Oil and Gas Refinery Safety 

Oil & Gas Refinery Shutdown Job Hazards & Safety Precautions

Shutdown Job Hazards & Safety Precautions.

Shutdown job is a term usually use in Oil & Gas Industries, Shutdown means temporary suspension & stopping of normal routine job or operation in process plants.

Purpose of Shutdown in Oil & Gas refinery: -

•          To carry out any maintenance of plant & equipment.
•          To install new equipment & pipe lines in running plants.
•          For cleaning or housekeeping. 

Activities after Shutdown of Plant/Equipment in Oil & Gas refinery: -

•          Hot work (Welding, Grinding, Gas cutting, Hot tapping Etc.)
•          Electrical and Instrumental work.
•          Work at height.
•          Confined space entry.
•          Cleaning or housekeeping.
•          Erection of equipment and pipelines.

Hazards & Risk in Work after Shutdown of plant.

Oil & Gas Refinery Shutdown Job Hazards & Safety Precautions

Hazards and risk in Shutdown job may be unexpected or riskier than the routine job in process plant.

IndianOil's Haldia refinery fire is one of the recent example of fire accident inShutdown job

• Fire and explosion due to presence of Flammable vapor in equipment & pipe line, while performing hot work job on equipment & pipe line fire accident can occur due to heat and excessive temperature from welding, cutting spark.
• Immediate death due to inhalation of toxic gases, inadequate cleaning of plant can increase the the risk of exposure to toxic gases.
• Slip & Trip due to spillage of chemical & improper stacking of materials.
• Using damaged tools & tackles.
• Not following LOTO procedure, LOG OUT - TAG OUT to be followed during work on electrical & other operating machineries to prevent accidents.
• Confined space entry.(Oxygen deficiency/enrichment, toxic gases)
• Improper functioning of safety devices.
• Unexperienced/uneducated tea.
• Unauthorized operation.
• Lack of PPEs awareness.

shutdown job hazards and safety precautions.

Safety precautions/measures in Shutdown job.

• Proper planning of job to be done.
• Clarity of role & responsibility of each member of team.
• Proper education and training such as: -

1.      Plant training.

- Plant training includes information of, hazards associated with the material used to produce the products.

- First aid for the person exposed to harmful chemicals & products.

- Welfare facilities.

2.      Emergency response. (how to respond in case of emergency)

3.      About safety devices.

4.      Fire safety.

       Fire Safety Hindi Book.

5. Job specific training.

shutdown job safety

• Permit to work, for every job job supervisor must have valid work permit.
• Proper cleaning of equipment & plant to remove flammable vapor and toxic gases from equipment & pipelines.

There are three methods broadly use to remove flammable vapor and toxic gases from equipment. (Shutdown work safety)

1. Flushing: - flowing out products (Fuels, gases, chemicals) by opening valve, drain & vent.  
2. Steam blowing: - By pushing hot pressurized steam through equipment & pipelines.
3. Nitrogen purging: - By passing & filling nitrogen gas in equipment & pipeline, nitrogen gas displace/replace the hazardous gases and oxygen from equipment & pipeline which prevent the risk of fire, Nitrogen is a silent killer because nitrogen is odorless, colorless & replace the oxygen so only authorized & trained person will be allowed for nitrogen purging. 

• Proper cleaning of spillage chemicals.
• Hot work must be done inside fire blanket booth.
• LEL test must be done before starting the job.
• Fire safety equipment & devices must be in working condition.
• Pre safetyinspection of tools.
• Follow LOTO procedure.

Oil & Gas Refinery Shutdown Job Hazards & Safety Precautions

Shutdown job hazards

Shutdown job Safety

Shutdown work hazards

Shutdown job hazards and Precautions

Oil & Gas Refinery Shutdown