Wrong liner profile delivered, crane not booked, bolt torque records missing — turns a 36-hour planned shutdown into a 72-hour overrun costing $140,000–$280,000 in lost clinker production. This checklist structures every relining event from wear confirmation through post-restart commissioning, with each task linked to a CMMS work order so nothing falls through the cracks. Book a demo to see Oxmaint's liner replacement planning module configured for your mill fleet.
This checklist covers five phases of a cement mill liner replacement event: pre-shutdown planning (6 weeks through 2 weeks prior), contractor and crew coordination, materials logistics, shutdown day execution, and post-relining commissioning. It applies to ball mill shell and end liner sets, intermediate diaphragm replacements, and grate plate changes. Each task maps to a CMMS work order item in Oxmaint's outage planning module.
Pre-Shutdown Planning
Relining decisions made late or without wear data result in emergency contractor mobilization — 3.5x the cost of planned crew dispatch. Every item below must be completed and logged in the CMMS outage planning work order before contractor engagement begins.
Frequency: 6–4 Weeks Before ShutdownContractor and Crew Coordination
Contractor scope gaps and inadequate crew size are the two most common causes of relining overruns. All contractor tasks must be assigned as sub-items under the CMMS shutdown work order with named responsible party and confirmed deadline.
Frequency: 3–2 Weeks Before ShutdownImport This Checklist as a Live Work Order in Oxmaint
Every item in this checklist can be assigned to a named technician, tracked against the shutdown timeline, and closed with photo evidence in the Oxmaint outage planning module. Book a demo to see liner replacement work order packages built from your mill data.
Materials and Spare Parts Logistics
Wrong liner profile or insufficient bolt stock causes mid-shutdown delays averaging 11 hours at $6,200–$9,400 per hour in lost production on a 150-tph mill circuit.
Frequency: 2 Weeks Before ShutdownShutdown Day Execution
Every safety and execution task below must be completed in sequence. No confined space entry until LOTO is confirmed and atmosphere clearance is issued. All torque records must be photographed and uploaded to the CMMS work order before mill restart.
Frequency: Shutdown Day — Pre-Entry SequenceSchedule Liner Replacements From Wear Data — Not the Calendar
Oxmaint's liner wear trending module projects replacement date at the plant's current throughput rate — so relining shutdowns are planned at the right time, not 15% too early or dangerously late. Book a demo to see throughput-linked liner scheduling for your mill fleet.
Post-Relining Commissioning
Post-relining commissioning records — torque check, ball charge quantity, initial bearing temperatures — form the baseline for the next wear cycle. All data must be closed in the CMMS work order before the relining event is considered complete.
Frequency: Post-Relining — Before Mill RestartRelining Problem Diagnostic Reference
Common fault signatures observed during or immediately after a mill relining event, with probable causes and recommended corrective actions.
| Observation / Pattern | Most Probable Cause | Recommended Action |
|---|---|---|
| Bolt loosening within 48 hours of restart | Incorrect torque sequence or insufficient pre-load — liner seating not achieved | Re-torque full liner set per sequence; review torque tool calibration certificate |
| Specific energy rise above baseline after relining | Wrong liner profile installed or ball charge level below optimum post top-up | Verify liner profile against mill specification drawing; check ball charge fill level |
| Mill vibration above baseline on loaded run | Uneven liner installation or ball charge segregation from non-uniform removal and refill | Inspect liner seating at all bays; equalise ball charge distribution before full production rate |
| Liner cracking within first 200,000 tonnes | Impact fatigue from incorrect ball charge grade or liner alloy specification mismatch | Verify ball grade against liner alloy specification; log batch certificate in CMMS asset record |
| Bearing temperature elevated post-restart | Liner bolt protruding into charge trajectory contacting trunnion bearing area | Shut down immediately; inspect bolt protrusion at each liner bay before restart |
| Blaine fineness below target after relining | Lifter bar height too low for current ball charge grade — insufficient cascading action | Compare lifter bar specification against ball charge grade; review liner selection at next planned outage |
Relining Performance KPIs
Six metrics that define liner replacement program performance — tracked automatically in Oxmaint against each mill asset record.
Frequently Asked Questions
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Run This Checklist as a Live Work Order in Oxmaint
Import every phase of this liner replacement checklist into Oxmaint's outage planning module — assign tasks to named crew and contractors, track completion in real time, and close with photo-documented torque records that anchor the next wear cycle baseline. Book a demo to see a relining work order package built for your mill.
