When one of four transfer lines underneath this reformer caught fire, an emergency shutdown and assessment were ordered. After the assessment, the client decided to proceed with an early planned shutdown (originally slated for the following year), and they contracted Melloy (a PCL company) for the emergency work. The scope included the removal and reinstallation of four transfer lines, eight sub headers, and 384 catalyst tubes.
Mobilizing manpower was a major hurdle, with 400 various skill sets required on very short notice. Labor was acquired from across North America, and everyone completed testing, training, and orientation within just 10 days.
The Melloy team demonstrated ingenuity during the engineering of a "jack and roll" system that aided in the removal and installation of the transfer lines and sub headers from the confined spaces below the reformer. This system enabled the team to remove the transfer lines and sub headers safely and in one piece, shortening the schedule by eight days. With teamwork and innovative ideas, the Melloy team completed this project successfully, ahead of schedule, with consideration of the budget, and — of course — safely.