In January 2024 Ballance required a contractor capable of delivering diverse mechanical services during their plant turnaround at New Zealand’s Fertilizer production facility. The reformer tubes needed to be replaced and welded as part of a scheduled turnaround. The reformer has 90 tubes or ‘pigtails’ that are subjected to extremely high levels of stress and required replacing and welding in the turnaround. Mechpro Solutions provided support for the welding trials and preparation. This support included procurement and bending of the tube material, welding trials, metallurgical assessment, non-destructive testing, project management and supply of tools and equipment. Mechpro Solutions also worked closely with the client for planning and decision making, ensuring that the strict quality requirements for the tubes were met, delivering them on time and within budget.
Mechpro Solutions mobilised a complete team including structural steel welders, mechanical technicians, fitters, supervision, and dedicated HSE personnel to the Kapuni site. We provided integrated oversight across all mechanical disciplines, ensuring coordination between different work packages. Our supervision team maintained active presence throughout execution, managing schedule pressures while ensuring safety and quality standards were maintained. We worked closely with Ballance’s inspection and certification requirements, ensuring all piping preparation work met the standards required for regulatory approval and extended plant operation.
All mechanical work was completed to specification, enabling Ballance to achieve a safe and successful turnaround. The piping systems were properly prepared for inspections, and the plant was certified for five years of continued operation. Ballance specifically recognised Mechpro’s contribution to the turnaround’s success. The project demonstrated Mechpro’s ability to provide comprehensive mechanical services across multiple disciplines, with the supervision and HSE capability required for complex industrial turnarounds. This successful delivery established an ongoing relationship with a major industrial client in New Zealand.
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