Barair Systems Limited was appointed to support the design and delivery of an in-line sampling nozzle and quill assembly for Sampling Consultants, including the supply of one-off manufactured nozzle and quill units. The project required more than a drawing exercise. It involved translating functional requirements into buildable designs, coordinating specialist manufacturing processes, and ensuring the finished components were delivered with the documentation and certification needed for industrial use.
A key challenge in the project was the nozzle geometry itself. The design required 23 individual compound-angle nozzle holes, creating a machining problem that could not realistically be achieved on standard three-axis equipment without excessive setups and accumulated positional error. A subcontractor with suitable five-axis machining capability therefore had to be identified and coordinated so that the feature geometry could be produced accurately and efficiently.
Alongside the geometry challenge, the final assembly had to be delivered in a form suitable for practical deployment. That meant the drawing pack needed to be clear, datums and tolerances had to be defined intelligently, fabrication and welding needed to be controlled where applicable, and inspection and pressure testing had to be planned and recorded in a way that supported traceability and acceptance.
Barair’s scope covered the detailed design of the nozzle and quill assembly, including interfaces, insertion geometry and assembly detail. Manufacture-ready drawings and specification notes were produced, and the manufacturing route was planned around a specialist five-axis machining subcontractor in order to maintain positional accuracy on the nozzle feature set. Where welded features were required, fabrication and coded welding activity were coordinated to ensure the design intent and quality requirements remained clear throughout manufacture.
Inspection and testing support formed part of the delivery process, ensuring that evidence of compliance and traceability was captured as the work progressed. At close-out, the final manufactured items were reviewed against the design intent and compiled into a technical documentation pack suitable for client use, future reference and any repeat-build requirements.
The project was delivered successfully as a one-off manufactured assembly, with the geometric requirements achieved through specialist machining and controlled fabrication. The finished nozzle and quill units were supported by a structured documentation and certification pack, giving the client confidence in both the technical outcome and the delivery process.
