Chemical & Petrochemical Industry

On-site machining, surface engineering and component refurbishment for chemical and petrochemical plants
Chemical and petrochemical production places demanding requirements on industrial equipment.

Process media, chemicals, temperature, pressure, corrosion, erosion and mechanical wear can gradually affect critical surfaces and dimensions. Even relatively localised deterioration in a shaft, sealing area, pump, valve or other process component can affect the reliability of the complete equipment.

PR Rolls provides specialised on-site machining, industrial coatings, dimensional restoration and component refurbishment for suitable chemical and petrochemical industry equipment.

Our capabilities include:

On-site machining
Precision milling and turning
Line boring
Grinding and precision finishing
Flange and sealing surface machining
Shaft and journal restoration
Bearing area restoration
Dimensional restoration
Industrial coatings
Wear-, corrosion- and erosion-resistant surfaces
Brush plating and localised repair
Measurement and alignment
Field balancing
Workshop refurbishment
Dynamic balancing of suitable removable components

The objective is to restore valuable process equipment according to its actual condition and operating environment.

Inspect → Measure → Repair → Restore → Protect → Verify

Maintenance Challenges in Chemical & Petrochemical Plants

When mechanical wear and process conditions affect the same component

Chemical and petrochemical equipment can be exposed to several deterioration mechanisms simultaneously.

A component may experience mechanical wear while also being exposed to corrosive process media. Flowing liquids or gases can contribute to erosion, while particles can introduce abrasive wear. Temperature and repeated operating cycles can further influence the condition of functional surfaces and mechanical interfaces.

Typical maintenance challenges can include:

Corrosion
Erosion
Abrasive wear
Mechanical wear
Chemical exposure
Surface damage
Dimensional loss
Damaged sealing areas
Shaft and journal wear
Bearing seat wear
Flange surface deterioration
Bore geometry deviations
Misalignment
Vibration and imbalance

The correct repair technology depends on the complete application.

Component + Material + Process medium + Temperature + Wear mechanism + Required surface function = Maintenance solution

PR Rolls evaluates what has deteriorated and which geometry, dimension or surface property needs to be restored.

On-Site Machining for Chemical & Petrochemical Plants

Repair large or installed equipment where it operates

Removing industrial process equipment for workshop machining can require extensive dismantling, lifting, transportation and reinstallation.

PR Rolls specialises in portable machining technologies that allow suitable components to be machined directly at the production site.

On-site machining capabilities include:

Milling
Turning
Line boring
Drilling
Grinding
Honing
Precision finishing

This approach can be particularly valuable for large, fixed or difficult-to-transport equipment and during planned plant shutdowns.

Instead of automatically moving the component to a conventional machine tool, PR Rolls can bring the machining technology to the component.

Pumps, Valves & Process Equipment

Restore critical functional surfaces

Pumps and valves operate at the heart of many chemical and petrochemical processes.

Their components can be exposed to combinations of flowing process media, corrosion, erosion, particles, mechanical contact and dimensional wear.

Relatively localised deterioration can affect the performance of an otherwise serviceable component.

Depending on the equipment and application, PR Rolls can provide restoration and surface engineering for suitable:

Pump components
Pump shafts
Pump housings
Sleeves
Valve components
Shafts
Journals
Bearing areas
Sealing areas
Other metallic process components

A typical restoration process can combine:

Inspection → Machining → Dimensional restoration → Coating or plating → Precision finishing → Verification

The objective is to restore the functional area while retaining the existing component where technically appropriate.

Industrial Coatings & Surface Engineering

Engineer the surface for the actual process environment

Chemical and petrochemical plants contain components where the surface must withstand more than mechanical wear alone.

Depending on the application, a functional surface may need to resist a combination of:

Wear
Corrosion
Erosion
Chemical exposure
Temperature
Particles
Friction
Repeated mechanical contact

PR Rolls provides industrial coating and surface engineering solutions for suitable new and existing components.

The appropriate coating is selected according to the actual operating conditions rather than from a predefined coating catalogue.

Potential applications include:

Pump components
Valve components
Shafts
Sleeves
Bearing areas
Sealing areas
Hydraulic components
Rolls and cylinders
Other metallic process equipment

Depending on the component, coating can form part of a complete restoration process:

Measure → Machine → Prepare → Coat → Grind → Finish → Verify

The objective is not simply to add another layer to the component.

The objective is to create the functional surface required by the application.

Wear, Corrosion & Erosion Protection

Different deterioration mechanisms require different surfaces

Wear, corrosion and erosion are different mechanisms and should not automatically be treated with the same coating technology.

For example, a pump component exposed to particles and flowing process media can require a different surface from a shaft exposed primarily to mechanical wear and corrosion.

PR Rolls evaluates the operating environment before selecting the surface solution.

Factors can include:

Component material
Type of process medium
Chemical exposure
Temperature
Abrasive particles
Flow conditions
Mechanical contact
Required dimensions
Required surface finish
Required corrosion resistance
Required wear resistance

Carbide-based and other metallic coating technologies can provide engineered surfaces for demanding industrial environments where technically suitable.

Fine-Particle Carbide Coatings

High-performance surfaces for demanding wear environments

Developments in thermal spray technology make it possible to produce dense carbide-based surfaces for demanding industrial applications.

Depending on the application, coating systems such as WC-CoCr and Cr₃C₂-NiCr can be selected according to wear mechanism, temperature, corrosion environment and required surface properties.

Potential chemical and petrochemical applications can include suitable:

Shafts
Sleeves
Pump components
Valve components
Bearing areas
Sealing areas
Hydraulic components
Wear surfaces
Precision machine components

Fine-particle coating technologies can also enable thinner coating systems and improved surface quality before final finishing in suitable applications.

The correct coating system must always be selected according to the actual process conditions.

Alternatives to Traditional Hard Chrome

Modern surface technologies for suitable applications

Hard chrome has traditionally been used on many industrial components requiring hardness, wear resistance, corrosion resistance and dimensional restoration.

However, conventional hard chrome electroplating can involve hexavalent chromium, Cr(VI), in the production process.

Modern carbide-based thermal spray technologies provide an alternative for suitable applications where hard chrome has traditionally been used.

Depending on the component and operating environment, HVOF- and HVAF-based coating technologies can provide:

High wear resistance
High hardness
Corrosion resistance
Dense coating structures
Dimensional restoration
Application-specific surface finish

Potential applications can include shafts, sleeves, hydraulic components, pump components and other precision industrial surfaces.

Not every hard chrome application can automatically be replaced with the same coating technology.

The correct alternative must be selected according to component geometry, substrate, chemical environment, temperature, tolerances and required surface function.

Shaft, Journal & Bearing Area Repair

Restore dimensions instead of automatically replacing the complete component

Shafts, journals and bearing areas can deteriorate through wear, corrosion, fretting or mechanical damage.

Where the underlying component remains technically suitable, PR Rolls can evaluate dimensional restoration instead of complete component replacement.

Depending on the application, repair can combine:

Measurement
Machining
Grinding
Thermal spray coating
Brush plating
Precision finishing

The restored area is finished according to the dimensional and surface requirements of the application.

This approach can be particularly useful when deterioration is concentrated in a limited area of an otherwise valuable component.

Brush Plating & Localised Repair

Restore specific areas without treating the complete component

Brush plating, also known as selective electroplating, is a localised surface restoration technology.

Unlike conventional tank plating, only the required area of the component is treated.

This can make brush plating useful for repair of large or difficult-to-remove components.

Suitable applications can include:

Shafts
Journals
Bearing seats
Bores
Seal areas
Housings
Local corrosion damage
Local dimensional errors
Other precision mechanical surfaces

Depending on the application, brush plating can be combined with machining and grinding:

Measure → Prepare → Restore → Finish → Verify

The technology is selected according to the component material, operating environment, required dimensions and functional surface requirements.

Flange & Sealing Surface Machining

Restore accurate mating surfaces on-site

Flanges and sealing surfaces are common mechanical interfaces throughout chemical and petrochemical plants.

Corrosion, erosion, mechanical damage, distortion or repeated assembly and disassembly can affect their geometry and surface condition.

PR Rolls provides on-site machining for suitable:

Flanges
Sealing faces
Mating surfaces
Contact surfaces
Large circular interfaces

Portable machining allows the surface to be restored directly at the plant where appropriate.

The objective is to restore the required geometry, flatness and surface condition before reassembly.

The required final surface must always be determined according to the specific sealing system and application.

Line Boring & Bore Restoration

Restore bore geometry directly at the plant

Wear or mechanical damage can affect bores and aligned bore systems in industrial equipment.

PR Rolls provides portable line boring for suitable components where accurate bore geometry needs to be restored without transporting the complete machine structure to a workshop.

Applications can include:

Bearing housings
Machine frames
Aligned bore systems
Worn bores
Damaged bores
Large mechanical structures

Where necessary, worn areas can first be restored before final machining establishes the required geometry.

Measure → Establish reference → Restore → Machine → Verify

Hydraulic Component Refurbishment

Restore precision surfaces and dimensions

Hydraulic components require accurate dimensions and high-quality functional surfaces.

Wear, corrosion or localised damage can affect sealing and component performance even when the main component remains suitable for continued operation.

Depending on the application, PR Rolls can combine:

Inspection → Machining → Dimensional restoration → Coating or plating → Precision finishing

Suitable applications can include shafts, rods, sleeves, bearing areas and other precision hydraulic component surfaces.

The restoration method is selected according to material, geometry, tolerances, operating conditions and required surface properties.

Measurement & Alignment

Establish the actual geometry before repair

Precision maintenance begins with understanding the condition of the equipment.

PR Rolls provides measurement and alignment services for industrial machinery and rotating equipment.

Measurement can be used to:

Determine existing geometry
Identify dimensional deviations
Establish centre lines
Measure alignment
Establish machining references
Support installation and assembly
Verify restored componentsConfirm final geometry

Integrating measurement with machining allows the repair to target the actual deviation.

Measure → Identify → Correct → Verify

Field Balancing & Rotating Equipment

Correct imbalance in suitable installed machinery

Rotating equipment can develop vibration due to imbalance, wear, deposits, repair work or changes in rotating mass.

PR Rolls provides field balancing – also known as on-site balancing – for suitable installed rotating equipment.

Balancing may be relevant following:

Repair
Machining
Surface restoration
Component modification
Changes in rotating mass
Detected vibration or imbalance

Because vibration can have several causes, balancing should be evaluated together with equipment condition, alignment, bearing condition and mechanical geometry.

Suitable removable components can also be dynamically balanced at the PR Rolls workshop.

Planned Shutdown Services

Combine specialist maintenance operations within the available shutdown window

Chemical and petrochemical plant shutdowns create a defined period for inspection, maintenance, repair and equipment modification.

Specialist machining and restoration work therefore benefits from advance planning.

PR Rolls can prepare on-site work according to:

Component condition
Dimensions
Required tolerances
Access conditions
Required machining
Surface restoration requirements
Portable equipment installation
Measurement references
Work sequence
Available shutdown time
Final verification requirements

Several maintenance technologies can be combined within the same project:

Measurement → Machining → Grinding → Surface restoration → Coating → Alignment → Balancing → Verification

The actual sequence depends on the component and maintenance requirement.

Workshop Maintenance & Refurbishment

On-site for installed equipment. Workshop service for suitable removable components.

Not every chemical or petrochemical industry component needs to be restored at the production site.

Suitable removable components can be refurbished at the PR Rolls workshop.

Depending on the component, workshop services can include:

Inspection
Measurement
Machining
Grinding
Dimensional restoration
Industrial coating
Brush plating
Precision finishing
Dynamic balancing
Final verification

This allows the maintenance strategy to be selected according to the component rather than according to one fixed service method.

Large or difficult-to-remove component → On-site service

Suitable removable component → Workshop refurbishment

Typical Chemical & Petrochemical Industry Applications

PR Rolls' capabilities can be applied to suitable mechanical and process equipment including:

Pumps and pump components
Valve components
Shafts
Journals
Sleeves
Bearing seats
Bearing housings
Sealing areas
Flanges
Mating surfaces
Bores and aligned bore systems
Hydraulic components
Rotating equipment
Rolls and cylinders
Machine frames
Large metallic process components
Other precision mechanical equipment

The deciding factor is not simply the type of component.

What has deteriorated, what does the surface or geometry need to do, and which restoration method is technically appropriate?

Repair, Refurbish or Replace?

Base the maintenance decision on actual component condition

Corrosion or wear in one area does not necessarily mean that the complete component has reached the end of its useful life.

Where the underlying component remains technically suitable, PR Rolls can evaluate whether the affected area can be repaired or restored.

The decision should consider:

Component condition
Material
Damage mechanism
Chemical exposure
Operating temperature
Mechanical loads
Required dimensions
Required tolerances
Surface requirements
Future operating requirements

This creates three principal options:

Repair
Correct local wear, damage or dimensional deviations.

Refurbish
Restore the component more extensively for continued operation.

Replace
Install a new component when continued restoration is no longer technically or economically appropriate.

PR Rolls' objective is not to repair equipment at any cost.

The objective is to identify the technically appropriate lifecycle solution.

Sustainable Maintenance for Process Equipment

Preserve valuable industrial components where technically appropriate

Chemical and petrochemical process equipment contains significant material, manufacturing work and economic value.

When deterioration is concentrated in a functional surface or mechanical interface, restoring the existing component can provide an alternative to premature replacement.

PR Rolls' approach is based on condition:

Maintain → Repair → Restore → Protect → Extend lifetime

On-site services can also reduce the need to dismantle and transport large industrial components to external workshops.

The objective is practical: preserve technically suitable equipment, restore the properties that have deteriorated and replace components when restoration is no longer appropriate.

Why PR Rolls for Chemical & Petrochemical Industry?

Chemical and petrochemical maintenance often requires more than one repair technology.

A worn pump shaft may require machining and dimensional restoration.

A damaged flange may require on-site machining.

A bearing area may require localised plating and precision finishing.

A process component exposed to wear and corrosion may require a new functional coating.

PR Rolls combines:

On-site machining
Precision grinding
Line boring
Flange machining
Shaft and journal restoration
Dimensional restoration
Industrial coatings
Wear and corrosion protection
Brush plating
Precision finishing
Measurement and alignment
Field balancing
Workshop refurbishment
Dynamic balancing

This allows the maintenance strategy to begin with the actual problem rather than a predetermined repair method.

Understand the component → Identify the deterioration mechanism → Select the restoration technology → Restore the required function → Verify the result

Frequently Asked Questions About Chemical & Petrochemical Industry Services

What services does PR Rolls provide for chemical and petrochemical plants?
PR Rolls provides on-site machining, grinding, industrial coatings, dimensional restoration, brush plating, measurement, alignment and balancing as well as workshop refurbishment for suitable industrial components.

Does PR Rolls repair pumps and valve components?
Yes. Suitable pump and valve components can be evaluated for machining, dimensional restoration, coating, plating and precision finishing depending on component condition and operating requirements.

Can PR Rolls provide coatings for chemically demanding environments?
Yes, for suitable applications. The coating must be selected according to the component material, chemical exposure, temperature, wear mechanism and required surface properties. No single coating is appropriate for every chemical environment.

Can worn shafts and journals be restored?
Yes, in suitable applications. PR Rolls can combine machining, grinding, thermal spray coating or brush plating and precision finishing to restore worn dimensions and functional surfaces.

Can PR Rolls machine flanges and sealing surfaces on-site?
Yes. Suitable flanges, sealing faces and mating surfaces can be machined directly at the plant to restore the required geometry and surface condition.

Does PR Rolls provide line boring?
Yes. PR Rolls provides portable line boring for suitable bearing housings, aligned bores and other large industrial components where bore geometry needs to be restored.

Can PR Rolls restore bearing seats and seal areas?
Yes. Depending on the component and damage, restoration can combine machining, coating, brush plating, grinding and precision finishing.

Does PR Rolls provide alternatives to hard chrome?
PR Rolls provides carbide-based thermal spray technologies that can be used as alternatives to traditional hard chrome in suitable applications. The appropriate solution depends on component geometry, operating environment, chemical exposure, temperature and required surface properties.

Can maintenance be performed during a planned plant shutdown?
Yes. On-site machining, measurement, grinding, surface restoration, coating and other specialist services can be planned around scheduled shutdowns.

Does PR Rolls only work on-site?
No. Large or difficult-to-remove equipment can often be treated on-site, while suitable removable components can be refurbished at the PR Rolls workshop.

Can several repair technologies be combined?
Yes. A complete refurbishment can combine inspection, measurement, machining, dimensional restoration, coating or plating, grinding, precision finishing and final verification.

Should a corroded or worn component always be repaired?
No. Repair is appropriate only when the component remains technically suitable for continued use. Component condition, material, damage mechanism, operating environment and future requirements should determine whether repair, refurbishment or replacement is the appropriate solution.

Restore Process Equipment. Protect Critical Surfaces.

Chemical and petrochemical plants expose industrial equipment to demanding combinations of wear, corrosion, erosion, chemicals and mechanical loads.

When critical surfaces or dimensions deteriorate, complete component replacement is not always the first technical option.

PR Rolls combines on-site machining, surface engineering, dimensional restoration, measurement, balancing and workshop refurbishment to restore suitable industrial components.

From pumps and valves to shafts, sealing areas, flanges and other process equipment, the starting point is the same:

What has deteriorated?
What caused the deterioration?
Which geometry or surface property needs to be restored?
Which repair or coating technology is appropriate for the actual operating environment?

Inspect → Measure → Restore → Protect → Verify → Return to production