Safety during Steel Manufacturing Unit Shutdown

???Overview of Safety during Continuous Steel Manufacturing Unit Shutdown

Safety consideration in steel manufacturing industries is a significant, mandatory investment in today’s competitive global market. It takes care of plant assets and ensures the protection of workforce safety and maintains a safe work environment. Most steel manufacturing units are operational round the clock and round the year to prevent any major breakdown and maintain the safety and health of equipment and their components.

A planned or scheduled shutdown is also called turnaround of the entire unit, shutdowns are scheduled as per demand of product in market and depend upon the need of the unit at pre-defined intervals production targets decided.

Shutdowns need to be addressed from the high-risk activities perspective because high risk processes are present at the installation in operational area, storage tanks, warehouses, silos, and pipelines even when the production process is not running and most of the equipment has been emptied and cleaned.

Sometimes emergency stoppages or unwanted situations in the steel manufacturing process activities force all operations to address remedial actions/ maintenance concerns such as cleaning, inspection, replacement and repair etc. Implementation of preventive measures, periodic safety checks, scheduled equipment inspections and condition monitoring as well as regular upkeep and planned preventive maintenance help to avoid emergency breakdown/shutdown.

The interruption during normal operation of the unit is a costly exercise, at the same time, the shutdown is very essential in managing a safe operation.

Shutdowns are to be Precise, on-schedule, and reliable.

Scheduled turnarounds are planned for total or partial plant units. These unit stoppages are critical for allowing contractors’ manpower and employees to perform crucial activities and plant upkeep to maintain facilities running safely, effectively and efficiently and they are to be accomplished during non-operation periods.

Shutdowns are scheduled to minimize disruption to normal operations and to maximize the benefits of the maintenance activities. Shutdown activities are an integral part of a plant’s comprehensive operational strategy.

??Types of Shutdowns in Industry:

1. Planned Shutdowns

2. Emergency Shutdowns

3. Partial Shutdowns

4. Full Shutdowns

A full shutdown involves a complete stoppage manufacturing process. These comprehensive shutdowns are planned with a detailed list of tasks to complete. During a full shutdown, the entire unit is under maintenance to address issues faced during normal operation and to ensure the upkeep of equipment and systems. This approach contributes to the long-term reliability and efficiency of the unit under shutdown.

Phases of shutdown activities:

· Plan- Create a detailed plan, outline a budget, and prioritize tasks.

·?????Communicate- Fix up the responsibilities of individual and team, update them on new processes, and identify potential risks?

·????Prioritize safety- Ensure all safeguards into plans and procedures, and give importance to safety protocols?

·???Review- On completion of shutdown, identify what went well and what need improvement.?Smooth restart of the asset/unit/plant and restoration to normal operation to be ensured.

Steps for Shutdown:

1. Strategic Planning & Scheduling

2. Task Prioritization

3. Resource Allocation

4. Communication and Coordination

5. Contingency Planning

6. Safety Measures

7. Documentation and Reporting

The last step is to record the activities that occurred during the shutdown to generate a report summarizing all the observations.

A variety of activities during shutdowns include:

Maintenance:?Preventative maintenance, repairs, and replacements.

Inspections:?Equipment inspections and safety inspections.

Upgrades:?Upgrades and modifications.

Removal of assets from production

Cleaning:?Cleaning and overhaul.

Testing:?Testing and commissioning?

The importance and impact of shutdowns in the steel plants affect productivity.

Pre-shutdown/Shutdown activities:

·?? Preparation: To ensure a safe shutdown 4 months in advance shutdown activities are planned at a micro level.

·? ?Regular plant inspections: Regular inspections of equipment, machinery and operation system/procedure are to be documented.

·? ?Education and Training of the workforce: Provide specific structured training to overcome high levels of risk associated with the work, and refresher training to be given every year.

·?? Disconnection/isolation of all equipment: Provide positive isolation to all equipment and system as documented.

·?? Storage of hazardous Materials: A safety is planned for the storage of all hazardous and dangerous materials.

·???Continuous Monitoring of exposure risk: Beware of the risk of exposure to toxic chemicals, acidic chemicals, flammable gases, toxic fumes, airborne fibbers, etc. A trained safety specialist to test exposure risk and ensure the correct protection.

·???Keep rotating equipment turned off: Ensure positive isolation of power to equipment, to make sure the system is turned off.

·???Keep enough resources: As per safety requirement deputation of adequate workforce to execute the shutdown are to be ensured.

·???Keep communicating: Develop a system to quickly and timely communicate if there is a danger. Arrange adequate safety slogans, safety talk messages, banners with a simple message such as “do not operate.” ?

·???Use qualified, certified and competent personnel: Ensure the shutdown workforce is well qualified and trained in their respective areas of concern to maintain safety.

·???Documentation and Procedures: Based on equipment inspection carried out obtain approval from inspectors to have a documented process to maintain equipment/machine. The procedure includes information like who will do the work, what is to be controlled etc.

·???Have appropriate PPEs and personal safety monitoring systems: Ensure appropriate hazard detection and protection equipment worker safety.

Shutdowns are usually a necessary part of a plant's annual routine operations.

Shutdown Engineering:

Shutdowns are strategically designed and meticulously followed to enhance overall performance and reliability. During shutdown periods, engineers along with maintenance teams do carry out meticulous inspection, repair/replacement, and upgradation of machinery and system which in turn proactively prevents unexpected breakdowns. These activities contribute to the longevity of the engineering systems and improve operational efficiency.

Safety management system is always a top priority in any unit shutdown. Ultimately shutdown contributes to the reliability and longevity of their equipment and systems.

All preventive measures are taken to keep the plant safe and viable in the future during the shutdown so that no emergency shutdowns happen in the future.

For any shutdown, a risk assessment, well-documented procedure, proper communication well-trained workforce, and effective safety management and technology are essential.

Major challenges during the shutdown activities include:

·?? Hazardous gases and toxic gases are constantly present.

·???Possible leakage of hazardous gases/liquids

·???Heavy lifts and relocation of equipment/ piping etc.

·???Poor housekeeping

·???Expertise in modification/alternation

·???Skills and Knowledge of the workforce

·???Ensuring workforce safety?

·???Availability of relevant information and metrics?

·???The coordination and management of complex resources.?

·???Transforming an organization from reactive to proactive.?

·???Managing the expectations of diverse stakeholders.?

·???No Violation of Work Permit Conditions

·???No line break without authorization

·??? No Confined Space entry without authorization.

·???Safety violations and Level of actions

·???Consequence Matrix

Area of concern during shutdown Activities

·???Hazard Communication

·???Confined Spaces

·???Hot work like Gas cutting, Grinding, Welding, etc.

·???Line Breaking

·???Fall Protection

·???Ladders, Scaffolding

·???Work at a height

·???Machine Guarding

·???Barricading

·???Oil Spills

·???Radiation

·???Specific Personal Protective Equipment

·???Temperature difference, Environment issues.

·???Housekeeping

·???Powered Industrial Trucks

·???Safe operation of vehicles

·???Powder-actuated tools.

·???Electrical hazards

·???Excavation Activities

·???Safety planning

·???Hazard identification.

·???Checklist

??

Shutdown completion report should include:

·???Identifying the successful aspects of the shutdown.

·???Recognizing the challenges or shortcomings encountered.

·???Proposing potential enhancements for future shutdowns.

·???Summary of risks and details of their management or containment.

·???Checklist covering all carried-out tasks.

For well-planned industrial shutdown thorough documentation and reporting are essential components. It is very essential to maintain detailed records of inspections, completed tasks and any issues arise during the shutdown for continuous improvement to enhance the effectiveness of subsequent shutdowns.

Plant Shutdowns are some of the most challenging undertakings in the steel industry to ensure the health and safety of the workforce.?At the same time an important aspect is to minimize cost and downtime. It is very much possible to manage any plant shutdown and maintenance activities successfully with well-trained and well-equipped personnel.

An expertise of shutdown management helps to prevent unexpected issues, to minimize downtime, and cultivate an encouraging industrial environment. An accurate planning and scheduling, understanding industrial shutdowns is a key skill for professionals to optimize operations and extend the lifespan of industrial assets.

?To maintain the safety & health of employees and operational units a comprehensive safety shutdown management system is planned, it creates interrelated layers of protection to detect, prevent, and to manage potential safety hazards and risks during the shutdown.

In summary, shutdowns are crucial to maintain operational efficiency and safety. This ensures that maintenance, repair, and inspection tasks are systematically being addressed. To ensure ongoing reliability and to enhance overall efficiency, a strategic approach, meticulous scheduling, task prioritization, resource allocation, are essential activities during shutdown.