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ICE was an integral part of the team process used during the Blast Furnace 24hr shutdown at BHP Whyalla. The Furnace’s movable armour – first installed at the top of the furnace during its reline in 1980 was wearing out and needed to be replaces. A number of options for repair of the segments were considered and tested. It was decided that cutting an access hole in the shell of the Furnace, in order to gain access to the segments, was the best method. Coldcutting of the shell with high-pressure water and grit as opposed to conventional oxy cutting – was chosen as the best method of cutting the hole in the Furnace shell. The major advantages of this method included safety of personnel, a safe working environment and an access hole that was neatly and cleanly cut through the Furnace’s steelplate (30 millimetres thick) and refractory lining (180 millimetres thick) in a short period of time. A cut of this type was also suitable for welding when the time came to close over the access hole. The job was completed three hours ahead of schedule, without any safety incidents. It was a very well executed and successful project, considering the potentially hazardous conditions and the heights and inaccessibility of some of the equipment.
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