FQM Ravensthorpe Nickel – Sulphuric Plant Shutdown and Maintenance

LOCATION

Ravensthorpe Nickel, Western Australia

INDUSTRY

Nickel Processing

Scope of Work

Provision of all labour, supervision, tools, equipment, consumables, and specialist services required to safely execute the Sulphuric Acid Plant shutdown, maintenance, inspection, repair, and reinstatement works. The scope also included isolation, draining, flushing, neutralisation and preparation of equipment handling strong sulphuric acid and process gas streams; inspection and maintenance of drying and absorption towers, acid distribution systems, mist eliminators, packing, internals, and associated piping; inspection and maintenance of gas cleaning equipment, ductwork, demisters, scrubbers, fans, dampers and associated systems.

All works performed in accordance with approved shutdown procedures, hazardous-area requirements, confined-space controls, acid and gas exposure controls, environmental requirements, quality requirements, and the Client’s permit-to-work and isolation systems, with full documentation and inspection records provided prior to plant recommissioning.

Project Resourcing:

APMS was engaged to supply suitably qualified and experienced specialist acid workforce of up to 110 personnel to support the Sulphuric Acid Plant shutdown and maintenance activities. The specialist team comprised of experienced supervisors, trades personnel, acid technicians, fitters, boilermakers, riggers, mechanical personnel, inspectors and other suitably qualified resources as required to safely execute the planned works.

All personnel attended the Client’s site induction, competency, medical, HSE and permit requirements and were appropriately equipped and trained for work involving corrosive acid and hazardous process gas environments.

Project Achievements:

110 specialist acid personnel with demonstrated experience in sulphuric acid plant shutdowns.
Strict isolation, LOTO, depressurisation, draining, flushing and neutralisation of acid and gas systems.
Robust controls for strong acid exposure, SO₂/SO₃ and other hazardous process gases.
Continuous atmospheric monitoring and gas testing in work areas and confined spaces.
Dedicated confined-space entry controls, including standby personnel, rescue equipment and emergency response arrangements.
Comprehensive PPE and acid-resistant protective equipment requirements for all personnel.
Controlled acid removal, containment and disposal to prevent personnel exposure and environmental release.
Formal permit-to-work, SIMOPS and task risk assessment/JHA processes.
Strict controls for hot work, line breaking, working at height and lifting operations.
Emergency response and rescue plans established for acid, gas exposure, fire and confined-space incidents.
Strong housekeeping and access/egress controls throughout the shutdown.
Daily pre-starts, toolbox talks and safety coordination meetings with Client teams.
Continuous HSE supervision, field verification and stop-work authority for unsafe conditions.
Formal reinstatement and pre-commissioning safety checks prior to introducing acid or process gas.