Author: isoadmin

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BLJ In-situ solutions were engaged to machine the Port Side lower dredge line flange face, after it was discovered the dredgers steel ring moved during the fabrication process. 2 highly skilled technicians were sent out to the port to discuss options with ships engineer’s. BLJ’s solution was to provide on-site machining of the flange face, using a  6′ to 40″ Flange Facer, removed 1.2mm of material, the flange face connection was steel to steel.

Flange Joint Management Services allows our clients to better maintain and refurbish pressure vessels, bolted joints and valves.

The steel ring of the Port Side lower dredge line flange face moved during the fabrication process.

On site machining of the flange face, using a  6′ to 40″ Flange Facer, removed 1.2mm of material, the flange face connection was steel to steel.

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Our client required a custom solution to machine a 10”/600# flange that had a scratch across its sealing face.

Client required the machining to be completed on site.

BLJ’s Flange Joint Management Service allows our clients to better maintain and refurbish pressure vessels, bolted joints and valves. This will help in improving plant safety and the environmental performance of the plant.

BLJ provided a highly a skilled technician and a 2”-24” Flange Facer  machine to remove the scratch on the flange sealing face.

Flange face machining was performed on-site at clients workshop location

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Our remote area client required a custom leak seal solution to seal and stop a medium pressure Steam Leak while the plant remained on-line, under pressure and temperature.

Leak sealing utilises specialist compounds and a mechanical retaining device to effect a seal. The process combines stringent procedures and risk assessments with highly experienced trained personnel and specialist equipment to ensure a safe process and an effective seal.

BLJ technicians were required to design and manufacture a clamp solution to meet clients specific application. They installed the peripheral seal clamp around the bonnet leak on the 6” 600# valve and utilised specialist compounds and a mechanical retaining device to effect a seal. Design Temp: 400 deg C. Design Pressure: 3800 Kpa.

Leak sealing and repair was completed with clamps designed to ASME VIII or AS1210 design codes.

This is a temporary fix to get the plant through to the next plant maintenance or scheduled shutdown, when the item is repaired or replaced to work within the clients timeframe and resources.

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One of the services we offer to 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 about safe use and good working practices. 

Our training is conducted by Certificate IV Qualified Trainer and Assessor with over 35 years 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 workshop
• Gladstone workshop
• Client site locations (interstate available on request.)

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Our client located in the Gladstone region encountered a leak in their cooling water system. Two parts of the gasket failed and blew out of the joint.

Leak sealing utilises specialist compounds and a mechanical retaining device to effect a seal. The process combines stringent procedures and risk assessments with experienced trained personnel and specialist equipment to ensure a safe process and an effective seal.

BLJ Gladstone technicians attended the site location and hot bolted the joint, installed injection washers and peened copper wire into the flange gap.

Once the wire was secure in the joint, BLJ technicians injected compound through the injection washers and sealed up the cavity/ leak path. The client was very happy with the result, and BLJ technicians service.

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BLJ was engaged for a one-off 12” 150Lb Hot Tap on a stainless steel tank that will serve as a drain point – the tank was to be emptied for inspections.

Our technicians utilised a T37 Hot Tap Machine to perform the 12” 150 Lb Hot Tap into the 11,200-diameter stainless steel tank. Product in the tank was beer sludge with 12% ethanol.

The hot tapping process was completed without leakage or loss of fluid. The job was successfully completed in 1 x 8-hour day shift.

blj_-_hot_tapping_tank (Small)

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One of our clients required On-Site Machining services to damaged flanges ranging from 2” 150lb to 26” 150lb on a Fuel Gas Coalescer vessel

BLJ dispatched technicians with portable Flange Facing machines to conduct machining on various sized damaged flanges on a Fuel Gas Coalescer vessel at the client’s premise.

The project was successfully completed due to BLJ’s expertise and experience in the process. The client is happy with our efficiency in completing the task.

blj_-_flange_facing_gas_vessel (Small)

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BLJ was tasked to rectify a gasket leak from flange joint flow element.

To manage and repair the leak, BLJ we manufactured a leak sealing clamp and mobilised 2 technicians on site.

BLJ technicians were required to custom design and manufacture a mechanical retaining device (clamp) solution to meet clients specific application. They installed a 1-1/2” 600lb flange and injected compound to stop the leak and effect a seal. 

Leak Sealing is a temporary fix to get the plant through to the next scheduled shutdown when the item is repaired or replaced to work within the clients timeframe and resources. Clamps are designed to meet ASME VIII or AS1210 design codes 

Product: MP steam

Design Temperature: 260 degrees Celcius

Design Pressure: 540 PSI

It was a clean leak seal with no downtime or disturbance – clients plant remained online during the repair process. 

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The client approached BLJ for installation of a new 6” line into the 12” line for 2 new Pressure Safety Valves.

BLJ technicians perform a cold cut (143mm hole) into the existing 12″ header line.

It was an effective solution – the cold cut produced a clean cut.

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BLJ was engaged to perform an online Leak Seal on an Exchanger that started leaking for a leading oil and gas company

The leaking exchanger was an Exchange flange size 1555 OD. After an initial assessment of the situation, BLJ technicians installed injection valves in the product.

Our site technician then partially sealed the bottom half before peening copper wire into the exchange flange gap.

The Leak Seal was completed with no downtime to the plant and the client was happy with the end result.

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BLJ was engaged to perform an Online Leak Seal on a leaking 1” valve bonnet.

The product involved was HP steam with a line pressure of 12,600 KPA. 

BLJ technicians performed an initial check, then custom designed and manufactured a mechanical retaining device (clamp) solution to meet clients specific application. The client required their plant to remain on line during this process. The BLJ site technicians proceeded to apply in-cased valve with peripheral seal clamp, injected with specialised compounds to effect a seal.

Although the leak was problematic to manage in the beginning, BLJ’s highly experienced technicians handled the situation skilfully and with ‘safety first’ motto

The leak seal installation was carefully finished by our technicians while allowing for a continuous plant productivity.

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One of our Australian based clients required a set of specialised on-site machining services on highly corroded and damaged sealing face on a knife gate valve outlet on a hydrocracker at their petroleum refinery in Vietnam. BLJ technicians were to work with the assistance of locally based company technicians.

As the damaged sealing face had a flange size of 88”, BLJ sent to highly skilled technicians to the clients international refinery location The technicians re-machined damaged sealing faces, using a Mirage 48” to 126” flange facing machine at the site

The project was completed with minimal disturbance and BLJ’s ‘working with’ approach ensured that our technicians teamed up well with other technicians in Vietnam.

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BLJ was contacted by the client to perform a tensioning procedure and flange joint management services on a new instalment of a gas pipeline.

BLJ formulated a customised solution, and tailored a bundled service package for this clients needs.

Our highly skilled technicians implemented BLJ’s Tensioning and Flange Joint Management Services with Flange size of 600mm 900lb and 100% tensioning of RTJ.

The new instalment went smoothly and our client was very happy with the final outcome.

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The client has a dysfunctional 2790mm slew ring needed to be machined.

BLJ provided 2 technicians that utilised our Mirage 48” to 126” with 6” milling cutter to remove 3.2 material from the slew ring.

The project was completed in 3 days with perfection and has assisted our client with smooth running operation due to BLJ’s capabilities of performing efficient on-site machining service.

Client:

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BLJ was engaged by the client to perform clamp installation and provide a leak sealing solution. A 2″ elbow was leaking on an HP Steam with line press of 15,300 KPA.

BLJ’s solution was to design and manufacture a clamp solution to meet clients specific application. A clamp was installed around the elbow leak, and to stop the leak, a compound injection was carried out. Leak sealing and repair were completed with clamps designed to ASME VIII or AS1210 design codes.

This is a temporary fix to get the plant through to the next plant maintenance or scheduled shutdown, when the item is repaired or replaced to work within the clients timeframe and resources.

The job was completed very efficiently, providing our client with a leak-free start-up. 

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CPB Contractors required BLJ’s technicians and portable machines to provide in-situ machining services in the Surat Basin site for pipelines and flange connections not to specifications.

CPB Contractors Pty Ltd (CPB) is the CIMIC Group’s construction company, with a team of around 23,000 people.

BLJ technicians and portable machines were engaged to provide on-site machining of various size flanges. Tensioning and Flange joint management services were also performed by BLJ technicians.

With fast mobilise response time to site, CPB and its clients were able to reduce the pipeline down time.

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BLJ was tasked by Dyno Nobel with shutdown bundled services at the Moranbah gas plant.

Dyno Nobel Asia Pacific Pty Ltd (DNAP) supplies the mining industry in Australia, Europe, China, Africa, Turkey, Albania, Romania, Finland, Indonesia and Papua New Guinea. In particular, DNAP supplies surface and underground mining in the thermal coal, metallurgical coal, iron ore and other metals sectors.

Due to the size of the project, BLJ supplied 12 technicians and 2 supervisors to execute various services on site. These include hydraulic torque up of flanges and machining various size flanges.

Dyno Nobel was happy with our efficient work, with the team working hard and solving problems along the way in between isolating and de-isolating the plant.

blj_dynonobel_moranbah

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Incitec required assistance with specific R612 Pipe Replacement to performed directly on their Gibson Island site.

Incitec Pivot Limited is a global diversified industrial chemicals company that leverages its manufacturing excellence and core competencies in nitrogen.

8 BLJ technicians were engaged to perform the required service on site. Replacement and installation of R612 pipes were performed – our team cut and prepare pipes of various sizes: 6”,8”,12”,14” and 16”.

It was a smooth and clean operation, with the team encountering no problem of performing pipe replacement in between isolating and de-isolating the plant.

incitec_gibson_island

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Caltex needed a seal fix for 4” 150# bonnet leak.

Caltex Australia Petroleum Pty Ltd is global petroleum brand name and operates the largest oil company retail network in Australia.

BLJ provided 2 of our experienced technicians to perform leak sealing services. The process involved replacing studs one at a time, as well as utilising fitted injection washers. 

We performed an excellent leak sealing service – successfully peened copper wire into the gap of the bonnet to ensure a leak-sealed joint.

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BLJ was tasked with major maintenance of the RTA (Rio Tinto Alcan) Yarwun plant. This includes on-site machining, controlled bolting, hot tapping services, under pressure leak sealing, labour support, digestion shut down packages, as well as minor, unplanned and major outages.

Rio Tinto is a leading global mining and metals group that focuses on finding, mining, processing and marketing the earth’s mineral resources.

BLJ are able to provide consistency in experience with the plant and RTA employees via seamless work practices which achieved the required outcome each time BLJ were engaged. Not only was the support from BLJ work site based but the knowledge and reliability of BLJ to demonstrate their expertise skills and problem-solving abilities was consistency utilized by all areas of the plant.

BLJ has had the ability to provide Rio Tinto with all their service needs consistently for over 9 years. BLJ exceeds the required KPI’s as set by the client, consistently demonstrates reliability, attention to detail and ultimate customer service. 

blj-rta_yarwun_plant

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BLJ was tasked to provide specialized services in building gas plants for a new construction site by Thiess.

Thiess is the world’s largest mining services provider – their expertise covers most of the world’s commodities including metallurgical and thermal coal, lignite, iron ore, copper, nickel, gold, and diamonds.

BLJ was asked to be involved in this project to provide various services, predominately; On-Site Machining & Controlled Bolting. This meant that across the numerous projects that were running simultaneously and all equally important with different desired outcomes and target goals. 4 BLJ technicians were engaged by Thiess to machining flanges from ¾’’to 42” on a permanent roster basis to work together with Thiess employees to meet the targeted goals. Our services also extended to tensioning various stud sizes from  1-1/4” to 2-1/2” and also pipe cutting and prepping from 6” to  42”.

BLJ played an integral role in constructing various Gas plants on this project. Our efficiency means Thiess maintained BLJ’s involvements throughout the entire project until the decommissioning phase to ensure that all sites were fully operational and compliant. This was the main goal of the head contract and it was achieved successfully.

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Laing needed assistance with on-site machining and dry hire tooling to be performed on site. This also involved dry hire of various bolting equipment.

Laing O’Rourke is a privately owned, internationally focused engineering enterprise with services comprising the full range of engineering, construction, and asset management services.

BLJ provided Laing on-site machining service and dry hire tooling with 2 BLJ technicians performing machining flanges 2” to 30”. Dry hire of various Hydraulic Torquing equipment throughout the duration of the project. BLJ provided a supervisory role to work together.

BLJ worked collectively with Laing which enabled them to meet their deadline and achieve their desired targets. BLJ demonstrated top-notch skills and reliability of our equipment that opened up more opportunities at other Laing’s construction sites.Integrating BLJ skills and equipment with Laing’s resources proved to be fruitful – it leads to a permanent commitment and roster to ensure that the project was completed while Laing had access to BLJ’s specialised services.

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Monadelphous requires labor support for the new construction site.

Monadelphous is a leading Australian engineering group providing construction, maintenance, and industrial services to the resources, energy and infrastructure sectors.

We provided our most sought-after service – Flange Joint Management Services to assist Monadelphous. 5 BLJ technicians carried out assembling of various size flange joints together with required torquing and tensioning.

Even though BLJ only provided skilled labour support on this project, BLJ’s involvement was critical as it helped Monadelphous achieved the desired goal of the overall project. Monadelphous valued the resources, experience, and skills that BLJ provided throughout the project to ensure that the target goals were achieved.

Workscope was effectively completed achieving a completely leak-free startup.

This goal was critical to the main client under a head contract and paramount to the project as a whole. Working collectively with our clients achieves a desirable outcome for all major projects of this scale.

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Newcrest needed on-site machining expertise to be performed on site.

Newcrest Mining Limited is an Australian-based corporation which engages in the exploration, development, mining and sale of gold and gold-copper concentrate.

BLJ In-Situ Solutions provided On-Site Machining services, as client engaged 4 BLJ technicians over a 12 month period to perform machining of various size flanges ranging from 6” to 60”.

BLJ’s expertise and experience allowed Newcrest to be ahead of schedule throughout the completion of designated work. This also fast-tracked the entire project to be completed within a shorter timeframe as a direct result of BLJ’s skilled technicians.

blj-autoclave_project