Context: A factory specialising in the production of acacia powder faced an urgent need to repair a critical component of its cyclone, which was threatening to severely disrupt production.

Problem: A sudden failure revealed a cracked zone in a critical part of the cyclone, requiring immediate cyclone inspection.

Solution: The factory called upon Bioscan’s crack test and repair services for a swift and effective response.

Project Execution:

• Problem Identification: The damaged area was visible and already identified by the client; however, a larger area was inspected using vessel crack inspection services as a precaution.
• Access Methods: Qualified IRATA rope access technicians safely accessed the damaged area inside the cyclone.
• Repairs: The damaged section was cut out and replaced with a stainless-steel 316L sheet by qualified welders. Repairs were carried out to the strict standards of the food industry, with finishing and polishing to a precision of less than 0.8 μm.
• Rechecking: Re-inspection of the zone and roughness checks were performed to validate the quality of the repair works.
• Report and Certificate: A detailed report with before and after photos of the repairs was provided.

Results:

• Quick and Effective Repair: The damaged area was repaired promptly in under 6 hours, minimising production downtime.
• Enhanced Equipment Lifespan: High-quality repair works and new inspection frequencies extended the cyclone’s lifespan.
• Reduced Maintenance Costs: Effective preventive maintenance reduces long-term costs and improves process reliability.

Conclusion

The urgent repair of the cyclone at the acacia powder plant demonstrates the effectiveness of Bioscan’s crack detection and tank inspection services in critical situations. By swiftly identifying the damaged area and performing the repairs the client was quickly back into production.