Oil and gas processing take place in some of the world’s most hazardous work environments. Plant sites can combine challenging site conditions with work in confined spaces, on slick surfaces, using dangerous gases and chemicals, involving numerous types of equipment and machinery.

However, when normal operations give way to planned or unplanned turnarounds or shutdowns for maintenance or repair— there are even greater risks of worker injuries and deaths despite significant planning. These risks also have an impact on productivity as they may decrease uptime and efficiency.

Third party-managed temporary contractor crews swarm the site; headcounts can triple. Work focus shifts to inspection, maintenance, repair, upgrades, or new equipment installation — all against unforgiving deadlines. Infrequent and “non-work” work is performed in both usual and unusual work areas. Jobs take place above, under, and within areas seldom accessed, or normally off-limits. New tools and equipment appear, along with gasses and chemicals not usually present or accessible.

When compared to day-to-day operations, there are more risks — and they are more frequently unexpected. Safety solutions, practices, and training must be adjusted accordingly. Given the ruggedness of turnaround work and the temporary nature of many contractor crews, safety solutions recommendations should favor personal protection equipment (PPE) that features increased ease of use, durability, reliability, serviceability, and compactness of design.

In these situations, gas hazards pose unique risks. If workers are to be kept safe from toxic and flammable gas exposure, seven key areas of safety risk demand special attention. They’re identified here as The Top Seven Critical Safety Challenges of Oil & Gas Turnarounds. Managers should consider how their safety practices and products match the unique mix of safety hazards they may face.