Caltex’s magazine for employees, franchisees & resellers
Issue 50 Dec – Jan 10
Focus
Work was carried out on cleaning and replacing parts in the refinery’s hydrogen production unit which converts low octane naptha into high octane product
Some T&I participants grew beards as part of a “safety isn’t a close shave” campaign they ran throughout the duration of the five week turnaround.
In this issue:
No close shaves in Lytton refinery turnaround
None of the 250 employees and contractors involved in the turnaround and inspection of Lytton refinery's hydrogen units was injured and the project was completed under budget.
The recent turnaround and inspection of Lytton’s hydrogen units was completed under budget and was injury-free.
It’s true. An unusually large number of men were wearing beards at Lytton refinery during the recent turnaround and inspection (T&I) of its hydrogen units. But it was no coincidence. The impressive chin-warmers were a direct result of Area North operators’ “safety isn’t a close shave” campaign. To create a visual reminder that refinery people need to work and return home safely, the operators decided to grow beards for the duration of the five-week turnaround. A single shift developed the slogan and led with their chins, so to speak. Many others then joined the initiative.
Their determination was vindicated by the best-possible result. None of the 250 employees and contractors involved was injured in the turnaround, which was completed under budget. “We secured great buy-in from the whole site,” says Lytton Event Manager Joe Callaghan. The teamwork involved was very pleasing.” Many people are owed thanks, says Joe, including those who ran the rest of the refinery and managed movements to keep customers supplied during the shutdown, which is scheduled every six years. “The turnaround team, the core teams, contractors, Supply and Distribution, the Kurnell personnel who were instrumental in pre-planning and providing ongoing support, refinery operators and employees who freed up the resources to allow the T&I to happen – they were all involved,” Joe said.
The teams worked on cleaning and replacing parts in the refinery’s hydrogen production unit – known as the reformer, which converts low octane naphtha into high octane product. This meant other units which draw hydrogen also had to be shut down. They included the benzene hydrogenation unit (BHU), the isomerisation unit and the diesel hydrotreating units (DHTU1 & DHTU2). “We actually performed T&I work on three units: the reformer, BHU and DHTU1,” explains Joe. “The T&I crew also did some maintenance or project work on DHTU2 and one of the crude units.”
Morale during the shutdown was high and there were signs the Incident and Injury Free (IIF) program was having an effect, with workers sharing incident-free principles.