Planned Shutdown / Turnaround Insulation Services
Planned shutdown (turnaround) periods are comprehensive maintenance, renewal and modernization windows where a plant is partially or fully shut down and all insulation, cladding and mechanical work must be completed in a short window before production restarts. These are high-cost operations under severe time pressure — so proper planning, rapid mobilization, material supply, modular insulation and experienced field teams decide success. With 100% on-time delivery across dozens of refineries, LNG plants, chemical plants, cement factories and power plants in Türkiye, Europe and Africa, ERATHERM keeps shutdown periods to a minimum and returns plants safely to production on schedule.
100% On-Time · 3 Continents
A Critical Non-Production Window
Turnaround is a planned shutdown for maintenance, revision and renewal. During this window the team works against the clock to restore the plant to peak condition:
- Old insulation removed and worn areas renewed
- Insulation jackets and cladding replaced
- Pipelines, turbines, tanks and boilers re-insulated
- CUI (corrosion under insulation) risks eliminated and equipment prepared for commissioning
The goal: maximum efficiency, minimum energy loss and long-term safety when the plant returns to production.
The Critical Challenges of a Turnaround
Turnaround insulation is unlike routine maintenance — engineering, logistics and field application must be managed concurrently.
Every minute is cost — production loss can run to millions of dollars.
Dozens of companies and hundreds of teams work the same site at once.
A shortage of material can halt the entire project.
High-temperature equipment, confined spaces and work-at-height risk.
A single error can delay the whole process downstream.
Every line must be inspected and ready for a safe restart.
From Pre-Survey to Zero-Delay Restart
End-to-end turnaround insulation across three synchronized stages — engineering, prefabrication and field application.
Pre-Survey & Engineering
Pre-site survey, removal scope, CUI control plan, isometric equipment/line lists and material/thickness engineering.
Detail engineering
Removal & CUI Control
Removal of old, wet or damaged insulation, surface preparation and corrosion-under-insulation control before renewal.
Prefab Jackets & Cladding
Custom-sized jackets, flange/valve/turbine pockets, removable modules and stainless/aluminium jacketing prefabricated ahead of the window.
Insulation materials
Turbine, HRSG & Equipment
Re-insulation of high-temperature lines, turbines, HRSG, tanks, flanges, valves and equipment to restore efficiency.
Turbine insulation
Cryogenic System Renewal
Renewal of cryogenic and cold-line insulation with PIR/PUR, aerogel and cellular glass under shutdown conditions.
Refinery insulation
Multi-Shift Application
Scaffolding, rapid mobile teams, 24-hour shifts, inspection, testing and commissioning support for a zero-delay restart.
Application servicesPrefabricated, Ready for the Window
Materials are engineered, sized and staged before the shutdown so the field team never waits.
High-temperature modules for service ≥1200 °C.
High-density panels for hot lines and equipment.
Cold and cryogenic line renewal under shutdown.
Removable insulation blankets for valves and flanges.
Durable cladding and protective jacketing.
High performance at low thickness in tight spaces.
Water-repellent, corrosion-under-insulation protected systems.
Prefabricated pockets for fast, repeatable fit-up.
Engineering + Logistics + Field, in Sync
Done right, turnaround insulation pays back across the whole production cycle:
- Problems identified before the plant is recommissioned
- Energy loss minimized and CUI/corrosion risk eliminated
- Post-maintenance equipment life extended and safety increased
- No need to stop the line again once production starts
100% On-Time Across Three Continents
Turnaround insulation delivered at dozens of refineries, LNG plants, chemical plants, cement factories and power plants in Türkiye, Europe and Africa — with a 100% on-time record alongside leading operators and EPC contractors.
Experienced engineers and field teams who adapt to variable conditions at every site keep shutdown periods to a minimum and return plants safely to production on schedule.
A Turnaround Partner Built for the Clock
A proven on-time delivery record across critical shutdowns.
Mobile teams and staged material for fast deployment.
Planning, engineering, material management and field work together.
Jackets and modules prefabricated before the window opens.
Coordinated with mechanical, scaffolding and inspection teams.
Occupational-safety practices for high-temp, confined and at-height work.
Sectors, Systems & Specialist Programs
Turnaround insulation connects to ERATHERM's wider portfolio of thermal insulation systems, industrial sectors and specialist defense, aerospace and nuclear programs.
Sectors & Systems
Engineering & Services
Turnaround Insulation — Common Questions
What is turnaround insulation?
Turnaround is a planned, non-production shutdown for maintenance, revision and renewal. Old insulation is removed, worn areas renewed, jackets and cladding replaced, pipelines, turbines, tanks and boilers re-insulated, CUI risks eliminated and equipment prepared for commissioning — ensuring maximum efficiency, minimum energy loss and long-term safety when the plant restarts.
Why are turnaround projects so challenging?
Turnarounds run under severe time pressure where every minute is cost, with dozens of companies and hundreds of teams working simultaneously, demanding material and logistics management, strict safety in high-temperature, confined and at-height conditions, and tight synchronization of planning and implementation — engineering, logistics and field application must be managed concurrently.
How does ERATHERM plan a turnaround insulation project?
In three stages: preparatory work and engineering (removal scope, CUI control plan, isometric lists, material and thickness engineering); material supply and prefabrication (custom jackets, ceramic/PIR/rockwool/aerogel panels, flange/valve/turbine pockets, removable modules); and application and field management (multi-shift teams, scaffolding, removal, surface prep, re-insulation, inspection and commissioning).
Which materials are used in turnaround insulation?
Ceramic fiber modules (≥1200 °C), rock wool and high-density panels, PIR/PUR cryogenic panels, removable insulation blankets, stainless steel/aluminium jacketing, ultra-thin aerogel and water-repellent CUI-protected materials.
Why is turnaround insulation important?
It identifies problems before recommissioning, minimizes energy loss, eliminates CUI and corrosion risk, extends equipment life, increases operational safety and removes the need to stop the line again after production starts — turnaround insulation is an operational sustainability strategy.
What is ERATHERM's turnaround track record?
ERATHERM has 100% on-time delivery across dozens of refineries, LNG plants, chemical plants, cement factories and power plants in Türkiye, Europe and Africa, offering end-to-end planning, engineering, material management, site organization, rapid mobile teams and occupational-safety practices.
Let's Plan Your Turnaround Insulation Project
Pre-site survey, removal/renewal plan, material engineering and supply, 24-hour shifts and turnkey reporting — the longer the turnaround, the higher the cost, so correct insulation means speed, efficiency and safety.