Together with the client, Titan initiated a direct feasibility assessment to replace the channel at the earliest opportunity. Two candidate materials were assessed for the replacement scope: Alloy 800H and Stainless Steel 347, Balancing availability, performance and weldability under an accelerated schedule.
Rapid planning: from feasibility to executable plan
The next morning, Titan mobilized a cross-functional task force bringing together Project Management, Engineering, Quality, Production and Site Management. The goal was to develop a realistic, accelerated execution plan, covering manufacturing and installation, so the client could restart operations safely and predictably.
- Mechanical engineering prepared the cutting and fabrication approach to allow immediate sourcing of materials.
- Welding engineering verified that all required welding procedure qualifications (WPQRs) were in place.
- Production reorganized capacity to prioritize this critical work.
- Quality aligned inspection and documentation steps to match the compressed timeline.
On Thursday afternoon, Titan presented a plan based on a 1.5 week lead time. Full approval followed on Friday, enabling immediate execution.
In-house fabrication in Titan’s workshop
Following approval, materials were delivered to Titan’s workshop on Tuesday afternoon and rolling and forming started immediately to bring the new channel into shape. Early Wednesday morning at 06:00, Titan’s certified welders began assembly and welding. With Quality closely aligned throughout the build, the complete channel was manufactured within a record of five days.
In parallel, Titan secured critical items to protect the overall schedule: the required sight glasses were ordered and the lower sections were machined from Alloy 800H.
Installation: preparing the site and reassembling the burner channel
While the channel was being fabricated, Titan’s construction team mobilized on site to prepare for reinstallation. This included coordinating access, lifting requirements, and the practical sequencing needed to reassemble the burner channel safely and efficiently.
With an experienced crew of VCA- and OSHA-certified welders and mechanics, the burner was hoisted into position under controlled lifting conditions and without incidents. Thanks to short communication lines between workshop, engineering, quality and site, the final fit-up, reassembly and completion activities were executed smoothly.
Result
By combining rapid feasibility, qualified procedures, in-house manufacturing and controlled on-site installation, Titan executed the complete replacement and reinstallation scope within two weeks, supporting a safe and predictable return to operation.
