion of the concrete floor, as well as to monitor the corium cooling.

After multiple simulations and theoretical validations, a complete system (sensors + electronics) has been tested with corium and has demonstrated its technological readiness.

 

Safety Culture

 Nuclear culture award

 

THERMOCOAX was distinguished with a  Safety Culture award from Rolls Royce. In 2019, THX will continue its effort to improve working practices and place safety as a main priority.

 

 Skills & Knowledge Management

 At the WNE, THERMOCOAX was nominated for an award in the “Skills & Knowledge Management” category.

In its Quality Assurance Manual, THERMOCOAX takes into account the requirement  presented in the ISO 19443.

One goal: anticipate chain standards for future nuclear supply today to maintain the highest standard of safety culture, quality and competitiveness.

“During Rolls Royce Nuclear supplier days” sounds unnatural in English but difficult to amend without knowing meaning of source text.