Speed only counts if the work comes back right. On repeat components, the real value is not turning one job around quickly, it’s making sure the next one does not carry the same problem.
The challenge
A major Queensland refinery had a recurring issue with its return heads. During the weld heat treatment process, the components were moving significantly out of round.
Ovality of that kind does not stay a workshop problem. It carries straight through to fit-up, installation time and service life, and it turns what should be a routine refurbishment into a source of ongoing risk.
Berg's approach
Berg treated the distortion as a process problem rather than a machining tolerance to chase after the fact.
The team combined precision machining with a purpose-developed bracing process, designed to restrain the component and control movement through the heat treatment cycle — addressing the cause of the distortion rather than correcting for it afterwards.
Post-process dimensional scanning was used to verify the outcome against previous heads.
The result
The scan results confirmed a marked improvement on previous heads, with the large ovality movements seen in earlier work substantially reduced.
The client asked Berg to carry the same bracing process forward as standard on future return head work — turning a one-off solution into a repeatable improvement across the component population.
“I would like to celebrate the scan results. Please continue the same bracing process on future work.
This is a massive turnaround from previous heads where there have been large movements in ovality during the heat treatment process. Thank you to all involved!”
– Client
Dealing with a component that keeps coming back with the same problem? Berg combines precision machining with engineering analysis to fix the cause, not just the symptom. Learn more about our 24/7 Support Service.
