Plant Turn Around Safety Tips

Plant Turn Around or yearly maintenance is a very big event, where almost all equipments will be opened for overhaul. This is the time when a ton of works are carried out at the same time based on a planned schedule, with a large numbers of workers. In this occasion, a group of people from third party also work in your plant site.

There are many types of works and operations carried out at that time. Chemical cleaning, welding, brushing, confined space works, tank clean up, piping modification, work at elevated height, leak test, hydrostatic pressure test, catalyst discharging, catalyst burning operation, and many more. All of those works contains potential risks. If it is not treated properly, then it will result work accidents.

In this case, safety aspect should be treated properly in order to prevent work accidents. Because a lot of works are carried out at the same time, naturally each work will link which each other. So it is very important to make sure safety aspect of each work and not to become hazards source for other works.

The following plant Turn Around safety tips will help you managing safety aspect in better way. The ultimate goal is how you can eliminate and reduce work risks, so that work accident can be prevented.

Safety Tips for Plant Turn Around

Please pay attention to the following safety tips and follow those tips if they are applicable for your plant conditions. The tips are taken from my personal experiences managing plant Turn Around for about 13 years.

  1. Make the Turn Around schedule with full safety consideration inside. All Departments in your company and third parties should attend during preparing the schedule to precisely match their works with others, to minimize safety risks.
  2. Safety induction is very important for everyone involved in Turn Around work including temporary workers.
  3. Define clearly every confined space works. Confined space works are ones of the deadliest works. You need to have perfect preparation doing such works.
  4. You have to ensure that all personal safety equipments are in good condition and available in adequate numbers.
  5. Oxygen and flammable gas detectors are ready to use and calibrated. Prepare back up equipments.
  6. Fire fighting pump, hydrant, foam mobile unit, fire extinguishers and other fire fighting tools are ready to use. If the pump is planned to be overhauled, prepare reliable back up system of fire fighting before hand.
  7. Safety work permit should be got for every work. No work can be done without this permit.
  8. Coordination is the key. Without good coordination, you are taking risks for people’s safety.
  9. Conduct daily safety talk. It is simple but effective to communicate safety among workers.
  10. Pay close attention to hydrostatic pressure test or pneumatic test. You should take care monitoring this work.
  11. Treat properly used chemicals, oils and other hazardous materials. Never collect them together in one bucket. Follow MSDS for each chemical.
  12. Most people ignore nitrogen gas hazard. Take care about this. Remember that nitrogen will cause oxygen deficiency! It’s very dangerous.
  13. Never leave your workplace before doing detail inspection. In my own word, you should inspect every step in the plant site and make sure there is no unsafe condition before you go home.
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