Case Study: Scaffolding Solutions in Large Refineries

Case Study: Scaffolding Solutions in Large Refineries

Refinery and petrochemical plants, the heart of heavy industry, are the world's most demanding work environments, characterized by high temperatures, active chemical lines, complex pipe bridges, and zero error tolerance. In the "shutdown" (planned outage) maintenance processes or new unit constructions carried out in large-capacity refineries, industrial scaffolding systems form the backbone of the work.

Our engineering and field experiences clearly show that superficial scaffolding planning errors and non-standard applications lie at the basis of occupational accidents and cost overruns in projects. When accident statistics in the sector are examined, we see that falls from height rank first in fatal occupational accidents, and injuries are directly related to scaffolding errors. In this case study, with Deta's industrial vision, we will deeply examine the anatomy of complex scaffolding solutions in refineries, critical errors frequently encountered in the field, and modern digital engineering approaches.

1. Technical Anatomy of Industrial Scaffolding in Refineries

Refineries do not look like standard buildings; there are no flat floors or easy connection points here. For this reason, it is of vital importance to fully calculate the static (TS EN 12810-2) and performance requirements (TS EN 12811-1) of the scaffolding system to be used.

Superiority of Flanged and Wedged Modular Systems

Traditional tube-and-clamp systems remain clunky and unsafe in the complex geometries of refineries. In modern refinery case studies, secure scaffolding products and systems where the connection points are flanges (rosettes) stand out. By passing the wedge-head of horizontal elements into the flanges located every 50 cm on vertical elements and locking the wedges with a hammer, a "positive connection" extremely rigid against torsion is obtained.

Load Classes and Equipment Quality

Steel platforms to be used in scaffolding are divided into load classes (Class 1 to 6) according to the nature of the work to be done. During heavy valve changes or installation of thick steel pipes, steel components suitable for TS 13662 standards are preferred for the platforms to maintain their structural integrity. The fact that the parts are coated with hot-dip galvanization in EN ISO 1461 standards is the primary factor extending the system life in refinery sector sites where the corrosion rate is high.

2. Challenging Field Application Processes and Safety Equipment

The installation process is not just about joining pipes; it is a dynamic risk management. During and after installation, the presence of the following equipment is non-negotiable:

• Main and Intermediate Guardrails: There must be a main guardrail approximately 1 meter above the working level, and intermediate protection elements (intermediate guardrails) must be installed so as not to leave a gap that a 47 cm sphere cannot pass through.
• Toe Board (Skirting): These are wood or metal elements mounted at least 15 cm above the floor level to prevent material from falling from the edges of the working platform.
• Base Jacks: Base jacks must definitely be used to bring the scaffolding system to a perfect level (spirit level) on the grated or inclined floors of the refinery.

3. 3 Critical Errors Encountered in the Field (Field Observations)

In the field audits of Deta's expert engineering team, we identified these three chronic errors that undermine project speed and safety in refineries:

1. Error: Use of Wedges Instead of Base Jacks: Using random wooden wedges, bricks, or barrels instead of standard base jacks to eliminate elevation differences on the ground causes the tons of load coming from the carrier standards of the scaffolding to be transferred to the ground unbalanced, leading to torsion and collapse of the scaffolding.
2. Error: Wedge Connections Not Fully Locked with a Hammer: Assembly teams not fully driving the wedges of the horizontal elements they attach to the flanges with a metal hammer, but pushing them by hand and leaving them. In these scaffoldings working next to vibrating refinery lines, half-locked wedges come out of their places over time, leading to the stretching of node points and the collapse of the platform.
3. Error: Material Stockpiling and Exceeding Load Limits in Scaffolding: Piling up insulation roll sheets, heavy pipe valves, or sandblasting equipment on platforms designed only for personnel walking (Class 2). Workers loading more than the material they need onto the scaffolding or piling materials in a way that prevents passage on the platform causes the steel planks to deflect and ultimately break.

4. Cost Impacts of Scaffolding Planning Errors

Even one hour of production downtime in refineries is equivalent to tens of thousands of dollars.

• Logistics Waste: Bringing scaffolding elements whose galvanization is worn and rusted to the site leads to their rejection during OHS audits and subsequent dismantling.
• Downtime: The interruption of work by OHS engineers due to the installation of scaffolding with missing anchors, gapped platforms, or not fully locked wedges leads to the deviation of the refinery's commissioning schedule after maintenance and causes massive production losses.

5. Future Scaffolding Planning Approach with DetaPlan

Managing scaffolding logistics and installation with manual drawings during the maintenance periods of large industrial facilities is now outdated. DetaPlan guarantees that the scaffolding provides millimetric compatibility with pipes and valves by performing collision detection analyses on the digital twins of complex refinery facilities.

A perfect scaffolding planning process carried out with DetaPlan ensures that only the needed parts are shipped to the site (zero waste), pre-verifies wind and load calculations in the digital environment, and shortens installation times by 30% compared to traditional methods.

Conclusion and Call to Action

Large refinery and petrochemical facilities in Turkey never tolerate "temporary" safety measures in temporary structures. Compliance with TS EN 12810 standards, flawless locking of modular flanged scaffolds with a hammer, and expert engineering planning are the building blocks of success.

If your company has an upcoming shutdown, maintenance, or new facility construction process, do not leave your installation, logistics, and occupational safety risks to chance. Contact the Deta engineering team to digitalize your operations with the power of DetaPlan and experience a unique scaffolding planning process.

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