One of the UK's largest refinery maintenance events required a highly coordinated approach to safety management. With more than 50 contractor companies working across the site and multiple high-risk activities taking place simultaneously, the client needed a partner capable of delivering integrated safety services at scale while maintaining operational efficiency and rigorous safety standards.

Breathe Safety was engaged to provide a comprehensive safety solution covering planning, consultancy, confined space management, rescue support, gas monitoring and specialist equipment provision throughout the turnaround programme.

Working closely with the client during the planning phase, our team supported the development of venting plans, rescue plans, equipment resource plans and digital confined space monitoring strategies. This early engagement ensured that safety controls were aligned with operational requirements before work commenced on site.

The project involved managing a complex network of confined spaces and process areas, many of which presented unique technical challenges. Our specialists provided detailed support for ventilation strategies and safe systems of work, including situations where multiple activities needed to take place simultaneously within the same work area.

A key part of the solution was the deployment of digital confined space monitoring and access control systems across numerous work locations. This provided real-time visibility of personnel movements, improved accountability during emergency situations and helped streamline the management of permits and entry controls.

Alongside monitoring systems, Breathe Safety supplied a wide range of specialist safety equipment, including breathing apparatus, gas detection, ventilation, lighting and monitoring technology. To support continuous operations, dedicated personnel were available around the clock in a variety of safety-critical roles, working as a multi-skilled team capable of responding to changing operational demands.

The integrated approach delivered significant efficiency gains alongside enhanced safety performance. Digital monitoring and coordinated safety management reduced the number of personnel required to oversee confined space operations while maintaining robust control measures. During emergency exercises and operational alarm events, the system enabled personnel to be accounted for more quickly and provided improved communication with workers operating in confined spaces.

To support workforce competency, an on-site training facility was established for confined space and breathing apparatus training. Dedicated workshop and equipment support facilities also ensured equipment remained available throughout the project, minimising the risk of operational delays.

Outcomes

• Integrated safety management delivered for one of the UK's largest and most complex maintenance shutdown projects.
• Comprehensive planning support provided prior to mobilisation, including rescue, ventilation and resource strategies.
• Digital confined space monitoring implemented across multiple work areas.
• Improved personnel accountability and emergency response capability.
• Specialist safety equipment supplied and managed through a single provider.
• Multi-skilled safety teams delivered 24/7 operational support throughout the project.
• Significant efficiencies achieved through centralised monitoring and management.
• On-site training and equipment support facilities reduced downtime and improved operational readiness.
• Enhanced safety, efficiency and value throughout a time-critical maintenance programme.

The Breathe Difference

Complex shutdowns require more than individual safety services. They require a coordinated approach that balances protection, productivity and practicality across an entire project.

For this turnaround, Breathe Safety brought together planning, consultancy, monitoring technology, specialist equipment and multi-skilled personnel into a single integrated solution. By becoming involved early, improving visibility across the site and reducing operational complexity, we helped the client strengthen safety performance while improving efficiency and maintaining project momentum.

The result was a safer, more streamlined shutdown that delivered value at every stage, from planning and mobilisation through to project completion.