BLJ In-situ Solutions Provides Bolting Training Courses

Client:

Multiple Clients

Location:

Brisbane, Gladstone & Australia-wide

Related Services:

Related Industries:

Bolting Training Course

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


Introduction to the Training 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.


Course Content

For a full overview of the course content, please click on the button below to download our Inspection, Assembly and Tightening of Bolted Flanged Connections Awareness course structure.

If you have any queries regarding the course or would like us to prepare a specific program to meet your requirements, please don’t hesitate to get in touch with the friendly BLJ team of bolting experts on 07 3245 2203 or complete the form below.

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WWPS Pump Replacement

Client:

Australian Engineering and Utilities Company

Location:

Brisbane, Queensland

Related Services:

Related Industries:

Project Brief

Our client requested in-situ machining services of highly corroded gasket sealing faces on 600 x 150 outlet flanges at one of Queensland’s largest wastewater pump stations at a depth of 30m.


Solution

BLJ sent two technicians with a portable Mirage MM1000i flange facing machine


Results

Work was completed under the estimated timeframe allowed, and the pump replacement was able to proceed ahead of schedule.

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Leak Sealing – 1000kpa bonnet leak

Client:

Petrochemical client

Location:

Queensland, Australia

Related Services:

Related Industries:

Project Brief

2 BLJ technicians were engaged to perform an on-line leak seal  and repair to 1000kpa bonnet leak on a sour waterline, while the Petrochemical plant remained on-line, to reduce client down time. Highly trained Technicians changed out studs one at a time and installed injection washers, peen gap on bonnet flange and injected compound into the joint to provide seal leak.


Problem

A leaking valve bonnet.


Solution

Change out studs one at a time and install injection washers, peen gap on bonnet flange and inject compound into joint to seal the leak.

This leak seal solution 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.

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Flange Joint Management on Dredging vessel

Client:

Marine Industry client

Location:

Port of Brisbane 4178

Related Services:

Project Brief

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.


Problem

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


Solution

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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Fixing Flange Face Damage

Location:

Client business location Queensland, Australia

Related Services:

Related Industries:

Project Brief

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.


Solution

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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Resolving a Medium Pressure Steam Leak

Client:

Chemical Industry client

Location:

Mt Isa Queensland, Australia

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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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Inspection, Assembly and Tightening of Bolted Flanged Connections Awareness course

Location:

Brisbane, Gladstone, client BLJ site locations

Related Services:

Related Industries:

The Course

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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Leak Sealing Gladstone Region

Client:

International resources company

Location:

Gladstone Region, Brisbane, Australia

Related Services:

Related Industries:

Project Brief

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.


Solution

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


Results

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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Hot Tapping – Stainless Steel Tank

Client:

An Australian company in the engineering and construction industry

Location:

North Queensland

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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

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Flange Face Machining – Fuel Gas Coalescer Vessel

Client:

A local company in the engineering and construction industry

Location:

Clients site location Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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.


Results

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.

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Gasket Online Leak Sealing

Client:

A major company in the Australian engineering industry.

Location:

Regional Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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


Results

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

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Pipeline Cold Cutting

Client:

Oil and Gas Industry client

Location:

Phosphate Hill Mine, Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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


Results

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

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Exchange Leak Repair

Client:

Oil and Gas Industry client

Location:

Brisbane, Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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.


Results

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

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Online Leak Sealing Clamp

Client:

An Australian-based Oil & Gas company

Location:

Regional, Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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.


Results

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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Flange Facing – Knife Gate Valve Outlet

Client:

A major global company in the engineering industry

Location:

Vietnam

Related Services:

Related Industries:

Project Brief

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.


Solution

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


Results

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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Tensioning and Flange Joint Management

Client:

A major company in the engineering and oil and gas industry

Location:

Ruby Jo, Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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.


Results

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

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Slew Ring Machining

Client:

A major company in the Australian engineering industry

Location:

Hemmant, Queensland

Related Services:

Related Industries:

Project Brief

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


Solution

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


Results

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.

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Clamp Installation and Leak Sealing

Client:

A major company in the engineering and construction industry

Location:

Queensland, Australia

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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

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QGC Upstream Project Phase II

Client:

CPB Contractors Pty Ltd

Location:

Surat Basin, Queensland

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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

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Moranbah Gas Plant Shutdown

Client:

Dyno Nobel Asia Pacific Pty Ltd

Location:

Moranbah, Queensland

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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.

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Incitec Pipe Replacement

Client:

Incitec Pivot Limited

Location:

Gibson Island, Queensland

Related Services:

Related Industries:

Project Brief

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.


Solution

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”.


Results

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.

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Leak Seal 4” 150# Bonnet Leak

Client:

Caltex Australia Petroleum Pty Ltd

Location:

Lytton, Queensland

Related Services:

Related Industries:

Project Brief

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.


Solution

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. 


Results

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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RTA Specialised Contract (Yarwun)

Client:

Rio Tinto Alcan

Location:

Yarwun, Gladstone

Related Services:

Related Industries:

Project Brief

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.


Solution

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.


Results

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. 

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QCLNG Upstream 17+4 Project

Client:

Thiess Pty Ltd

Location:

Surat Basin Area

Related Services:

Related Industries:

Project Brief

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.


Solution

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”.


Results

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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We look forward to working with you.

For more information on our services, please fill out the form and one of our team members will be in touch.

BLJ In-situ Solutions Brisbane

Unit 2/20 Steel Street Capalaba, QLD 4157
Phone: 07 3245 2203

BLJ In-situ Solutions Gladstone

Unit 4/12 Crow Street Gladstone, QLD 4680
Phone: 07 4972 4408

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