Electrode Cutting During Shutdown Operations
During a scheduled cold shutdown, Solvocore was appointed to carry out specialised electrode cutting on three suspended graphite electrodes, each measuring 1.93 metres in diameter. The electrodes had sustained damage, including fractures and uneven surfaces, which posed a risk to furnace start-up integrity.
Sharp or fractured edges reduce arcing efficiency and may result in loose material circulating inside the furnace – potentially causing further damage or obstructing tap holes. The intervention was aimed at removing these compromised sections and restoring uniform, flat contact planes to support a stable restart.
Solvocore’s scope included the execution of three horizontal wire cuts, demolition of the cut sections into manually manageable pieces, and site housekeeping throughout the operation. Temporary platforms, electrode support, and rubble removal were coordinated with the principal contractor and handled by others.
all work was performed in accordance with OHS regulations and shutdown permit procedures.
The cutting was executed using diamond wire technology, chosen for its accuracy, efficiency, and ability to minimise stress on surrounding structures. The electrodes were pre-supported, and cut positions marked out by the principal contractor. Power and water sources were established within proximity of the work zone, and all equipment was moved into place with lifting assistance as required.
Cutting operations were carried out under isolation and access control, with full PPE compliance and continuous supervision. Once the electrodes were cut, the segments were mechanically broken down using hand-held equipment and cleared from the area. Housekeeping was maintained at all times to ensure platform safety.
Key logistical requirements included:
Reliable 3-phase and single-phase power access.
Water cooling for both equipment and cutting surfaces.
Secure working platforms and temporary supports.
Coordinated access and permit management.
We engineered a network of concrete anchor blocks, which were placed using a mobile crane from the surface. These held a pulley system in place to guide the wire saw in both horizontal and vertical planes – essential for cutting the caisson into smaller, retrievable segments.
All electrodes were successfully cut and cleared within the allocated shutdown window, with no safety incidents and no impact to the broader project timeline. By removing structurally compromised sections and restoring a clean, stable contact plane, Solvocore’s intervention directly improved the reliability and safety of the furnace restart process.
This project reinforces Solvocore’s capabilities in delivering high-risk, precision work within shutdown environments, with a focus on safety, execution efficiency, and technical control.
