In 4 days, from flat plate to finished Klopper torispherical heads (DIN 28011)

When BP Rotterdam faced a critical issue with a damaged burner tip, time was of the essence. Their regular supplier could not deliver the required components fast enough. The parts in question were two pressure vessel heads, Klopper heads according to DIN 28011, that would be installed in the flare system. Within days, BP turned to Antonius for help. The result: from four flat plates to two fully formed, welded and tested Klopper heads in just four days.

Ralph Hofman, Sales Engineer at Antonius, explains how the project came about: “A contact from my previous role in the pressure vessel industry called me. BP needs two replacement Klopper heads for their burner tip installation, but their supplier couldn’t deliver in time. He connected me with BP’s supplier, and they asked whether Antonius could take over the job. From there, things moved very quickly.”

Precision under pressure

The two Klopper heads would later be mounted together, forming the upper part of the burner tip. This meant there was no room for deviation: the circumference of both heads had to match perfectly.

“Tolerance was extremely tight,” says Hofman. “We couldn’t afford even minimal deviation in diameter, because the heads needed to fit together like two halves of a UFO. To achieve that, we closely monitored the forming process. Once we start shaping, we constantly measure and adjust, making the second head directly to fit the first one and checking after every step until the match is exact.”

Flexibility in forming Klopper torispherical heads (DIN 28011)

The short lead time was a challenge on its own. “Our forming machines operate almost continuously,” Hofman says. It is not easy to manage these kind of rushorders but we try to minimize the impact on other running projects in our production. We can therefore serve our customer with almost impossible leadtimes. “

The Klopper heads were made from plates that were first welded together before forming. Once the main radius was pressed, the edges were shaped in the knuckling process, where the distinctive curved rim of the head is formed to meet the DIN 28011 profile. While this process requires precise control, Antonius has the in-house expertise to manage it safely:

“If we weld the plates ourselves, we know exactly how the seams behave during forming,” Hofman notes. “That gives us full confidence in the integrity of the product.”

A lasting connection

Once the job was done, the two Klopper heads were tested, inspected, and shipped to Luxembourg for final assembly. “I personally watched the truck leave,” Hofman recalls with a smile. “I even texted the client to let them know it was already on its way. It is satisfying to see such a fast-paced project come together perfectly.”

The collaboration arose through an old professional connection and has since developed into a new partnership. “We still supply them with specialized components,” Hofman says. “It is nice when a quick job like this leads to a new working relationship. In the end, it shows that even under extreme time pressure, Antonius can deliver precision and high quality without compromise.”

Want to know more about working with Antonius? Contact our sales team at sales@antonius.nl or call +31(0)475 439 000 to learn more.