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A dredging company in South QLD reached out to BLJ In-situ Solutions to repair a damaged shaft on one of their vessels. A team of BLJ technicians were sent on-site to perform routine Journal Turning on a 140mm OD shaft.

Marine dredging vessels are essential in creating and maintaining shipping and boating channels at major ports and so our primary goal with this project was to get them back up and running with minimal downtime and provide quality work that will last.

Our expert BLJ technicians set up our Journal Turning lathe machine on the end of the shaft and machine welded off the shaft. This machine bolts directly to the end of the workpiece and rotates around the shaft allowing our technicians to achieve the required concentricity, surface finish and circularity tolerance as specified by the client.

With our Journal Turning lathe machine, BLJ successfully repaired the damaged shaft onsite with minimal downtime or disruptions to operations. This precision machining tool assists us in performing consistent and accurate machining of cylindrical surfaces for shafts from 4″ to 11.25” in diameter.

Journal Turning collage

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Newcastle’s Orica infrastructure includes 3 Nitric Acid Plants (NAP1, 2 & 3), 2 Ammonium Nitrate Plants (ANP1 & 2) and an Ammonia Plant. Orica operates from its Kooragang Island facility in New South Wales, Australia. These plants are approved to produce 500,000 tpa of ammonium nitrate product each year which are used in a variety of industrial and consumer products, including fertilisers and explosives. The Kooragang Island facility is an important part of Orica’s operations and plays a crucial role in the company’s production of these chemicals.

Our BLJ In-Situ Solutions team was called in to perform scheduled maintenance during a turnaround at Orica’s Nitric Acid and Ammonium Nitrates Plants ((NAP1) & (ANP1)) at Kooragang Island. Two technicians were on site for approximately three weeks, performing machining tasks on flanges ranging in size from 1″ to 48″ and general fitting works. 

One of the key challenges during this project was minimizing downtime in the plants to ensure Orica’s production capabilities and schedules were minimally impacted.

In order to achieve this efficiency, our highly skilled BLJ technicians were on-site, able to respond quickly to any issues that arose. We provided high-quality machining, flange face management and fitting services using a Mirage portable flange facing machine to help ensure the smooth operation of the Nitric Acid and Ammonium Nitrates Plants.

Thanks to the efforts and expertise of the BLJ technicians, the Orcia Kooragang Island scheduled maintenance turnaround was a success. Our client is extremely pleased we were able to minimise downtime and help them maintain the smooth operation of their plants. 

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Our client, a Fertiliser Plant in North West Queensland, contacted BLJ In-Situ Solutions to repair a 3” elbow pipe leak.

Product: Medium Pressure (MP) Steam

Design Temp: 250 deg

Design Pressure: 4000 kPa

BLJ manufactured a custom peripheral seal clamp off-site to fit the client’s MP Steam leak in an elbow pipe. A team of knowledgeable technicians then mobilised to the Plant once the clamp was ready for action. Our team injected the leak with a compound to prevent further leakage and repaired the pipe.

Thanks to BLJ’s specialist clamp development and efficient expert team, our client returned to full functions with little disruptions to their operations. BLJ was happy to assist our client with this project to seal the leak and return to operations with peace of mind.

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Our client, iPipe / CSG Engineering requested in-situ machining services at the Strathblane Origin GPF site 1.5 hours from Roma in central Queensland.

The Strathblane GPF to Spring Gully GPF Line is a transmission pipeline owned by Australia Pacific LNG (APLNG), which is a joint venture between Origin Energy, ConocoPhillips and Sinopec.

The Strathblane GPF to Spring Gully GPF Line connects the Strathblane Gas Processing Facility (GPF) with the Spring Gully GPF.

BLJ In-situ Solutions was required to machine compressor baseplate pads on-site. We were tasked with machining the new welded on pads.

BLJ sent a team of four expert technicians to set up an on-site XY Milling Machine. Our team made up a bespoke frame for the XY mill to sit on, welded to the compressor skid and new pads machined to levels as requested by our client.

The task took our specialist team of four technicians four shifts to complete.

All 8 x pads were machined within 0.1mm/1m tolerance in an estimated timeframe with little disruption to the site’s processes. Our client is extremely pleased with the work completed and they are now operating smoothly due to BLJ’s technician’s capabilities and expert knowledge.

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One of our large petrochemical clients requested in-situ machining services for a 1800 mm diameter stainless flange with a Mirage 2000i flange facer.

The M2000i is a portable, internally mounted flange facing machine using fixed gears to produce 6 continuous groove gramophone finishes to ASME Standard. This tool is ideal for all types of flange facing, seal grooving, weld preparation, counter-boring and heat exchanger repair.

Our team removed the damaged flange to weld a new one. In this procedure, the flange was distorted due to the welding.

BLJ sent a team of highly skilled technicians to machine the flange back to the specs required. The technicians re-machined the damaged gasket faces through the use of the portable Mirage 2000i flange facing machine set up to the best plane of fit to the gasket face and the spigot OD.

The machining of the flange was completed within the timeframe allowed, and the vessel was returned to service where it performed as if it was brand new.

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Location:

Throughout June and July 2022, BLJ was engaged by Shell (Curtis Island) to undertake a large site maintenance project which involved the isolation of the plant, machining 140 damaged flanges of varying sizes and then de-isolating the plant.

Shell’s QGC venture is located on Curtis Island near Gladstone in Queensland and acts as one of the leading onshore natural gas producers in Australia. Tapping into the Surat Basin, this operation consists of over 3000 production wells, 6 processing plants, 25 field compression stations, 2 water treatment plants, all connected to a two-train LNG export facility. Queensland Curtis LNG (QCLNG) Train 1 is part of the two-train LNG development operated by Shell.

Utilising BLJ’s comprehensive knowledge and experience in our most sought-after service, Flange Joint Management, 4 supervisors and 34 technicians were able to successfully maintain all 140 flanges which required attention. All site safety requirements and conditions were met by our dedicated team as they worked on flanges of all different sizes. Shell valued our efficiency and effectiveness in maintaining their Train’s flange joints.

BLJ successfully managed to supply cost-effective maintenance solutions to 140 flanges including over 2400 broken joints. There were 0 leaks detected upon start-up – a commendation to our hard-working and dedicated team.

Our highly experienced team of 38 were onsite throughout the project ensuring seamless 24 hour service. Meet some of our amazing ‘day shift’ team members in the left hand photo below and our equally incredible ‘night shift’ team members on the right below.

BLJ would like to thank everyone who came on board as part of our team to assist with the work at Curtis Island QGC Train 1 and 2. It was a pleasure to be able to work with everyone and to achieve such great results. No leaks with 2243 flanges broken (range of sizes) outstanding effort – until next time take care!

curtis-island-lng-plant

Image Source : Shell Australia – Queensland Curtis LNG

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One of the products we’ve developed for our clients is an Inspection, Assembly and Tightening of Bolted Flanged Connections Awareness course.

This course provides workers with the skills, ability and job knowledge in specialist critical bolting. It demonstrates aspects of hazards, health and safety, guidance and practical exercises for safe use and best work practice

Our training is conducted by Certificate IV Qualified Trainer and Assessor with over 35 years of practical industry experience. The Inspection, Assembly and Tightening of Bolted Flanged Connections Awareness course consists of:

• Technical theory testing/examination
• Practical assessment/examination with dedicated practical training rigs

Training courses are available at all BLJ In-situ Solutions locations (Brisbane and Gladstone workshops) as well as all client’s premises on request. We are available to conduct the course in any state across Australia.

The course content can be modified if you require specific topics to be covered for your projects or workplace requirements. The course is capped at 10 participants per day, with a minimum of 6 participants required for the course to be run.