Risk Management Assessment During Maintenance Shutdown of a Water-Tube Boiler in a Petroleum Refinery: A Case Study

Abstract

In process industries with continuous production, scheduled maintenance shutdowns are essential to ensure equipment reliability and efficiency, but they also involve significant challenges, especially regarding safety. This study analyzes risk management and safety procedures implemented during the maintenance shutdown of a water-tube boiler in a petroleum refinery. By monitoring the process, it was possible to evaluate the risk management methodology used, identify failures and procedural deviations, and propose improvements. Although no serious accidents occurred, the recorded incidents revealed vulnerabilities, highlighting the need for preventive adjustments and targeted interventions. The study demonstrates that effective safety management contributes directly to the operational success of complex shutdowns and can strengthen organizational safety culture. As a result, practical recommendations were developed to support future shutdowns of similar equipment, emphasizing that occupational safety should be integrated into strategic planning rather than treated merely as a legal obligation.