Refineries and petrochemical plants present unique dust risks: catalyst fines, coke and carbonaceous dust, insulation fibres, and general construction debris during turnarounds. Some dusts are respirable, some are combustible, and many are generated in awkward, high-energy locations.

Plan by task, zone and hazard

Map tasks against hazardous area zoning and COSHH assessments. Prioritise enclosed or remote methods. Confirm whether dust is combustible or toxic and specify equipment accordingly. Coordinate with permits to work, lockout/tagout and confined space rules.

Source capture and LEV

Use tool-mounted extraction for cutting and grinding and select LEV with materials compatible with site chemistry and temperature. For catalyst handling, use close-capture hoods and minimise drop heights. Avoid free falls from transfer points; fit skirts and seals.

Air control and containment

Where indoor or inside vessels, create containments and run negative pressure using air scrubbers with high-efficiency (H13–H14) filtration, ducting exhaust to a safe area. Size units on required air changes and verify airflow under load. Use differential pressure or smoke tests to check integrity.

Housekeeping and maintenance

Avoid sweeping and compressed air. For zoned or potentially explosive areas, use ATEX-appropriate industrial vacuums and anti-static tooling. Plan filter changes and waste handling so fines are not released; double-bag and label. Maintain LEV and record inspections.

People and verification

Provide task-appropriate RPE (typically P3), train on donning/doffing and decontamination, and manage clothing to prevent carry-over. Use particulate monitors to trend PM peaks and confirm that controls are effective before hand-back.

Practical takeaways

• Match controls to zoning, chemistry and temperature from the start.
• Use LEV and close-capture methods; minimise material drop heights.
• Run negative pressure with H13–H14 filtration where containment is feasible.
• Vacuum-only housekeeping with ATEX-appropriate equipment.
• Trend PM levels and maintain clear COSHH/DSEAR records.

With disciplined planning and the three-layer approach—source, air, surfaces—plants can reduce exposure, avoid contamination and keep turnarounds on schedule.