Turnaround Maintenance (TAM) is one of the highest-risk operational phases in the lifecycle of an FPSO facility. It involves the planned shutdown, inspection, repair, replacement, and restart of critical process systems—often under compressed schedules, increased manpower, and heightened operational complexity.
From a process safety perspective, turnaround periods are statistically associated with major accident hazards, including hydrocarbon releases, fires, explosions, confined space incidents, and loss of containment. Poorly managed turnarounds have contributed to some of the worst industrial disasters in history.
This article provides a comprehensive HSSE-focused guide to Turnaround Maintenance, structured specifically for FPSO Process Safety integration, and aligned with international best practices.
What Is Turnaround Maintenance?
Turnaround Maintenance is a planned, periodic shutdown of process facilities to perform:
- Statutory inspections
- Major equipment overhauls
- Safety-critical repairs
- Modifications and upgrades
- Integrity assurance activities
On FPSOs, turnarounds may be partial or full, depending on production philosophy, reservoir constraints, and regulatory requirements.
Key distinction:
Unlike routine maintenance, turnaround work introduces simultaneous operations (SIMOPS), temporary equipment, abnormal plant states, and large contractor workforces—making process safety management critical.
Why Turnaround Maintenance Is High-Risk on FPSOs
1. Loss of Normal Barriers
- Isolation of systems removes engineered safeguards
- Temporary bypasses and overrides increase vulnerability
- Safety Instrumented Functions (SIFs) may be impaired
2. Increased SIMOPS
- Hot work near hydrocarbon systems
- Confined space entry alongside lifting operations
- Electrical work during partial energisation
3. Workforce Surge
- Large number of contractors unfamiliar with FPSO hazards
- Cultural and language barriers
- Variable competence levels
4. Abnormal Operating Conditions
- Draining, purging, nitrogening, and re-pressurisation
- Start-up and restart phases (historically high incident rates)
Turnaround Maintenance Within FPSO Process Safety
Turnaround Maintenance must be treated as a Process Safety Critical Activity, not just a maintenance event.
It directly affects:
- Loss of Containment (LOC) risk
- Barrier health
- Safety Critical Elements (SCEs)
- Major Accident Hazard (MAH) controls
For FPSOs, TAM must be embedded into:
- Process Safety Management (PSM)
- Barrier Management frameworks
- Permit to Work (PTW) systems
- Management of Change (MoC)
Key Phases of Turnaround Maintenance (HSSE View)
1. Planning & Preparation Phase (12–36 Months Ahead)
Process Safety Focus:
- Define scope using risk-based inspection (RBI)
- Identify Safety Critical Elements impacted
- Perform detailed HAZID / HAZOP reviews
- Develop isolation philosophies and procedures
- Contractor HSSE prequalification
Best Practices:
- Freeze scope early to avoid late changes
- Conduct SIMOPS risk assessments
- Align TAM scope with FPSO risk register
2. Shutdown & De-Inventory Phase
Major Hazards:
- Hydrocarbon releases
- Incorrect isolation
- Inadequate depressurisation
Critical Controls:
- Verified isolation and lockout/tagout (LOTO)
- Double block and bleed where applicable
- Gas testing and atmospheric monitoring
- Permit-controlled depressurisation
3. Execution Phase (Maintenance Window)
This is the peak risk period.
Common Hazards:
- Confined space entry
- Hot work
- Dropped objects
- Temporary power installations
- Scaffold failures
Process Safety Controls:
- Strict PTW enforcement
- Toolbox talks before every shift
- Dedicated SIMOPS coordinators
- Continuous gas detection
- Permit audits and site inspections
4. Reinstatement & Pre-Startup Safety Review (PSSR)
Why This Phase Matters Most
Many major accidents occur during restart, not during maintenance.
Key Activities:
- Removal of all temporary modifications
- Verification of valve line-ups
- Instrument calibration checks
- Safety system functional testing
- Confirmation of SCE availability
PSSR Checklist Must Confirm:
- All MoC actions closed
- PTWs closed and signed off
- No blinds, spades, or jumpers left in place
- Alarms and trips fully operational
5. Start-Up & Stabilisation Phase
High-Risk Activities:
- Pressurisation
- Introduction of hydrocarbons
- Control system transitions
Critical Safeguards:
- Start-up procedures strictly followed
- Senior supervision presence
- Real-time monitoring of process parameters
- Emergency response readiness
Safety Critical Elements (SCEs) and Turnarounds
Turnarounds directly affect SCE integrity, including:
- Pressure vessels
- Relief valves
- Emergency shutdown valves (ESDVs)
- Fire and gas detection systems
- Structural supports
Process Safety Rule:
👉 No FPSO should restart unless all required SCEs are verified, tested, and accepted.
Permit to Work (PTW) During Turnaround
PTW systems often fail under turnaround pressure due to volume and complexity.
Best Practices:
- Dedicated TAM PTW teams
- Permit segregation by area and activity
- Digital PTW systems where possible
- Permit audits every shift
- Clear handover protocols
Human Factors in Turnaround Maintenance
Turnarounds amplify human performance risks, including:
- Fatigue from extended shifts
- Cognitive overload
- Time pressure and production bias
- Communication breakdowns
Mitigations:
- Fatigue management plans
- Shift rotation controls
- Clear command hierarchy
- Stop-work authority reinforcement
Lessons Learned From Major Incidents
Industry investigations repeatedly highlight:
- Poor isolation management
- Inadequate restart checks
- Failure to control SIMOPS
- Weak contractor oversight
Turnaround Maintenance is not just a maintenance challenge—it is a process safety leadership test.
🔹 Essential Turnaround Safety Equipment
- Portable Multi-Gas Detectors – For confined space and hydrocarbon monitoring
👉 Check current models on Amazon - Lockout/Tagout (LOTO) Kits – For isolation integrity during shutdowns
👉 View industrial LOTO kits on Amazon - Flame-Resistant (FR) Coveralls – Mandatory PPE during hot work and start-up
👉 Browse FR coveralls on Amazon - Confined Space Rescue Tripods & Harnesses
👉 See certified rescue equipment on Amazon
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Related Topics:
Some of the articles related to turnaround maintenance (TAM) include:
- FPSO Process Safety Management
- SIMOPS Risk Management
- Permit to Work Systems
- Safety Critical Elements (SCEs)
- Management of Change (MoC)
- Major Accident Hazard (MAH) Control
Conclusion
Turnaround Maintenance is one of the most safety-critical events in FPSO operations. When poorly managed, it can dismantle years of safety performance in weeks. When executed with strong process safety discipline, it becomes an opportunity to restore integrity, strengthen barriers, and improve long-term reliability.
For FPSO operators, turnarounds must be planned and led as major process safety events—not maintenance shutdowns.
