Client Requirements
During a planned plant shutdown, the client discovered heavy corrosion on the flange of a process vessel. Standard protective coatings couldn’t be applied due to process restrictions, making machining the only viable option. The challenge was threefold:
- Restricted access: The flange was located against a foundation wall with a cable tray beneath, preventing the use of conventional flange machining tools.
- Tight deadline: The repair had to be completed within the shutdown window to avoid costly delays.
- High precision: Machining had to restore sealing accuracy to eliminate leakage risks once the plant was back online.
Our Solution
BEP Flow Solutions collaborated with a specialist machining partner to develop a tailored in-situ solution:
- Designed a custom jig and compact setup to fit the restricted workspace.
- Adapted a line boring arrangement for precision machining directly on-site.
- Conducted rigorous alignment checks to ensure dimensional accuracy and sealing reliability despite the space limitations.
Outcome
- Rapid turnaround: From first client call on Wednesday morning to deliverying fully machined flange by Friday noon.
- Precision achieved: Flange dimensions restored, ensuring a reliable sealing surface.
- Zero delays: Work was completed entirely within the shutdown window, avoiding downtime extensions and production losses.
Client Impact
The client avoided both leakage risks and schedule overruns thanks to a fast, precise, and engineered solution. This case highlights how BEP Flow Solutions delivers custom machining solutions when conventional methods simply won’t work - keeping plants safe, reliable, and on schedule.
