Refinery & Plant Turnarounds

During a turnaround (shutdown), a plant brings in hundreds or thousands of contract workers to inspect, clean and repair equipment on a tight schedule. Hazards multiply when so many crews work at once.

• Refineries & Plants

Top hazards

• Residual chemicals and gases when opening lines and vessels (benzene, H2S, hydrocarbons)
• Confined space entries into vessels, towers and heat exchangers
• Hot work near hydrocarbons
• Heavy lifts and congested work areas
• Heat stress and long shifts (fatigue)
• Start-up hazards when units come back online

Key practices

• Complete site orientation, and know the plant’s alarms and muster points.
• Work only under a valid permit, and stay within its scope. See Permit-to-Work.
• Wear your personal gas monitor and FR clothing; know the H2S and benzene procedures.
• Verify isolation before breaking lines; wear required PPE for line breaks.
• Manage fatigue: get rest between shifts and speak up if you’re too tired to work safely.

Process safety

Refineries and chemical plants handle large amounts of flammable and toxic material under pressure and heat. They operate under OSHA’s Process Safety Management rule, which requires management of change, mechanical integrity, hot work permits and contractor safety programs. As a contractor, you’ll be trained on the plant’s hazards and emergency plan before you start. See Process Safety Management.

Line breaking

Opening a line or flange for the first time is one of the highest-risk tasks in a turnaround. Even after draining and purging, lines can hold trapped liquid, gas or pressure.

• Line break permit issued and isolation verified
• Line drained, depressurized and purged
• Required PPE on (often chemical suit, face shield and supplied air)
• Bolts loosened on the far side first so any release is directed away from you
• Area barricaded and gas monitoring in place

Benzene and H2S

• Benzene causes leukemia. Know where benzene is present and follow the respiratory and exposure monitoring rules.
• Hydrogen sulfide can kill quickly and deadens your sense of smell. Wear your monitor and leave immediately when it alarms. See Hydrogen Sulfide.

Start-up

Start-up after a turnaround is a dangerous time: unfamiliar conditions, rushed schedules and equipment that was just worked on. Make sure all blinds are removed, all permits are closed, all workers are out of the unit, and everyone knows the start-up schedule.

Last updated: October 1, 2026