Project 3

Dow Corning - Barry, South Wales 1996 Shutdown

Mechanical inspections, equipment overhaul and planned maintenance work carried out at the Dow Corning Silicone products manufacturing plant at Barry with Dow Corning management and supervision and labour resource provided by ROCKALL.
The main process units involved in the shutdown were:-

Fluid bed reactor plant
Distillation plant
Bulk chemical storage plant
Hydrolysis reactor plant
Waste treatment plant
Utilities Shutdown

Duration - 21 days

ROCKALL supplied teams of Mechanical Fitters, complete with protective clothing, safety wear and basic tool kits to Dow Corning for the duration of the shutdown. In the period leading up to the shutdown ROCKALL located and mobilised a locally based, quality labour force whose duties and responsibilities embraced the following:-

making/breaking bolted flanged gasketted and other forms of joints
hydro-pressure testing of vessels
making/breaking bolted closures (square/manways/etc)
removal of lagging (non asbestos)
simple jigs/fixtures/fabrications to facilitate working only (i.e. not permanent plant)
simple pipework fabrication (screwed/preparation of welding)

effecting the following:-

removal/refit manual and actuated valves removal/refit of pipework
opening of vessel nozzles
removal/refit of vessel
instrumentation/fitting
removal/refit of pumps
opening of vessel inspection closures removal/refit of relief valves
renewing of joint gaskets/jointing
pressure of testing of vessels
removal of redundant plant
installation of new plant
removal of new plant
removal only of bursting disc assemblies
renewal of equipment internals (e.g. filter elements)

The Shutdown Project was completed on time and with virtually no labour turnover.