ON-SITE MACHINING CASE STUDY

Enhancing Heat Exchanger Reliability Through On-Site Flange Machining

Heat exchangers are static devices used in chemical production to transfer heat between two different mediums, reducing the temperature difference. They are commonly used as heaters, coolers, evaporators, and other applications in chemical production, making them essential equipment in the process.

The main components of a fixed tube-sheet heat exchanger include the head, heat exchange tubes, baffle plates, shell, support, and tube sheet. During operation, heat exchangers are subjected to high temperatures, high pressures, and medium corrosion, making maintenance of flange seals crucial. In addition to repairing leaks, regular preventive maintenance is an important measure to reduce downtime.

MT Portable Machine has developed a set of dedicated components for repairing flange seals on heat exchangers. These components can repair over 90% of various heat exchanger flange sealing surfaces and include rawl bolts, main setting plates, back facing kit, nut blocks, and centralizer.

PRODUCT INTRODUCTION

The FI60 On-Site Flange Facing Machine is a robust internal-mount refacing tool designed for precision repair of large-diameter flanges during field maintenance operations. With a facing range from 12.6" to 59" (320–1500 mm), this machine is ideal for pressure vessels, heat exchangers, and pipeline flanges in oil & gas, chemical, and power generation sectors.

Its modular design ensures rapid setup and flexibility, while the pneumatic or electric servo drive options make it suitable for a wide range of industrial environments. Whether you're restoring a flat face (FF), raised face (RF), RTJ, or custom sealing groove, the FI60 delivers accurate, ASME B16.5-compliant finishes—directly at the job site.

MACHINE FEATURES

ASME-Grade Surface Quality

Equipped with 6 continuous auto-feed settings, FI60 produces consistent spiral or smooth finishes, eliminating sealing issues on large flange faces.

Extreme Rigidity for Large Diameters

Uses NSK bearings and precision-ground V-guideways to maintain accuracy, even when cutting 59" flanges.

Custom Tooling Flexibility

The 360° swivel tool post supports multi-angle grooves, weld removal, and re-machining of sealing profiles including RTJ and V-groove.

Smart Mounting Design

Includes 3 modular, micro-adjustable bases that align securely within the flange ID for stable, quick setup in any orientation.

TECHNIAL SPECIFICATIONS

HOW TO CHOOSE THE RIGHT POWER OPTION FOR ON-SITE FLANGE FACING

Pneumatic Drive – FI60P

Powered by a 4.1 HP Modec air motor, this version is ideal for explosive or ATEX environments.

Pro: No electrical hazard in sensitive zones

Con: Requires a strong air supply; in remote areas, a dedicated compressor may be necessary.

Electric Drive – FI60E

Uses a Panasonic servo motor (4.1 HP), delivering continuous torque, stepless speed control, and digital feedback on a remote control box.

Ideal for workshops, power plants, or chemical facilities with stable electricity.

Offers superior control and cutting performance.