In-Line Sampling Nozzle & Quill — Design, Manufacture & Certification (Sampling Consultants)
Barair Systems Limited was appointed to support the design and delivery of an in-line sampling nozzle and quill assembly, including the supply of one-off manufactured units (nozzle and quill). The project required a combination of detailed mechanical design and practical delivery support: converting functional requirements into buildable drawings, coordinating specialist manufacture, and ensuring the final items were supported by appropriate documentation and certification.
The challenge
The assembly included a nozzle feature set that required multiple compound-angle ports (23 individual nozzle holes), creating a manufacturing challenge: the geometry was not feasible on standard 3-axis equipment, and a capable subcontractor with 5-axis machining capacity was needed to achieve positional accuracy and finish without excessive setups and error stack.
In addition, the final product needed to be delivered in a way suitable for industrial deployment, meaning:
robust drawings and clear interfaces
controlled fabrication/welding where required
appropriate inspection and pressure testing
a structured documentation pack to support acceptance and traceability
Engineering scope
Barair’s scope included:
Detailed design of the nozzle and quill assembly (geometry, interfaces, assembly detail)
Manufacture-ready drawings and specification notes
Subcontractor identification and coordination for specialist machining (5-axis)
Coordination of coded welding and fabrication activity where required
Inspection and pressure testing coordination/support
Final technical review and certification of the delivered assembly and documentation pack
Method (how we delivered it)
Design capture and interface definition
Establish the functional requirements, interfaces to the pipeline, insertion lengths, and assembly constraints.Detailed design and drawing pack
Produce buildable drawings with clear datums, tolerances, and inspection expectations for the nozzle hole geometry and interfaces.Manufacture route planning
Identify an appropriate machining strategy and a subcontractor with 5-axis capability to reduce setup error and maintain positional accuracy.Fabrication and welding coordination
Where welded features were required, coordinate coded welding and ensure the design intent and quality expectations were understood.Inspection and pressure testing support
Ensure inspection/testing was planned, executed and recorded in a way suitable for acceptance and traceability.Close-out and certification
Review the final manufactured items against the design intent and compile the supporting technical documentation for client use.
Deliverables
Manufacture-ready drawings and specification notes
Defined datum/tolerance strategy for complex features
Specialist subcontractor coordination (5-axis machining)
Inspection and test support (including pressure test evidence where applicable)
Final technical review and certification / close-out documentation pack
Implementation-ready assembly suitable for deployment
Outcome
The nozzle and quill assemblies were successfully designed and manufactured as one-off units, with specialist machining and controlled fabrication coordinated to meet the geometric requirements. The project was delivered with supporting documentation suitable for acceptance and future repeat builds, and the client was satisfied with both the technical outcome and the delivery process.
Adrian Lowes BEng(hons) CEng MIMechE ASME
Adrian Lowes is a Chartered Mechanical Engineer and the founder of Barair Systems Limited, with over two decades of experience delivering innovative engineering solutions.
A graduate of the University of Bradford, he has worked on projects from automated vision systems for the automotive industry to oil and gas research with Cranfield University. He has developed products for brands including Microsoft, ICI, Toyota, and Florette. His expertise spans machinery design, finite element analysis, CE marking, and industrial accident investigation.
A lifelong musician, Adrian has directed Skipton Brass and Brass Ten, and served on the Alumni Committee of the National Youth Brass Band of Great Britain. Based in West Yorkshire, he combines technical precision with creative problem-solving in every project.
Key deliverables
Detailed mechanical design and manufacture-ready drawing pack
Datum/tolerance strategy for complex compound-angle features
Specialist subcontractor coordination (5-axis machining capability)
Welding/fabrication coordination where required
Inspection and pressure testing support with recorded evidence
Final technical review and certification / close-out documentation pack
Call to action
If you need complex mechanical design delivered through to manufacture, including coordination of specialist machining, inspection/testing, and documentation, request a design review. We’ll define the requirements clearly and deliver buildable outputs with evidence to support acceptance.