Not every urgent job is a straight swap-out. Some arrive with a component in poor condition, a shutdown clock already running, and no clear answer to the first question that matters: can this be repaired, or does it need to be remade?
The challenge
A major Queensland refinery required urgent refurbishment of a stub shaft housing. The component had washout, surface defects, broken studs and a welded plate arrangement that limited how it could be reworked.
Berg's approach
Establish the facts first
Rather than guess, Berg opened with assessment:
- Positive material identification (PMI) to confirm the housing material and establish whether it was suitable for weld repair of the surface defects.
- 3D scanning of all parts to verify bolt hole alignment and orientation, compare the sample body against the original, and confirm whether the sample could be modified to meet original specification.
- Modelling and drawings generated from the scan data — used to determine the most suitable path between refurbishment and manufacture, and handed to the client as a documented basis for future spare unit manufacture.
Deliver the refurbishment
With the facts established, Berg carried out the work across three components.
The adaptor plate was weld repaired to remove washout and skim machined to a 1.6-micron surface finish, with all holes cleared and re-tapped. The termination plate was pre-machined, weld built-up around the through holes and centre hub bore, then final machined flush to leave a defect-free vacuum seal face, with the keyway reinstated. The sample housing had broken studs and the seal ring ground out, washout and surface defects filled, and the bearing area machined to match the original arrangement — with the bolted connection redesigned to move away from the existing welded plate arrangement.
Keep the client’s options open
In parallel, Berg compared alternate material options against availability, manufacturing lead time and refurbishment lead time, so the client could make the call with a genuine comparison in front of them rather than a single option. Labour and material availability were confirmed as a priority so a lead time could be issued the same day.
The result
The housing was returned to service fit for purpose, with a redesigned bolted connection that improves how it can be maintained in future — and with a full set of models and drawings the client now holds for spare unit manufacture.
It is an approach built for live shutdown conditions: fast decisions, backed by evidence, with the flexibility to absorb changes as they come.
“I’d also like to thank the Berg team for their excellent support on this repair. Thank you for the way you handled our quick requests, constant changes, and on-the-fly decisions. Your flexibility and teamwork made this project possible and as painless as it could be.”
– Client
Facing an urgent repair with an unclear scope? Berg’s 24/7 emergency response team can start with assessment and define the path from there. Learn more about our 24/7 Support Service
