A mobile welding crew upgraded plant pipework while the line kept running.
The challenge: A food processing plant needed a section of process pipework upgraded to a larger diameter to improve flow, but the line could not be shut down for more than a single weekend. The work was inside a clean area, so hot work and grinding dust had to be contained.
Our approach: We prefabricated the new pipe spools in the workshop to match the measured route, so site time was only removal of the old section and bolt-up/welding of the new spools. On site we set up a weld screen and extraction, isolated the relevant line, and sequenced the work so the critical path was the flange connection. We used a combination of bolted flanges and one site weld to minimise hot work in the clean area.
The outcome: The upgrade was completed within the single weekend window. The line was back online on Monday morning with the new flow rate, and the clean area required only a standard clean rather than a deep scrub. The plant engineer later booked us for the next section upgrade on the same basis.
Process pipe spools prefabricated in the workshop to a measured route, bolted flanges plus one site weld to minimise hot work in the clean area. Scope included on-site measurement, prefabrication, weekend shutdown removal and refit, and pressure testing with the client's engineer.