Customer: Major North American Refinery
Asset Type
Refinery – Multiple Processing Units
Location
North America
Project Phase
Planned Maintenance / Turnaround
Scope
Machining, Pipeline Isolation, Localised Weld Testing
Pipe Sizes
DN20 to DN400 (¾" to 16")
# of Clamshell Machines Deployed
18
Team
8 technicians + dedicated project manager
Timeline
45 days
As part of a scheduled maintenance shutdown, several critical processing units at a major refinery producing more than 100,000 barrels per day, were taken offline for essential upgrades. Pipework of various diameters (from DN150 (6") to DN400 (16")), materials and wall thicknesses needed to be cut, beveled, counter‑bored, and flange‑faced to meet exact specifications. Alongside machining services, safe pipeline isolations were required during hot work activities and new welds needed to be pressure tested before start up. The shutdown window was fixed. Hydratight had 45 days to complete all machining and testing with zero impact on the restart schedule.
Hydratight deployed a full package of portable machining and weld-testing services designed specifically for fast-paced turnaround environments.
Precision Onsite Machining
Eighteen portable clamshell machines were approved and mobilised to cover the refinery’s diverse pipework requirements. Their flexibility made it possible to switch quickly between diameters and operations, supporting the evolving needs of the project as schedules shifted.
Dual-Purpose Isolation & Weld Testing
To maintain safety during hot work and verify weld integrity:
- Hydratight’s dual-purpose isolation/weld test tools were used to create a reliable vapor barrier during welding.
- The same tools then conducted localised pressure tests on welds ranging from DN20 to DN300 (¾" to 12").
This approach reduced handling, improved productivity, and supported the operator’s stringent HSE requirements.
Experienced, Around-the-Clock Workforce
A team of eight experienced technicians, led by an on-site project manager, operated across day and night shifts.
This ensured:
- Continuous workflow
- Tight schedule adherence
- Coordination across multiple units
- Zero compromise on safety
The client highlighted the team’s adaptability and ability to maintain pace even as work-front priorities changed.
Hydratight completed all machining, isolations, and weld testing within the 45-day shutdown window, enabling the refinery to return to production on schedule. Key outcomes included:
Multidisciplinary tooling and experienced technicians reduced downtime between tasks
Proven isolation methods created safer work environments during hot work
Efficiency gains and fewer schedule disruptions helped minimise overall maintenance costs
Only essential personnel were present at any time, in line with the customer’s HSE expectations
If you need a partner who brings specialist equipment, competent technicians, and proven processes to keep your assets safe, reliable, and on schedule, Hydratight is ready to support you.
Contact us to discuss your next turnaround or maintenance project.
