On-site machining of flanges at a paper mill
At the heart of a paper mill, mixing tanks and pulpers handle large volumes of abrasive fluids. Over time, large-diameter flanges and valve or agitator seats lose their flatness. A deformed flange means constant leaks, lost efficiency, and unscheduled downtime.
The problem was clear: the part was too large to be moved, and plant downtime had to be minimal.
The Solution: iZanda Portable Facing
Our solution involved deploying a portable machine tool designed and manufactured by iZanda:
- Confined Space Installation: The portable flange facing machine was mounted and leveled directly inside the tank cone. The rigidity of portable machinery allows it to absorb vibrations even in complex working positions.
- Circular Machining: The cutting tool rotates 360°, eliminating imperfections in the stainless steel and ensuring the surface is perfectly flat and perpendicular to the axis.
- Safety and Efficiency: The use of pneumatic or hydraulic tools in these environments ensures zero spark intervention, complying with plant safety regulations.
The Result: A Guaranteed Airtight Seal
After in-situ machining:
- Superior Surface Finish: Controlled roughness was achieved (phonographic or smooth finish, as required) allowing for optimal seating of the sealing gasket.
- Geometric Restoration: The “valleys” and deformations caused by erosion were eliminated, restoring the flange’s original sealing capacity.
- Time Savings: What previously required weeks of civil works and dismantling was resolved in just a few hours of effective machining.
Benefits of In-Situ Machining in the Paper Industry
- Zero Logistics: There’s no need to cut pipes or move giant tanks.
- In-Situ Precision: We achieve micron-level tolerances right where the machine operates.
- Sustainability: We extend the lifespan of expensive components instead of replacing them with new parts.
