Foreman & Supervisor Validation Training
• Petrochemical & Refinery Shutdown Activity
Training Objective
• Validate competency of supervisors ,Foreman
• Ensure safe shutdown execution
• Improve safety & productivity
EQUIPMENT TO WORK
• Vessel
• Heat Exchanger
• Tanks
• Distillation Column
• Fin Fan
• Reactor
• Boilers
• Furnace
• Drum
• Valve
• Line Replacement
• Compressor
Shutdown Workflow
• Planning and preparation
• Isolation and blinding
• Opening and maintenance
• Closing and commissioning
Shutdown workflow
• Opening equipment
• maintenance
• repair
• test
• inspection
• Box up
• start up
Full job procedure
• 👉 “Explain complete job from opening to commissioning”
• Example:
• Receive shutdown plan
• Apply isolation & LOTO Gas testing
• Equipment opening
• Inspection
• Repair
• Replacement
• Reassembly
• Torqueing
• Hydro test / leak test
• Box-up clearance
• Commissioning handover
GENERAL STATIC SUPERVISOR
QUESTIONS
• What is your role as a Static Supervisor during shutdown?
• How do you plan manpower and tools for a shutdown job?
• What documents must be checked before starting any job?
• What is Method Statement (MS) and Job Safety Analysis
(JSA)?
• How do you ensure work is completed within shutdown
timeline?
• What will you do if job is delayed?
• How do you coordinate with operations, safety, and
QA/QC?
• Steps for tray removal and installation ?
• What is torqueing sequence for manhole?
Content
Activity During Shutdown
Blinding Isolation
CSE - Confined space entry
Critical crane lifting
Hydro jetting
Hydro test
Hot work
Work at height
Scaffolding activity
Radiography
Internal tray replacement from column
Bundle Pulling
Valve maintenance
Blinding isolation
Blinding & Isolation
• What is blinding
• Types of blinds
• What is spade spacer
• What is double block and bleed
• How do you track blinds during shutdown
• Ensure positive isolation
• Apply loto system
• Drain, vent and flush lines
• Verify zero energy
Isolation
Loto removal steps
Confined space
Confined space entry
• What is a confined space?
• Safe oxygen level?
• LEL acceptable level?
• What is standby man role?
• What is entry permit requirement?
• Rescue plan in case of emergency ?
• What PPE required inside vessel?
Confined Space Entry
• Valid entry permit required
• Oxygen level 19.5%–23.5%
• Continuous ventilation required
• Standby man must be present
• Gas test
• Rescue plan
• Checklist
• Blind list p&id
• Lighting
Lifting Operations
Lifting & Critical Lifting
• What is critical lifting?
• When lift becomes critical?
• What is lifting plan?
• What is SWL (Safe Working Load)?
• What is role of rigger and signalman?
• What checks before lifting ?
• What is tagline use?
Lifting Operations
• Use certified lifting tools
• Follow approved lifting plan
• Use trained riggers only
• Stop work if unsafe condition
Hydro jetting
Hydro jetting
• 1. Pre-Job Preparation Review method statement & JSA (Job Safety Analysis)Confirm permit to
work (PTW) – hot/cold work as applicable Ensure equipment is isolated, depressurized,
drained, and cooled Blind/lockout all connected lines (LOTO)Gas test if hydrocarbon service
(LEL = 0%)Supervisor check:✔ Drawings (P&ID) available✔ Proper lighting & barricading✔
Emergency plan ready
• 2. Equipment Setup Hydro jet pump, hoses, lance, nozzles inspected Pressure rating of hoses >
operating pressure Foot valve (dead man switch) tested Secure hose routing (no sharp bends
or damage)Typical equipment High-pressure pump Flexible lance Rotating or fixed nozzle PPE
(see below)
• 3. PPE Requirements Helmet with face shield Cut-resistant / hydro jetting suit Safety shoes
(steel toe, anti-slip)Gloves (high-pressure resistant)Hearing protection.
• 4. Hydro jetting Operation Insert lance carefully into tube Maintain proper stance (never in
front of nozzle)Start with low pressure, gradually increase Clean tube from one side to another
Monitor discharge water for debris Critical Safety Points: ⚠ Never point nozzle at body⚠
Maintain communication with pump operator⚠ Stop immediately if vibration/leak observed.
• 5. Post-Cleaning Activities Inspect tubes (visual / bore scope if needed)Flush with clean water
Dry tubes (air blowing if required)Remove blinds and restore system Close PTW after
inspection
Hydro jetting
• Hydro jetting is used to clean fouling (scale, sludge, deposits) inside heat exchanger tubes using high-pressure
water (often 10,000–20,000 psi or more depending on system).
• High-pressure water injection injury Hose burst / whipping Slips due to wet surface Chemical exposure (if residues
present) Noise hazard.
• Supervisor Questions (Very Important)Before Starting Is equipment fully isolated and LOTO applied ?
• Is pressure released and temperature safe?
• Are all workers trained for hydro jetting ?
• Is PTW approved and valid ?
• Are hoses and connections tested ?
• During Job Are workers maintaining safe distance and posture ?
• Is communication clear between lance operator and pump operator ?
• Is pressure within safe limit?
• Any leak, vibration, abnormal noise?
• Safety-Focused Questions What will you do in case of hose burst ?
• Where is the emergency stop / kill switch ?
• Is the area barricaded and access controlled?
• Is first aid available (especially for injection injury)?After Completion Are tubes properly cleaned and inspected ?
• Are all tools and hoses removed safely ?
• Is system ready for reinstatement?
• Has PTW been closed properly?
Hydro test
Hot Work Safety
• Valid hot work permit required
• Gas test must be within safe limits
• Fire watch and extinguisher mandatory
• Remove flammable materials
Safety Leadership
• Conduct toolbox talks
• Report unsafe conditions
• Use Stop Work Authority
• Ensure team coordination
Evaluation Criteria
• Technical knowledge
• Safety awareness
• Confidence and leadership
• Practical experience
Conclusion
• Safety is top priority
• Right person for right job
• Zero incident goal