Permit to Work and SIMOPS Planning for a Petrochemical Shutdown

The Challenge

The turnaround was a critical operational event involving over 200 contractors working across a 6-week period. The client faced complex safety and coordination challenges:

• Coordinating simultaneous operations (SIMOPS) including hot work, confined space entry, working at height, and lifting operations
• Managing interactions between live process areas and shutdown work zones
• Ensuring robust permit to work control across multiple contractor organisations
• Developing emergency response capability specific to shutdown scenarios
• Meeting tight programme deadlines while maintaining rigorous safety standards
• Satisfying COMAH regulatory expectations for major hazard control during non-routine operations

Our Approach

Operational Assurance Group was engaged six months ahead of the shutdown to develop the permit system and SIMOPS plan. Our approach included:

• Development of a bespoke SIMOPS plan identifying all interface risks and control measures
• Design of a multi-permit framework covering hot work, confined space, working at height, electrical isolation, and lifting operations
• Creation of a permit authorisation matrix and competency framework for permit issuers and receivers
• Site-specific emergency response framework including confined space rescue, medical emergency, and fire response
• Shutdown-specific risk assessments and safe systems of work
• Pre-shutdown training sessions for site management, permit issuers, and contractor supervisors

All documentation was tested and refined through pre-shutdown planning meetings and coordination workshops. We worked closely with the client's operations and maintenance teams to ensure the systems were robust yet practical for the fast-paced shutdown environment.

Outcomes

The turnaround was completed on schedule with exemplary safety performance:

• Turnaround completed on schedule with no programme delays due to safety incidents
• Zero lost-time incidents across the entire 6-week shutdown period
• Over 1,200 permits issued and managed without control failures or permit breaches
• SIMOPS plan successfully managed complex interface risks between live and shutdown areas
• Permit system retained for ongoing use as the site standard for maintenance operations
• Client recognition for quality of shutdown planning and safety documentation

The framework we developed enabled the client to deliver a complex, high-risk turnaround safely and efficiently, demonstrating that rigorous safety control and operational delivery are not mutually exclusive.