Engineered Systems Group

Industrial Contracting

Superior Products. Innovative Solutions. Proven Results.

Engineered Systems Group

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Highly-Skilled Metal Fabrication Services

Engineered Systems Group (ESG) was formed as a branch within Performance Contracting, Inc. in the 1970’s. We are guided by a set of goals that remains true today—develop superior products, deliver our goods and services as specified and on time, and solve our client’s problems as though they are our own.

More than 40 years later, these goals have allowed us to establish and grow a loyal customer base not only in the Nuclear Market worldwide; but also in the Metal Fabrication Industry.

With PCI’s strong financial position and national branch resources, ESG is capable of providing a superior range of services, purchasing power, experience, and knowledge to give you fast, reliable and comprehensive service for all your needs under our nuclear accepted QA program.

Safety and Quality are part of Performance Contracting, Inc.’s core values; and we at ESG hope if you have not yet contacted us for service, you will do so after reviewing the information on our website.

 

Engineered Metal Services

Quality Products. Custom Solutions. Experienced Craftsmanship.

ECCS/CSS PWR (GSI-191)

Emergency Core Cooling System and Containment Spray System for Pressurized Water Reactors

GS-191 Testing

PCI, with the help of the Sure-Flow® Strainer Team, can offer the following Test Protocols to help qualify your strainer to comply with GSI-191:

Large Flume Test Protocol: PCI’s proprietary large flume test incorporating debris settlement

Small Flume Test Protocol: LFTP offered in the small flume with small scale strainer

Tank Test Protocol: Scaled test performed with mixing energy to suspend debris in the flow stream

CVPL (Closed Vertical Pipe Loop): Testing facility for parametric studies, etc.

Any of these testing protocols can be used to help qualify your current strainer, no matter which vendor supplied it.

Joining PCI in the Sure-Flow® Strainer team are AREVA NP, Inc. and Alden Research Laboratory, Inc. The Sure-Flow® Strainer Team has been collaborating to provide ECCS/CSS Sump compliance solutions since 1996. PCI has and can work with other engineering companies familiar with your design basis as well. In addition to the testing protocols listed above, the SFS Team can offer Debris Generation analysis, Debris Transport analysis, Computational Fluid Dynamics analysis, In-Vessel testing, and Other Down Stream Evaluations (DSE) for GSI-191.

Sure-Trap™ Pre-Screen

PCI’s patent pending Sure-Trap™ installed over your existing Strainer will help you meet your Fiber Bypass requirements to prevent In-Vessel Reactor Coolant blockage. Sure-Trap™ is a series of filter panels installed around your current ECCS Strainer while maintaining an open flow path. The filter panels are positioned to maximize the amount of Fibrous Debris captured following a Loss Of Coolant Accident.

BENEFITS INCLUDE:

  • Fiber is Trapped Before It Reaches Strainer
  • Lower Fiber Bypass
  • Clear Flow Stream Maintains a Flow Path
  • Reduces Debris to Strainer, Which Can Reduce Head Loss

High Fiber plants may realize additional benefits by implementing the Sure-Trap™ in conjunction with PCI’s exclusive Large Flume Test Protocol (LFTP). PCI’s Sure-Trap™ and LFTP, used together, will reduce the costly replacement of your current fibrous insulation. When considering insulation replacement and worker radiation exposure costs alone, Sure-Trap™ will save you money.

Sure-Flow® Strainer

PCI is a proven industry leader in providing sump screen regulatory compliance. Our track record of success began with the resolution of RG 1.82 and is now focused on helping you resolve GSI-191. Our Sure-Flow® Strainer is a key product in helping your achieve GSI-191 compliance.

BENEFITS INCLUDE:

Stacked Disk Design: Despite what others may claim, the stacked disk design provides the most surface area of any strainer design available. PCI’s Sure-Flow® Strainer is a scalable system that provides a maximum surface area in a minimum footprint.

Customization: PCI’s Sure-Flow® Strainer can be customized to fit in a variety of locations. The Sure-Flow® Strainer has been successfully installed within the sump pit at 13 out of 42 plants resulting in little or no impact to future maintenance projects.

Flow Control : PCI’s patented Flow Control Device ensures an evenly distributed debris bed which results in lower head loss through the debris bed.

Versatility: The Sure-Flow® Strainer can accommodate a variety of configurations based on the needs of your plant. We can ship large pre-assembled modules or small components to be assembled in the field.

Proven Success: PCI’s Sure-Flow® Strainer has a proven history of regulatory acceptance not only in the United States, but also internationally. The Sure-Flow® Strainer has been successfully installed in 18 PWR plants in the United States as well as 24 PWR plants internationally.

Sure-Hold™ Bands

PCI has developed Sure-Hold™ Bands to reduce quantities of LOCA-generated insulation debris.

Sure-Hold™ Bands are removable/reusable steel bands which can be easily installed, at a regular interval, around the metal jacketing that covers the containment area insulation, such as metal-jacketed NUKON® Insulation, or around Reflective Metal Insulation (RMI).

Sure-Hold™ Bands are designed to reinforce the existing thermal insulation so that it can withstand the high-pressure jets of the post-LOCA steam and water blowdown. Tests using a simulated pipe break have shown that standard insulation without Sure-Hold™ Bands can be severely damaged by these jets at pressures as low as 10 psi. However, with the use of the Sure-Hold™ Bands, the same types of insulation can be protected at pressures as high as 190 psi.

ECCS/CSS BWR Sure-Flow® Strainer

Emergency Core Cooling System and Containment Spray System for Boiler Water Reactors

Sure-Flow® Strainer – BWR

PCI is a recognized industry leader in providing Sump Strainer regulatory compliant solutions for BWR plants. Our success was proven when we were selected for 15 of the 35 U.S. BWR plants to resolve RG 1.82 Rev 1; by GE for the supply of Lungmen Units 1 & 2 in Taiwan, and then for the first 3 BWR units implemented in Japan by TEPCo.

We continue to lead the industry with our ECCS Sump compliance solutions and are now preparing for future regulatory bulletins based on In-Vessel Fuel Assembly Blockage research for BWR plant reactors. New generation BWR Sure-Flow® Strainer concepts are currently being developed to meet future fiber bypass requirements and changes proposed in RG 1.82 Rev 4.

By combining our innovative GSI-191 compliance solutions with our experience as the #1 strainer supplier to the U.S. BWR industry, PCI is again poised to be the world’s leader in BWR strainer compliance solutions as requirements are defined.

Accomplishments:

  • PCI’s patented flow control device is still the industry’s only flow control device
  • Preferred Strainer Vendor for 15 of 35 U.S. BWR reactors
  • A BWR Chugging Test Facility capable of realistic, robust testing of strainer modules in a reduced scale torus
  • Closed Vertical Pipe Loop at Alden’s facility where the NRC conducted the original NUREG CR/6224 mixed debris head loss research

Nuclear Insulation & Radiation Protection

Reflective Metal Insulation

Performance Contracting Inc., (PCI) is proud to introduce our partnership with KAEFER based in Bremen, Germany. PCI is dedicated to the professional service of its customers. This is why the joint venture with KAEFER to bring their RMI insulation technology to the U.S. and other interested clients is exciting for us, and hopefully to the many nuclear licensees and construction companies who have been looking for a viable alternative to the current U.S. RMI technology product offerings. KAEFER PCI, LLC now produces the finest Reflective Metal Insulation (RMI) in the world right here in the USA.

Our state of the art manufacturing facility is located just outside of Kansas City, MO. Combining German engineering and technology with PCI’s proven record of performance, innovation, reliability and experience as a supplier of safety related systems to the domestic and international markets it is a “Win-Win” for all nuclear sites. KAEFER PCI’s reflective metal insulation technology will meet the performance expectations of the specification and licensees.

NEW! Expanding Cassettes Now Available
NEW! Cassette Lined with a Non-Lead Radiation Barrier

Advantages of KAEFER PCI’s RMI product:

  • Accurate Dimensions And Precise Fabrication
  • Overlapping Joint Closures
  • Welded Foils
  • Seams Sealed Against Liquid Penetration
  • No Sharp Edges on Corners
  • RMI Is Designed To Be Re-Used For The Lifetime Of A Nuclear Plant
  • It Is Tested According To LOCA Conditions (Reg. Guide 1.82) By Independent Institutes

Radiation / Thermal Insulation Systems

Our NUKON® insulation or our Reflective Metal Insulation can be equipped with a Non-Lead Radiation Protection System. This radiation protection is a Non-Toxic safe alternative to lead blankets, it is comprised of either tungsten or iron combined with silicon to be formed to any shape or size. These radiation barriers are placed within our NUKON® or RMI cassettes. This will eliminate the use of lead blankets during any outage work saving time, money, radiation exposure and environmental issues.

NUKON®

The NUKON® Containment Insulation System is designed, fabricated and supplied to provide superior performance on hot service piping and equipment inside light water reactor nuclear power plants. Each component of the NUKON® system is supplied in such a way that it can be quickly removed and reinstalled, thereby keeping insulation handling off the plant’s critical path. The NUKON® insulation is also designed to be extremely durable. When subjected to normal usage, it will last the lifetime of the plant. To determine its installed performance, PCI has performed a number of tests and engineering analyses on the NUKON® system. With the NUKON® system installed in over 100 nuclear containments worldwide, it has become the world’s standard for nuclear containment thermal insulation.

BENEFITS INCLUDE:

  • High Thermal Performance
  • Lightweight
  • Removable
  • Durable

Available With The Following Add-Ons:

  • Stainless Steel Jacketing
  • MSJ
  • Support Rings and Metal Jacketing

Q-Insulation Materials

We provide a full range of insulation materials and insulation accessories as Nuclear Safety Related material. These materials are compliant with U.S. NRC Regulatory Guide 1.36. The items sold as Q-Materials are purchased and tested according to the procedures set forth by our Quality Assurance Program.

The Q-Materials that we supply include:

  • Stainless Steel Insulation Jacketing
  • Fiberglass Pipe Covering
  • Fiberglass Cloth
  • Bolting
  • Identification Tags
  • Insulating Cements and Mastics
  • Accessory Pins, Clips and Wire
  • Insulation
    • NUKON®
    • RE\WRAP
    • Board Type
    • Foam Glass
    • Calcium Silicate
    • Mineral Wool
    • Needled Glass
    • Closed Cell Anti-Sweat

Re/Wrap Insulation (Commercial)

RE/WRAP Insulation System is designed around a flexible blanket of resilient high-temperature woven fibrous glass fabric. Components are secured in place over piping, fittings and equipment with either Velcro-type hook-and-loop fasteners or lacing hooks. Outer covering materials are sewn together with high-integrity thread to encase the insulation.

RE/WRAP insulation covers for elbows, flanges, valves, pumps, turbines, manways and other equipment are computer-engineered for a close fit to customers’ particular requirements.

RE/WRAP Insulation System consists of rapidly removable and reusable, highly effective thermal insulation blankets as a total system including pipe, fitting and equipment covers. It may also be installed to provide easy access to locations requiring in-service inspection or maintenance, indoors or outdoors. These blankets can be provided with certification to USNRC Regulatory Guide 1.36 under a full 10CFR50, App. B quality program, and with acceptance of 10CFR21 liability.

The RE/WRAP system is easily installed, by PCI crews or by customers’ personnel trained in correct procedures by PCI technicians. No special skills, tools, or techniques are required to achieve a neat and effective insulation job, eliminating energy-wasting gaps between sections.

Radiation/Thermal Insulation Systems

Our NUKON® insulation or our Reflective Metal Insulation can be equipped with a Non-Lead Radiation Protection System. This radiation protection is a Non-Toxic safe alternative to lead blankets, it is comprised of either tungsten or iron combined with silicon to be formed to any shape or size. These radiation barriers are placed within our NUKON® or RMI cassettes. This will eliminate the use of lead blankets during any outage work saving time, money, radiation exposure and environmental issues.

Custom Metal Fabrication and Appendix B Metals

Custom Metal Fabrication

PCI offers a complete line of laser cutting, welding, and metal fabrication services with the ability to handle both large and small jobs.

PCI has a full range of light and heavy gauge sheet metal equipment including one of the largest production laser cutters in North America. This laser cutter allows PCI to cut thicker material faster and with cleaner lines. PCI’s laser also has the ability to quickly laser etch and mark metal with product names, logos, or coding information.

Along with a complete line of metal fabrication services, PCI offers high quality in-house welding services performed with SMAW, GTAW, GMAW and Fusion processes. A full CAD design team is also available to work with a customer’s existing drawings or can create new drawings to the customer’s specifications.

PCI has an extensive quality assurance program that can be utilized to meet your job requirements. The quality assurance program is fully compliant to ISO 9001: 2008, 10 CFR 50 – Appendix B, and ASME NQA-1 (2008).

Appendix B Metals

PCI’s offers to nuclear and non-nuclear utilities and contractors custom metal fabrications. PCI has an extensive quality assurance program that is fully compliant to ISO 9001: 2008, 10 CFR 50 – Appendix B, and ASME NQA-1 (2008).

PCI has a complete line of laser cutting, welding, and metal fabrication services with the ability to handle both large and small jobs.

PCI has a full range of light and heavy gauge sheet metal equipment including one of the largest production laser cutters in North America. This laser cutter allows PCI to cut thicker material faster and with cleaner lines. PCI’s laser also has the ability to quickly laser etch and mark metal with product names, logos, or coding information.

Along with a complete line of metal fabrication services, PCI offers high quality in-house welding services performed with SMAW, GTAW, GMAW and Fusion processes. A full CAD design team is also available to work with a customer’s existing drawings or can create new drawings to the customer’s specifications.

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Metal Fabrication_01
Metal Fabrication_03

Custom Laser Cutting and Welding Services

PCI offers a complete line of laser cutting, welding, and metal fabrication services with the ability to handle both large and small jobs. Along with one of the largest production laser cutters in North America, PCI also has high quality in-house welding services performed with SMAW, GTAW, GMAW and Fusion processes. A full CAD design team is also available to work with a customer’s existing drawings or can design to the customer’s specifications.

EMR

.48

Industry Leader in Safety

PCI’s culture of safety makes the difference. A safe work environment is the foundation that PCI was built upon. Our award-winning “Target Zero Incidents” safety program is absolutely integral to every project. This program provides training and keeps workers fully dedicated and accountable to the safety and integrity of your project and property. This is reflected by an EMR safety rating that far exceeds national standards.

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Innovative Metal Solutions