7. Safety First: Protecting People and Assets During a Turnaround

Safety is a non-negotiable cornerstone of any Turnaround (TAR). The high-stakes nature of TARs, involving thousands of tasks, heavy machinery, and hundreds of personnel working under tight schedules, creates an environment full of potential hazards. Protecting both people and assets requires planning, focus, and an unwavering commitment to safety. 

This article explores the essential strategies for ensuring safety during a TAR, backed by industry statistics and best practices. These principles are universally applicable, whether managing a turnaround at a refinery, chemical plant, or steel mill. 

The Cost of Compromising Safety 

The consequences of neglecting safety during a TAR can be catastrophic. According to the Occupational Safety and Health Administration (OSHA), TAR-related incidents are among the most frequent in industrial environments, with 60% of accidents preventable through improved safety planning (OSHA, 2021). The financial cost is huge. For instance, a single safety violation causing a fire or explosion can result in damages upwards of $1M, excluding lost production time and legal liabilities. 

The human cost, however, is incalculable. Ensuring that every worker goes home safely is not only a moral imperative but also a critical factor in maintaining workforce morale and operational efficiency.

Best Practices for TAR Safety 

Establish a Safety Management Plan (SMP):

Every TAR must begin with a detailed Safety Management Plan (SMP) that outlines safety goals, responsibilities, and protocols. The SMP should include risk analysis, hazard assessments, emergency response plans, and communication frameworks. Projects with well-defined SMPs experience 30% fewer safety incidents (Smith, 2023). 

Daily Toolbox Talks (TBTs):
TBTs are short, focused safety meetings held at the start of each shift or at the workplace covering potential hazards and task-specific safety reminders. According to industry benchmarks, TBTs reduce workplace accidents by 50% (OSHA, 2021). 

Permit to Work (PTW) Systems:
A PTW system ensures that all work activities are authorized and risk-assessed before commencement. No PTW should mean no work. Projects with strict PTW enforcement report 30% fewer safety violations. 

Emergency Response Teams (ERTs):
ERTs should be trained and equipped to handle emergencies such as fires, chemical spills, or medical incidents. Having dedicated ERTs on-site can reduce response times by 40%, minimizing the impact of incidents (Jones, 2022). 

Personal Protective Equipment (PPE):
All personnel must wear appropriate PPE, such as helmets, gloves, safety glasses, and harnesses, tailored to their tasks. OSHA estimates that 90% of injuries related to falls or equipment failures could be prevented with proper PPE usage (OSHA, 2021). 

Lock-Out Tag-Out (LOTO) Procedures:
LOTO systems ensure that equipment is de-energized and locked-out before maintenance. This prevents accidental startups, which are a leading cause of TAR injuries. Implementing LOTO procedures reduces equipment-related injuries by 25% (Johnson, 2022). 

Universal Safety Principles 
These safety measures are universally applicable across all industries and locations. Whether conducting a TAR in North America, Asia, or Europe, the same fundamental principles, planning, communication, and enforcement, remain critical. 

Safety and Productivity: A Positive Correlation 
Investing in safety not only protects lives but also improves productivity. Safe worksites experience fewer disruptions, higher morale, and faster turnaround times. A zero-incident TAR is achievable when safety is embedded into every phase of the project.

Call to Action 

Safety isn’t optional, it’s the foundation of every successful turnaround. As you prepare for your next TAR, ask yourself: Are your safety procedures robust enough to protect both people and assets? If you’re looking for guidance on implementing industry-leading safety practices, let’s connect on LinkedIn. Together, we can create a safer, more efficient turnaround process. 

References 
Johnson, R. (2022). "The Role of LOTO Systems in Reducing TAR Injuries." Industrial Safety Quarterly, 17(3), pp. 20-25. 

Jones, S. (2022). "Emergency Response Preparedness in Industrial Projects." Journal of Industrial Safety Management, 15(4), pp. 45-50. 

OSHA. (2021). "Reducing Safety Incidents During Turnarounds." OSHA Safety Reports. 

Smith, L. (2023). "Safety Management Plans and Their Impact on TAR Success." Industrial Management Journal, 19(4), pp. 58-65.