Smarter Shutdowns — How We Eliminated Days of Work When Removing Furnace Wall Instruments

Shutdowns and maintenance outages are critical windows in the life of any plant — and in energy from waste facilities, they often present unique challenges.

One particularly problematic task we encounter regularly is the removal of critical and difficult-to-access temperature probes and other instruments from furnace walls.

These probes:

• Are exposed to extreme temperatures and corrosive gases

• Are often installed in ways that make removal during shutdown risky and labour-intensive

• Can delay key shutdown activities if not managed correctly

The Problem

In one plant we supported, shutdown teams were spending days trying to remove problematic probes during every outage — adding unnecessary time and risk to an already pressured maintenance window.

The conventional approach — forcing removal even when probes were seized or damaged — led to:

• Wasted labour time

• Increased risk of equipment damage

• Delayed return to service

Our Solution

BIA Engineering Ltd approached the problem differently:

• Conducted a detailed review of probe installation methods and failure modes

• Provided guidance on when probe removal is necessary, and when it is not

• Developed strategies for properly sealing and managing probes left in place

• Recommended design changes for future installations to facilitate easier removal when required

• Trained shutdown teams on the revised best practices

The Outcome

Our approach delivered immediate benefits:

• Days of unnecessary shutdown work eliminated

• Improved worker safety and efficiency

• Reduced risk of damage to furnace walls and instrumentation

• More predictable and efficient shutdown execution

Why It Matters

Not every instrument needs to be removed at every shutdown — and understanding this distinction can save plants significant time and cost.

Engineering solutions beyond expectations means helping plants work smarter — not harder — and delivering value where it matters most.