Refinery Turnaround Safety Concerns_FD

1. Introduction: Refinery Turnaround Safety at a Glance

Refinery turnaround operations—also known as shutdowns—are among the most perilous phases in a refinery’s operational cycle. The surge in workforce, tight timelines, and disruption of normal workflows create an environment where even minor lapses can lead to serious incidents.

Turnaround operations involve complex and high-risk tasks requiring comprehensive safety planning. To keep workers safe and operations smooth, it’s vital that every team member—whether long tenured or newly onboarded—receives proper instruction in material handling, standard operating procedures, and PPE usage. Clear understanding of shift schedules and hazards prevents costly confusion, delays, or accidents.

Key Safety Challenges in Turnarounds

• Workforce variability: Turnarounds often include an influx of temporary or contractor personnel. This turnover demands uniform training on how to handle dangerous substances and utilize PPE effectively.
• Uncertain timelines: With many variables—from unanticipated equipment failures to hazardous discoveries—the actual turnaround duration can vary significantly, risking safety and budget overruns. These maintenance shutdowns typically last from 10 days to over two months.
• PPE forecasting challenges: Without confidence in project length, it's tough to reliably estimate how much PPE (e.g., flame-resistant coveralls, chemical-resistant suits, respirator-fit options) will be needed, especially when the types of hazards ranging from chemical exposure, toxic fumes, and flammable liquids, are yet to be fully known.

Proactive Safety & Planning Strategies

1. Set realistic turnaround targets: Build in contingencies for unexpected delays—these are common and can quickly push schedules off track, costing millions if underestimated. Adding buffers into your schedule and cost forecasts helps to cover inevitable surprises—unexpected damage or defects can add hours, days, or weeks to a turnaround.
2. Prioritize comprehensive training and communication: Regular briefings pre-turnaround ensure all personnel—new and veteran—understand risks, safety protocols, and proper PPE usage. Start engaging team members early. Frequent coordination with contractors, refresher training for returning workers, and clear communication channels help ensure everyone stays aligned and safe.
3. Maintain detailed post-event analysis: Conduct structured reviews upon completion. Document lessons learned and archive them systematically so future teams can avoid repeat errors and hit the ground running. Maintaining archival records helps streamline future turnarounds with confidence.
4. Secure reliable PPE suppliers: Having access to consistent, high-quality protective garments (e.g., flame-resistant coveralls, respirator-fit suits, chemical-barrier ensembles) relieves safety managers from last-minute scramble and ensures protection is never compromised. Partnering with a dependable supplier ensures steady inventory through crises and unexpected delays.

2. Injury Trends: Understanding the Stakes

• Across 153 U.S. refineries from August 2017 to March 2023, there were 1,539 reported injuries and 7 fatalities, reflecting the elevated risk during extended operations.
• In oil and gas extraction (closely aligned with refinery operations), OSHA-reported severe injuries (amputation, eye loss, hospitalization) totaling 2,101 from January 2015 to July 2022. Notably, 42.6% involved upper extremities, especially the hands, while lower extremity injuries accounted for 17.9%.
• Studies show that in refineries and oil fields, contact with objects/equipment accounts for 25% of fatal incidents, followed by fires and explosions at 15%.

3. Common Hazards During Turnarounds

• Struck-by / caught-between incidents account for almost 59% of refinery maintenance safety events. Tubulars and heavy hoses are frequently involved.
• Abrasive, sharp surfaces—from corroded pipes to welding scraps—these items pose cut and puncture hazards.
• Noise hazards during hydroblasting and machinery operations can lead to hearing damage.
• Hot work and fire risks, including vapor release and welding sparks, amplify burn hazards.

4. Key Protective Clothing & Equipment

To mitigate these hazards, effective PPE is non-negotiable. Here’s a breakdown:

• Secondary Flame-resistant (FR) suits and garments—e.g., PyroGuard FR®—are built to resist ignition and self-extinguish in flash-fire scenarios, complying with ASTM D6413 standards. PyroGuard CRFR^TM  is both chemical-resistant and flame-resistant for numerous industrial chemicals. Fabric also self-extinguishes and does not melt or drip to avoid molten drip hazards.
• Chemical-resistant suits—such as ChemSplash® 1 and 2—offer splash and caustic protection per ISO 6350, EN 368, and Type 5/6 designations.
• Disposable particulate-barrier coveralls (like SMS or MicroGuard MP®) shield against dust and grime while ensuring comfort and breathability. MicroGuard MP® is tested for numerous industrial chemicals for better overall protection than SMS.
• Body protection types include:
• Durable coveralls for general dirt and minor injury protection. This includes SMS garments and microporous garments.
• Full chemical-resistant suits, critical for chemical handling.
• Flame-resistant suits for high-heat or ignition-risk tasks.
• High-visibility attire to reduce collision risks in busy zones.
• Chemical Protective Clothing (CPC) levels:
• Level A: Full encapsulation + SCBA—highest protection.
• Level B: Respiratory protection with chemical-resistant suit.
• Level C: Splash protection + air-purifying respirator.
• Level D: Basic workwear in low-risk zones.
• Additional PPE essentials:
• Hand protection (gloves) to prevent lacerations and burns.
• Eye/face protection: goggles, face shields, or full-face respirators—depending on splash or inhalation risk.
• Hearing protection (earplugs, earmuffs, or both) in noisier zones—an affordable way to prevent long-term hearing loss.

5. Proactive Safety Measures

• Risk assessment: Conduct thorough evaluations to match PPE to specific hazards—this includes the PPE’s chemical testing, physical testing, ergonomics, and breathability.
• Training: Make sure operators—not just full-time staff but also contractors—are trained in properly donning, using, doffing, and discarding PPE.
• Consistent gear supply: Ensure reliable access to the right sizes and gear variants—especially critical in high-turnover turnaround phases.
• Post-turnaround review: Analyze any incidents or close calls to refine future safety strategies and PPE planning.

Refinery Maintenance PPE Strategy

Now, let’s explore how tailored refinery maintenance planning—backed by proper PPE like FR suits, chemical-resistant gear, and CPC level guidance—reduces common turnaround injuries and ensures safer shutdowns.

Major refinery maintenance requires careful planning across logistics, safety, and personnel protection. With a surge of contractors and temporary workers, organizations must ensure everyone is adequately trained and properly equipped with PPE fit for the hazards they’ll face.

1. Setting the Stage: Maintenance Planning as Safety’s Foundation

Refinery maintenance turnarounds demand intricate coordination of manpower, scheduling, and safety—especially when stop-work windows are narrow and stakes are high. Over 80% of turnarounds exceed budget due to scope creep, further stressing safety systems.

2. Planning Challenges & PPE Implications

• Uncertain duration and workforce: Your refinery must account for high wear and turnover. Fluctuating project timelines make PPE forecasting difficult— it’s better to be overprepared than underprepared. Many disposable PPE options have a long shelf-life and can be stored for later use.
• Non-routine tasks like confined-space entry, hot work, and heavy equipment handling increase hazards. Ensuring your gas detection equipment is properly calibrated beforehand, and reviewing safety precautions for each type of work performed will help prevent accidents and better prepare workers.

4. Building a PPE Strategy That Matches the Risk

Key PPE types:

• Flame-resistant gear for ignition-prone tasks (e.g. welding).
• Chemical barrier suits for splash and toxic exposures.
• Particle-resistant coveralls for dusty or particulate-heavy tasks.
• High-visibility clothing to reduce vehicle collision risks in low-light and busy zones.
• CPC levels: Choose Level C or B ensembles when respiratory or splash risks rise, choose Level A in high-consequence vapor environments.
• Other essentials: gloves, eye/face gear, hearing protection, and proper footwear—each tailored to job-specific threats.

1. Planning Tips for Effective PPE Deployment
2. Hazard mapping: Identify job-specific risks—such as chemical exposure, sharp edges, noise, or heat.
3. Select CPC levels appropriately based on exposure—e.g., Level C for splash tasks vs. Level A for unknown vapors.
4. Ensure durability and ergonomics: Protective clothing should offer puncture and abrasion resistance and remain flexible. Seam and tensile strength are critical for garments subject to movement and strain
5. Plan for scale: Maintain sufficient PPE inventory—even in extended turnarounds or during workforce surges.
6. Train & communicate early: All personnel must understand PPE protocols and safety plans—especially contractors.
7. Post-event debrief: Capture lessons on PPE performance, injuries, and areas of improvement to refine next turnaround planning.

Resources