GeniSYS Proves a Winner in US


Hydratight's new geniSYS220 portable CNC milling unit couldn't have had a tougher test than on its US debut on a refinery refurbishment.

But the amazing machine had no problem handling the removal and rethreading of 3¾in and 3½in studs - even inverted ones - in a fraction of the time it would have taken conventional methods.

The studs, at the top and bottom of four separate catalyst reactors, had been exposed to the elements. Typically, the studs in these common reactors endure 700°F and 1,500bar pressure for up to three years between maintenance turnarounds and over time can become damaged and even break in the reactor, leading to expensive repairs. Studs can also leak - potentially very dangerous in such high temperature and pressure conditions.

Hydratight technicians at first expected to remove and restore 12 of the 3½in studs: in fact by the end of the job, 21 days later, 48 studs had been restored with two men working each shift, two shifts a day. By contrast, a crew on the previous turnaround, using conventional methods, had managed to restore only one stud in four days using four-man shifts.

But that wasn't all: the geniSYS was so quick, Hydratight staff went on to undertake a large amount of extra work over the three-week project time - also completed without fuss.

"Refinery staff were amazed we managed to restore the 48 main studs over the 21 days," said Hydratight's project manager Robert Trouts.

"When we went on to restore 10 even bigger studs, some of them upside down... and then we did another 96 17/8in studs, as well as other work, they were extremely impressed.

"But we knew the geniSYS would do the job; it really is an incredible new tool. Everyone who sees it in action has the same reaction, and its speed means it can save a client a lot of money.

"Adding a day to a turnaround like this, for example, could push up the lost-production bill by well over a million dollars. Not only was it not necessary in this case, but the geniSYS allowed us to do the additional work - and every one of joints on which the machine was used was leak-free on start-up."

o Elsewhere on the three-week turnaround, Hydratight provided split-frame clamshells to cut out diaphragms on an exchanger, and smaller clamshells to reface gasket surfaces and diaphragm cut-outs on 11 different surfaces. Hydratight also provided a bolting trailer, with a variety of nut splitters, RSL torque wrenches and other equipment, used throughout the refinery.

For more info contact project manager Robert Trouts: robert.trouts@hydratight.com

For general information contact:
Hydratight - Houston, TX
713 860 4200 or 800 895 3849 651
Email: houston@hydratight.com

Hydratight - Red Wing, MN
388 8661 or 800 283 1937
Email: redwing@hydratight.com

Press contact:
Joan at Access-JUPR.
Direct tel: +44 (0)1457 833346
Email: joan@accessadvertising.co.uk

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