In Pre-Turnaround and Turnaround projects, SILICON teams excel at rapidly developing new refractory anchoring solutions on the spot. Our defining characteristic is the ability to think outside the box and create innovative solutions in real-time.
This story highlights the creation and installation of refractory anchors within the Turnaround timeframe. Creativity, rapid guidance, and flawless execution perfectly capture the essence of these Turnaround success stories.
SILICON has been working with this customer since 2015. For a two-month turnaround project in Canada, a team of nine was mobilized, including two Project Managers, one Senior Supervisor, one Quality Control Technician, one Operating Supervisor, four Operators, and one Administrator. The work was divided into a confirmed scope and an additional scope yet to be decided.
Due to this long-term relationship, they still had some SpeedHex® 3 stock left in their warehouse. SpeedTab®Mega, SpeedVees®, and additional SpeedHex® 3 were ordered and shipped to the site. Thanks to SILICON's in-house production facility, SpeedVee® anchors could be quickly annealed and laser marked.
This repair area was identified in the later stage of the Turnaround, where traditional Monster Tabs proved too slow to install and required significant modifications to fit the curvature. Recognizing these inefficiencies, SILICON proposed a more efficient anchoring system to address the challenges. SILICON Project Manager sketched and suggested custom-cut SpeedTab®Mega. After the inspector’s approval, the installation was upgraded in both quality and speed. That is how Rhino Tab was born.
With nearly 11 years of continuous Turnaround Projects at various plant units for this customer in Canada, we have accumulated numerous field stories. This project involved a crew of 14 people working across three units. We successfully completed these refractory anchor installations within six weeks.
In one of the units, the customer initially planned to use 10 mm TWS hand welding anchors. However, they realized it would be time-consuming and inefficient due to the need to cover a large area. This project highlights the rapid transformation of V-anchor from hand-welding to SpeedVee® under the tight deadlines.
We proposed designing a new anchor to meet their specifications, as they wanted to stick to the original design. Since they were using SpeedHex® 3 with 10mm, they didn't need to create a new Welding Procedure Specification (WPS) for welding, which would have required approvals from the laboratory and other higher authorities, potentially delaying the entire project.
SILICON engineers designed the new SpeedVee® anchor with 10 mm in just three days. The project received approval on the very first day after we submitted the drawings, and the new anchors were produced and delivered within a week.
If your turnaround project is falling behind or requires a new anchoring solution, SILICON team of engineers and Rapid Arc Welding (RAW) Technology can work with you to overcome your challenge and make up for lost time.
