Client:

Location:

The client, a transportation company based in Larapinta, required precision machining of king pin hats on their trailers to meet specific tolerances. King pin hats play a critical role in ensuring secure and stable connections between trailers and towing vehicles. To achieve the desired result, a 0-12” Mirage flange facer was required to complete the job with precision. However, modifications to the trailers were necessary to accommodate the mounting of the machining equipment.

The client entrusted BLJ In-situ Solutions with the task, recognising our expertise in onsite machining services and delivering solutions tailored to complex mechanical maintenance needs.

BLJ In-situ Solutions developed a customised plan to machine the kingpin hats to the required tolerances while minimising the client’s downtime.

1. Design and Fabrication of Jig Plates:

• We designed and fabricated two jig plates specifically for the project. These plates were welded onto the underside of the trailers, providing a stable base for mounting the 0-12″ Mirage flange facer.
• The jig plates ensured the machining process could be carried out with precision while maintaining safety and efficiency.

2. Onsite Setup and Machining:

• Our team visited the client’s site in Larapinta and mounted the jig plates onto the trailers. The mounting process was carried out with meticulous attention to alignment to ensure proper setup for the machining process.
• Once the jig plates were in place, we mounted the Mirage flange facer onto the trailers and began machining the king pin hats. Using state-of-the-art equipment, we achieved the required tolerances for the king pin hats, ensuring they met the client’s specifications.

2. Completion and Cleanup:

• After completing the machining, the client removed the jig plates and refitted the king pins to the trailers. The removal of the jig plates was seamless, as they were designed to be cut off without causing damage to the trailers.

The project was completed successfully, delivering precise results that met the client’s requirements and expectations.

• Precision Machining: The king pin hats were machined to the specified tolerances, ensuring they were ready for reliable and safe operation.
• Custom Solutions: The fabrication of jig plates tailored to the trailers’ structure ensured the machining equipment could be mounted securely and effectively.
• Efficient Process: By performing the machining onsite, the need for costly and time-consuming transport of the trailers to an offsite facility was eliminated.
• Client Satisfaction: The client was pleased with the outcome, as the solution provided by BLJ allowed them to meet their operational needs without significant downtime.

Client:

Location:

BLJ In-situ Solutions was engaged by Inox, a client experiencing persistent leakage issues with four stainless steel vessel flanges. Despite multiple attempts using various gaskets, the flanges continued to leak, jeopardising the integrity of the vessel and disrupting operations. Inox required a reliable solution to address this ongoing problem during planned maintenance activities to avoid further downtime and ensure safe operations. 

Upon assessing the situation, BLJ In-situ Solutions proposed an innovative solution: onsite machining of the vessel flanges. Our team recommended executing this task while the vessel was upside down during the scheduled maintenance period, allowing for effective access and ensuring minimal disruption to other operations. 

The machining process involved precision work on all four stainless steel flanges. Our experienced technicians utilised specialised onsite machining equipment to achieve a flat surface over the bolt holes, adhering strictly to the required flange specifications. The goal was to achieve a surface finish between 3.2 and 6.3 Ra, ensuring a proper seal and preventing any further leakage. 

BLJ’s commitment to quality and efficiency allowed the machining process to be completed swiftly, ensuring that the vessel was ready for operation without unnecessary delays. 

The onsite machining of the vessel flanges was a resounding success. Following the completion of the machining work, operations at Inox were able to resume without any leaks, significantly enhancing the vessel’s performance and reliability. The client reported that the leak-free startup was achieved seamlessly, leading to improved operational efficiency and reduced risk of product loss. 

This project not only resolved the immediate leakage issue but also demonstrated the effectiveness of BLJ In-situ Solutions’ expertise in onsite machining services. By providing a tailored solution to a complex problem, we reaffirmed our position as leaders in the field of mechanical maintenance and machining maintenance. 

Through our commitment to quality, reliability, and innovative approaches to industrial maintenance challenges, BLJ In-situ Solutions continues to support clients like Inox in achieving operational excellence and minimizing downtime. 

Client:

Location:

The Orica Ammonia plant on Kooragang Island is not just a crucial part of ammonia production, but also a significant contributor to the New South Wales economy. Its role in manufacturing fertilisers, explosives, and various industrial chemicals is vital for industries such as mining, infrastructure, and medical. Ensuring the plant’s operational efficiency and safety, especially during scheduled shutdowns, is paramount for maintaining these industries’ productivity and safety standards.

The scope of work for this project included a wide range of tasks necessary for the successful shutdown and restart of the plant. Specifically, BLJ was responsible for isolating and de-isolating the plant, removing end covers and channel heads from exchangers, performing various machining and pipe-cutting jobs, removing and replacing valves, and opening vessels for inspections followed by reassembly (box-up). To accomplish this, BLJ supplied a team of 18 highly skilled technicians and 2 experienced supervisors to oversee and conduct these essential maintenance works on-site.

Understanding the critical nature of the tasks at hand, BLJ In-situ Solutions deployed a well-coordinated team of professionals to execute the work scope efficiently and safely. The team’s meticulous planning and organisation ensured minimal disruption to the plant’s operations and strict adherence to the shutdown timelines, demonstrating their professionalism and dedication to the project.

The first phase involved safely isolating the plant to prepare for maintenance activities. This process was carefully managed to ensure all systems were properly shut down and secure. Technicians then worked on dismantling critical components of the exchangers, ensuring they were safely removed for inspection and maintenance.

BLJ’s team utilised advanced machining and pipe-cutting techniques to perform precise modifications and repairs, ensuring the plant’s infrastructure remained in optimal condition. Valves were removed and replaced with precision as required, ensuring that all new components met the necessary specifications and were correctly installed. Vessels were carefully opened for thorough inspections, followed by meticulous reassembly to ensure they were sealed and operational.

The shutdown project was completed successfully, meeting all safety and operational requirements. The expertise and efficiency of the BLJ In-situ Solutions team ensured that all tasks were completed on schedule, allowing the Orica Ammonia Plant to resume production without delay. The thorough inspection and maintenance activities performed during the shutdown significantly enhanced the plant’s safety and reliability, reducing the risk of future operational issues. Thanks to the precise coordination and execution by BLJ’s team, the shutdown period was minimised, ensuring that the plant could quickly return to its critical role in ammonia production.

By providing comprehensive and professional mechanical services, BLJ In-situ Solutions played a crucial role in maintaining the Orica Ammonia Plant’s high safety and performance standards. This project not only highlighted BLJ’s technical capabilities but also underscored our commitment to supporting essential industrial operations throughout Australia.

Client:

Location:

BLJ In-situ Solutions was engaged to assist with the installation of new road signs on the Bruce Highway. The primary task involved torquing bolts on Variable Message Signs (VMS) splice plates to ensure they were installed securely and correctly. This work was essential to maintain the signage’s structural integrity and safety, providing real-time information to motorists.

To address the project requirements, BLJ deployed a team of skilled technicians to work night shift, minimising disruption to daytime traffic and ensuring the safety of both workers and motorists. The team utilised a Rad Gun 2500, a high-torque pneumatic tool known for its accuracy and efficiency, to achieve the precise torque specifications needed for the splice plates.

Key steps in our solution included:

• Conducting operations during night shifts to avoid daytime traffic disruptions.
• Ensuring all safety protocols, including proper lighting and high-visibility gear, were strictly followed.
• Utilising the Rad Gun 2500 to ensure precise and reliable torquing of each bolt on the VMS splice plates.

The project was completed successfully, with all VMS splice plates torqued to the required specifications and the new road signs securely installed. 

Proper torquing ensured the road signs were securely installed, reducing the risk of structural failures and enhancing safety for motorists.

Night shift operations minimised traffic disruptions and demonstrated BLJ’s commitment to operational efficiency and client convenience.

The skilled execution by BLJ’s technicians, combined with the use of advanced equipment like the Rad Gun 2500, ensured the highest standards of workmanship.

Overall, BLJ In-situ Solutions’ involvement in the Bruce Highway Road Signs Nightworks project highlights our capability to deliver critical mechanical services in challenging environments. Our commitment to safety, precision, and efficiency ensured the successful completion of the project, reinforcing our reputation as a reliable partner in infrastructure maintenance and construction.

Client:

Location:

A fibre cycle company in Toowoomba that recycles paper into kitty litter, experienced a critical failure in their paper shredder’s keyway. The keyway had previously undergone a weld repair that ultimately failed, disrupting their operations.

The damaged keyway on the paper shredder shaft required an immediate solution to maintain production until new shafts, ordered from Germany, could be installed.

BLJ In-situ Solutions deployed a team of skilled technicians to address the issue with precision and efficiency.

Our technicians executed through assessment of the damaged keyway and the shaft condition before utilinsg specialised equipment to precisely cut a new keyway 180 degrees in the shaft. We ensured the new keyway was cut to exact specifications to seamlessly fit with the existing components.  

Rigorous testing was conducted to ensure the new keyway’s integrity and alignment, verifying that the shredder operated smoothly with the newly cut keyway, maintaining production efficiency.

The successful cutting of a new keyway allowed this fibre cycle company to continue their recycling operations without significant downtime. This temporary but effective solution will keep the shredder operational until the arrival and installation of the new shafts from Germany.

BLJ In-situ Solutions demonstrated technical expertise and a commitment to minimising client downtime. Our prompt and effective intervention ensured the client could maintain their production schedule, highlighting our capability to handle critical repairs in the recycling industry.

Client:

Location:

BLJ was contacted by a power station in Darling Downs, contracting one of our expert technician teams to perform on-site machining services for various pipe cutting and transition weld repairs throughout the plant.  

BLJ sent a team of 12 expert technicians to perform a series of on-site transition weld repairs, including removing an existing weld on a pipe 949mm in diameter and 53mm wall thickness. 

Over the course of 13 days (dayshift and nightshift work included), the BLJ on-site machining team successfully carried out various pipe cutting projects.

All weld repairs and pipe-cutting works were completed with little to no disruption to the power station 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.

Client:

Location:

BLJ’s client for this project was a well-known Australian company that operates in the packaging, paper, and recycling industries. Since thier inception in the 1940’s, they have grown to be one of the largest privately-owned packaging and recycling companies in the world.

The client reached out to the team at BLJ to assist them in installing a new pipeline. The new pipeline required work to be conducted while the primary pipeline was still operational.

To allow work to continue at the plant, a team of expert BLJ technicians were engaged to perform a 4″ 150# hot tap into an 8″ Natural Gas line. Our team utilised a range of special equipment to cut the hole into the pipeline and insert a fitting, allowing for the connection of the new pipeline. Our hot-tapping services served as a safe and efficient way of making connections to pressurised systems.

Our meticulous hot-tapping procedure, performed by our highly trained personnel, allowed for the continued operation of the plant and individual pipeline while the modifications were made. This minimised shutdown time at the plant, resulting in increased efficiencies.

Client:

Location:

A prominent metalwork and fabrication company based in Brisbane encountered an issue during the commissioning phase of one of their projects. The client’s machinery flanges were leaking, jeopardising their equipment’s overall integrity and functionality. This unexpected problem demanded a swift and effective solution to prevent costly delays and potential hazards.

To address the issue, BLJ In-situ Solutions deployed a team of highly skilled technicians to assess and rectify the flange problem. Upon inspection, the technicians identified that the flanges were 7.6mm out of flatness, causing an improper sealing of the flange faces. To remedy this, they employed precision machining techniques to adjust the flange face to the required specifications.

The technicians utilised a portable Mirage flange facing machine (MM1500i) to perform the necessary machining on the flanges. However, this task was not without its challenges. In some instances, bricks had been installed within the flanges, complicating the machining process. In another scenario, the flange was installed upside down, adding an additional layer of complexity.

Following the meticulous machining of the flanges by BLJ technicians, the client experienced a significant improvement in their equipment’s performance. Upon startup, there were no leaks detected, ensuring the machinery’s functionality and safety were restored to optimal levels.

This successful project demonstrates BLJ In-situ Solutions’ expertise in precision machining and our teams ability to resolve complex issues efficiently. The client’s machinery is now operational without any leaks, ensuring their plant’s continued reliability and safety.

Client:

Location:

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

Client:

Location:

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. 

Client:

Location:

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.

Client:

Location:

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.

Client:

Location:

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.

Client:

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

Client:

Location:

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.

Client:

Location:

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.

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

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

Client:

Location:

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.

A leaking valve bonnet.

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.

Client:

Location:

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.

Location:

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

Client:

Location:

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.

Location:

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.)

Client:

Location:

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.

Client:

Location:

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)