Case Study

Challenge : Large Scale Repair Works With Minimal Downtime Disruption

Bioscan recently assisted a client in October 2023 with some major repair works to their spray drying chamber alongside the assistance of our access platform and expert technicians.

This is where utilising Bioscan’s access platform was discussed, meaning that no scaffolding was required to be installed inside the dryer. After initial setup of the platform which took 4 hours, the repair works could begin. As seen in the photos large sheets were cut out and replaced with ease from careful planning of the operation from the inside and outside of the drying chamber.

Once the repair works were complete, Bioscan performed a final check of the welds and removed the platform. This saved the client approximately 4 days of production downtime from not requiring scaffolding.

This method can also be applied to other large scale projects within spray dryers such as sonic

horn, hammer, nozzles, fire suppression installation, modifications and removals.

To discuss how Bioscan can help you optimize downtime, please contact us today or send an email to sales@bioscanltd.co.uk.

Further Read: Inspection & Repair of Infant Formula Spray Dryers: Vietnam Case Study

Project: Inspection and Repair of 2 Large Infant Formula Spray Dryers (13m diameter x 20m high)

Location: Ho Chi Minh City, Vietnam

In May 2023, Bioscan completed the inspection and repair of two of the largest infant formula spray dryers in South-East Asia in only a 5-day shutdown window.

Above photo shows the inspection of the roof being performed

As the access into the dryers was extremely complex and Bioscan could not use their gantry platform, we decided that the best method would be using rope access. 3 Rope Access Technicians were deployed to the site and a 100% inspection was performed on each dryer, which lasted a total of 5 days. This included the setup and removal of the rope systems, inspection, repair and polishing of 10 defects.

Above photo shows a repair in the roof being performed

The client had been previously required to use scaffolding for these dryer inspections, which required a total of 2 weeks. Bioscan was therefore able to significantly reduce the client’s shutdown time by almost 10 days, therefore allowing for substantial cost savings and huge increase in their productivity of infant formula. Also, without Bioscan needing to use scaffolding, there was no introduction of wooden materials into the dryer and the risk of damage from the scaffolding installation/removal was eliminated.

Above photo shows the inspection of the cone being performed

Utilising Bioscan’s expertise and electronic inspection technology, combined with rope access methods to locate all types of visual and non-visual defects, the client was extremely satisfied in knowing they could continue production of their high care infant formula products in safe conditions.

To find out more about our services and experience, you can explore our website or reach out to us at sales@bioscanltd.co.uk

Reducing the frequency of preventative maintenance inspections of spray dryers and other vessels can often have a negative impact. Implementing a more frequent annual inspection routine gives companies numerous benefits such as;

Increased life span of assets, reduction of costs long term by discovering issues in their early stages, improves budgeting/planning strategies for major corrective actions, lowers overall operating costs, reduces cross contamination and product recall risks, increases productivity long term, improved reliability and customer confidence.

Case study

After completing a repeat inspection of a spray dryer for a client in January 2021, Bioscan’s findings resulted in the client facing major corrective actions. In total there was an area of 25cm x 3m in the upper chamber which required immediate attention. This area had developed severe stress corrosion cracking in the weld seams, which was unable to be repaired without the requirement of cutting out the parent metal and replacing it for new. The client had not planned for this amount of repair works to be performed during their 72-hour shutdown schedule.

Photos of the unrepairable stress corrosion defects found:

The client was now facing a lengthy shutdown period and extensive costs for the corrective actions. Costs that could have been either significantly reduced or eradicated altogether if a more frequent annual inspection programme had been implemented.

In addition, a further 50 cracks were identified in the 2021 inspection. During the previous inspection performed in 2016, a total of only 15 defects were found and repaired. Bioscan determined that as the client had decided upon an inspection frequency of 5 years for the spray dryer, the issues found in 2021 could have been resolved in their earlier stages or better planned for with an annual inspection.

This low-cost short term thinking towards inspections had led to very high costs and an increased shutdown to perform the required corrective actions, this in turn had a negative overall impact on the productivity of the plant.

To find out more about our services and experience, you can explore our website or reach out to us at sales@bioscanltd.co.uk