Welding and installation Works During Shutdown – How to Minimize Delays in Industrial Installations
A planned shutdown is one of the most critical phases in the life cycle of an industrial installation. Time is strictly limited, the scope of works is extensive, and every hour of delay generates measurable financial losses.
In projects executed at power plants, process installations and waste-to-energy facilities, the organization of welding and mechanical works, combined with strict quality control, is essential to maintaining the restart schedule.
PRO-Welding operates as an industrial welding contractor for shutdown projects across Europe, supporting power plants, refineries and process installations with certified welding teams, mechanical execution and strict quality supervision.
Why Is a Shutdown a High-Risk Project?
A shutdown involves the simultaneous execution of multiple activities within a limited timeframe and often in confined working areas.
During a shutdown:
parallel dismantling, installation and welding works are performed;
the schedule is tight and dependent on multiple contractors;
critical systems frequently require 100% non-destructive testing (RT/UT);
a delay in one section may postpone the restart of the entire installation.
The most common sources of delay include:
shortage of qualified personnel;
insufficient coordination between fitters, welders and NDT teams;
incomplete or unprepared WPS/WPQR documentation;
repair work following radiographic testing (RT).
In such an environment, any non-conformity may directly affect the planned recommissioning date.
Rapid Mobilization of Welding Teams – Maintaining the Schedule
In shutdown projects, rapid mobilization is decisive.
The welding team must be:
ready to operate in shift-based systems;
trained in accordance with site-specific requirements;
prepared for defined material groups (e.g. high-alloy steels, pressure components);
equipped with valid welding certifications.
The ability to implement day-and-night shift systems significantly shortens the execution time of critical welding and installation stages.
A properly prepared welding team minimizes downtime risk and ensures continuity of works during shutdown execution.
100% RT / UT – Preparing the Welding Process for Full Quality Control
In power generation and process installations, radiographic testing (RT) and ultrasonic testing (UT) often cover 100% of welds.
To minimize the risk of repairs, the following is essential:
use of approved Welding Procedure Specifications (WPS) qualified in accordance with WPQR;
ongoing visual and interpass inspection;
close cooperation with the NDT team;
proper preparation of materials and joint geometry.
Correct preparation of the welding process significantly reduces the number of post-test repairs and shortens the overall shutdown duration.
Fitter – Welder – NDT Coordination
In a shutdown environment, communication and coordination are critical.
An effective execution model includes:
planning of installation sequences;
dimensional control prior to welding;
immediate release of completed sections for NDT;
continuous reporting of work progress;
ongoing updates of quality documentation.
Lack of coordination results in downtime, which directly translates into delays in plant recommissioning.
Industrial Welding Contractor for Shutdown Projects
In industrial projects, shutdown support should not be limited solely to manpower supply.
Key factors include:
experience in working on active industrial facilities;
understanding of strict safety and quality requirements;
organizational flexibility;
ability to operate within demanding schedules;
readiness to respond quickly to scope changes.
Summary
A properly prepared welding team is a critical element of successful shutdown execution, directly determining timely completion and minimizing cost and schedule deviations.
Our extensive experience in delivering welding and installations works during shutdowns at power and process installations across Europe enables us to effectively manage schedule-related risks while maintaining the highest standards of quality and safety.