Merit Award: Steloy
Project : Fast track supply of 210 sets of cast reformer-tube components to the USA

Steloy Castings has over the past five years established itself in the highest ranks of international foundry
activity, notably in the supply of advanced high-alloy castings to the petrochemical industry.

Steloy’s ability to meet exceptional standards of customer service, technical proficiency and product quality
was again borne out in November 2006 when it successfully executed a fast-track contract to supply 196 sets
of reformer tube components for a refinery in Hawaii. Cast to advanced material specifications, the components
were delivered within only four weeks – compared to normal lead times of up to six months.

During November 2006, Steloy supplied 196 sets of reformer tube components to US furnace design and
construction company OnQuest Inc following the failure of a reformer bank at the Tesoro refinery in Hawaii.
The refinery is located next to an American Air Force base and the failure of the reformer bank posed such
a threat, evacuation of the base was even considered.

When the refinery managed to shut down the reformer bank successfully, a new threat emerged – that the
entire island, including military bases, would run out of fuel within six weeks. Some contingency plans were
put in place, but the race was on to produce new reformer assemblies in record time.
The customer’s requirement was for Steloy to cast tube components within the incredibly tight timeframe of
four weeks, normal delivery for these components can take as long as six months, and to advanced material
specifications, to upgrade the reformer bank to the latest technology.

The components consisted of catalyst tubes, manifolds, reducers and plates, and transition cones.
Steloy Castings operates Africa’s only stainless steel centrifugal casting plant, which is one of only a
handful worldwide. Its ability to produce tubes to the most exacting standards helped secure the order.
The components were produced at Steloy’s Chamdor facility using a new-generation, proprietary heat-resistant
alloy called HP Micro comprising 25 chromium and 35 nickel with a very tight carbon range and micro-alloy with
titanium and zirconium. All components were machined and subjected to rigorous quality control testing – most
to level 2 radiography.

The entire shipment, which weighed in at some 40 tons, was express air-freighted, half to Dallas in the US and
the other half straight to Hawaii, for assembly, which was completed in week seven.
“It doesn’t matter where you are in the world – if you are technically proficient and provide an exceptional
service, the opportunities in the global marketplace are almost limitless,” says Steloy’s chief executive
Danie Slabbert.