Planning refractory work for a shutdown: a practical checklist

Refractory work is often on the critical path of a shutdown. When it overruns, the whole plant waits. Most delays can be avoided with planning done weeks before the stop.

6 to 8 weeks before

• Review inspection records, shell scans and previous repair history
• Define the scope: zones, areas and lining thickness to replace
• Fix the lining design, materials and quantities
• Place material orders, especially for special shapes and castables

2 to 4 weeks before

• Confirm material dispatch dates and test certificates
• Agree the day-by-day schedule, crew size and shifts with the contractor
• Plan cooling time, access, scaffolding and lighting
• Complete permits, HSE induction and method statements

During the shutdown

• Hold a short daily progress meeting
• Inspect the shell and anchors once the old lining is removed
• Check joints, expansion allowances and anchoring as work proceeds
• Keep spare material for surprises found during demolition

Before startup

• Complete a joint inspection of the finished lining
• Agree and follow the heat-up and dry-out schedule
• Collect documents: drawings, test certificates, dry-out chart and completion report

With an annual maintenance contract, JISPL handles inspection, scoping and material planning in advance, so your shutdown slot is ready before the plant stops.