Complex rebuild completed without incidents
With this reactor assignment, we resolved a case characterised by technical challenges, a changed scope, and extensive requirements for inspection and documentation.
The work ranged from internal repairs to a complete rebuild of the reactor head. Today, the facility is back in stable operation at Equinor.
Challenge
The collapse created a need for extensive repairs and replacement of critical components such as quenches, grids and brackets.
The work also included demanding welding in the shell with a material thickness of 50 mm under strict quality requirements.
Solution
The rebuild covered internal components, the shell and the reactor head and was carried out around the clock.
As part of the project, a new WPQR was qualified in accordance with the customer’s requirements, followed by extensive welding work – including in the 50 mm-thick shell – with full NDT inspection throughout all phases (RT, PAUT, MPI, HT).
The reactor head was reinstalled, the inlet rebuilt, and catalyst loaded in close collaboration with Buchen.
Results
The project was completed with approx. 8,000 working hours without incidents.
The reactor is now back in stable operation.
· Extensive welding work (approx. 120 passes, ~300 kg of welding consumables used)
· Access conditions have been re-established with a steel structure, and all tests were approved prior to commissioning.
Why choose Jernbro
- Proven safe project execution – without incidents
- High flexibility and the ability to manage changes and additional work
- Proven experience with advanced welding in thick-section material combined with extensive NDT
- Proven ability to deliver under time pressure
