Since we started this blog back in 2013 we've covered many different topics, including, industry news, machine specifications, infographics, machining tips and much more. Wherever possible, we've tried to include bespoke projects and real life applications and these have been well received,
When it comes to flange facing projects, these are usually simple 'quick-fix' tasks, which on their own, haven't warranted the creation of 'in-depth' articles. Our flange facers are so easy to set up and operate, which means there's not a great deal of scope for detailed case studies. So how can we demonstrate they perform to expectations out in the field?
Here's two very simple real life applications where Mirage Flange Facing Machines were used to repair damaged flanges within a tight timescale.
Example 1. Vessel Flange Facing
This case study describes how a Mirage Flange Facing Machine was rapidly deployed to carry out an emergency repair at a vessel fabrication shop. A brief synopsis of the project is shown below and you can download the full details here in PDF format here.
A fabrication shop making a vessel for the petrochemical industries had a damaged flange which needed to be re-faced quickly before they could ship it to their customer. One common cause of flange damage is tools being accidentally dropped or dragged across sealing area and that is what happened in this instance.
An on-site machining company located 45 minutes away from the fabrication shop was contacted to carry out the emergency resurface. The machine used was a pneumatically powered Mirage MM860i, an internal mounted machine capable of machining up to 36” diameter. A total of 0.030” was taken off the flange face, using 3 passes of 0.010”.
The damaged flange was repaired quickly thanks to the machinist and co-worker who were able to set the machine up in just 15 minutes. One initial concern was the air supply on-site being just 40 psi, but despite this the machine operated smoothly and efficiently. The total time for set up and machining was less than the time taken to get to the job site.
Example 2. Refacing Galvanized Flanges
This case study clearly demonstrates the quality of surface finish that can be achieved using a Mirage Flange Facing
Machine. In this situation the MM1000i was used to recover the situation after an inferior competitor machine produced poor results. As before, a brief synopsis of the project is described below and you can download the full details here in PDF format here.
An issue arose at a pipe fabrication company following the galvanising process which covered the flange sealing surfaces. These needed to be machined back to the base metal and a gramophone finish created. Initially, a machine from a Mirage competitor was used on the eight 300NB (485 OD) flanges, but the results were unsatisfactory. An inspector rejected the gramophone finish for being too smooth. Other difficulties encountered included poor stability, resulting in the flange facer moving during machining and creating an unwanted large groove in the flange face.
The customer contacted our regional Mirage representative, who responded immediately by arranging for an MM1000i flange facing machine to be supplied on a rental basis. This machine has the capacity to face diameters from 6” to 40” and includes a three-speed continuous feed gearbox, to deliver three different gramophone surface finishes.
The situation was resolved in just a matter of hours, with the machine being supplied from Mirage rental stock, the machine operator being fully trained and flanges machined to the desired specification.