p 4 [1 05]=psi plant safety inspection (35) jul.2012

7/30/2019 P 4 [1 05]=PSI Plant Safety Inspection (35) Jul.2012

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Plant Safety Inspection(PSI)

By

A.K. Gupta


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What we shall learn Definition of plant safety inspection

Objectives of PSI

Difference from safety survey,safety tour and safety sampling

Techniques of PSI

Types of inspection Inspection procedure

Benefits of PSI


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PSI is a method of discoveringhazards and potential risks.

Its basic aim is to identify andeliminate or minimise hazards inthe jobs before accidents canoccur. (Proactive approach)

It is useful in accident preventionjust as product inspection is inquality control.

It is one of the oldest techniques

of accident prevention.

Plant Safety Inspection (PSI)


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Development of safety-related statutoryregulations and inspections by Factory

Inspectorate have given impetus to PSI. Not only unsafe conditions, but all unsafe

acts should also be noted.

Since majority of accidents are caused byunsafe acts, it is necessary that all unsafeacts are noted in each PSI round.



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It may not be possible to find all hazards

in the entire plant in a single inspection.

Hence regular periodic inspections arenecessary.

PSI helps in adopting safe practices with

an ultimate aim of removing all unsafeacts and unsafe conditions.



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How is PSI different from: Safety survey,

Safety tour,

Safety sampling, and

Safety audit?


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What is the difference?

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Safety Inspection: A scheduled inspection ofa plant or unit

Safety Survey: A detailed examination of anarrow field

Safety Tour: An unscheduled tour of a plant orunit carried out by an outsider (a person from

a different department) such as the S.O. orother dept. manager or the Works Manager.

Safety Sampling: A statistical method withspecific application of a safety tour designed

to measure the accident potential. (Contd.)


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PSI vs. Safety Audit [RoSPA] A safety inspection is generally limited to a

detailed examination of the physical conditions

within an organisation so that an assessment can

be made of basic legal compliance or of meeting

the specification.

A health and safety audit is the collection of

independent information pertaining to theefficiency and reliability of the organisation's total

OH&S management system and involves drawing

up plans for corrective action where necessary.

10(Contd.)


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PSI vs. Safety Audit Inspection is to examine closely any equipment or

facility. It may be formal (with a plan and a checklist)or informal. Examples:

Inspection of a Fire Tender with a checklist for itsoperability, worthiness of its pump, fire monitor, etc.

Inspection of the pressure vessel for finding any deformity,corrosion, thinning, etc.

Safety Audit is a process of evaluation that is basedon standards, statutes and guidelines and it identifiesthe compliance and non-compliance based onstandards and applicable statutes.

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Technique of PSI Take round of the plant.

Record all unsafe practices and any deviations

from statutory requirements, SOPs, SMPs andthe companys HSE Policy.

Find facts, not faults of persons.

Record all findings and give recommendations. Faults and deviations should be corrected by

the line manager or under his authority.


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Making Physical or

Mechanical Conditions Safe This can be achieved by:

Selecting safer raw materials and processes

Erecting plants according to standards Incorporating systems safety or built-in safety

Machine guarding and fencing

Instrumentation for safe operations

Interlocks, alarms and trips

Developing and implementing safe work procedures

Maintaining plant integrity


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Developing Safe Attitudes Changing employee attitude is the key.

Education and training

Managers/Supervisors setting examples

Adherence to work procedures

Encouraging use of required PPE

Plant safety rounds or SAE rounds / STOP

(Safety Tour and Observation Programme)

Addressing OH&S-related problems promptly


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Involving workers is useful Plant managers, supervisors or safety

officer carrying out PSI could make it

more successful by consulting workers,thus

Enlisting their cooperation

Getting useful suggestions from them Realising practical aspects of problems

Making implementation of any changes orrecommendations easy


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Visible Safety Management Regular plant safety inspections and

prompt corrective measures go a long

way in demonstrating managementinterest in and commitment to OH&S

High employee morale

Maintaining employee interest in OH&S Encouraging employees to report hazards

Safe employee attitude


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Responsibility for PSI Any competent plant personnel can carry

out PSI.

Safety is basically a line managementresponsibility (line function).

Hence, the line management is mainly

responsible for PSI. The responsibility for PSI should be shared

by all concerned in the line function.


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Responsibility for PSI (Contd.) Within the plant, all personnel at various

levels should clearly understand their

responsibilities and functions to implementthe management objectives through theirindividual and coordinated efforts.

In addition, PSI can also be carried out by the

staff functions like safety officer, maintenanceengineer, etc.

It is a good practice to involve both the linefunction and the staff function in PSI.


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1.PSI by Line Function By Senior Management:

Safety starts from top

Set examples Interest in OH&S can be created and sustained at all

levels if senior management makes it obvious that it iskeen on safety

Ensure that a safety policy is formulated and implementedeffectively

Ensure that all legal obligations are met

Carry out PSI on a regular basis

Regular PSI by senior management shows it is committedto OH&S

Workers feel that management cares for them.

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1. PSI by Line Function (Contd.) By Line Supervisors:

As an integral part of his duty, each supervisor

should look out for any U.A. or U.C. in hisdepartment.

Besides continual inspection of this type, he

should carry out PSI regularly

He should also periodically carry out special

inspections of the equipment in his department

Report to senior management and take corrective

actions promptly

Ensure all procedures and safety rules are

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1. PSI by Line Function (Contd.) By Workers:

Since workers are closely in the

know of the plant, equipmentand tools, etc., they can easilydetect any hazard, unsafecondition, defect, or abnormality.

They should be encouraged toreport any hazard, defect, orabnormality to the management.


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2. PSI by Staff Function By Maintenance Staff:

They can make an effective

contribution to OH&S bycarrying out PSI and

maintaining equipment in

safe condition

They can enhance safety by

carrying out preventive and

planned maintenance.


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2. PSI by Staff Function (Contd.) By Safety Officer:

S.O. can play a useful role in PSI

He knows the statutory requirements betterthan others

He will have a different perspective and beunbiased unlike people from the samedepartment

He may identify U.A. and U.C., whichotherwise would have been overlooked bythe plant staff.


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Types of Inspection There are 5 types of inspections:

(1) Periodic Inspection

(2) Intermittent Inspections

(3) Continuous Inspections

(4) Special Inspections

(5) Statutory Inspections

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Types of Inspection(1) Periodic Inspection

It is well planned and carried out

at regular intervals Periodicity of PSI would depend

upon the need

Generally, it is carried out by theline function, but it may be

carried out by staff function aswell.

They may also include statutoryinspections


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Types of Inspection (Contd.)(3) Continuous Inspections

Some selected employees spend their time in

maintaining and serving certain equipment oroperations Instrument technicians

Electricians

Example: Continuous inspection of tools in the tool-

room of a workshop, or scaffold material Inspection of equipment/ pipelines on a continuous

basis (Mech./Elec./Inst. Departments)

Supervisors ensuring that subordinates follow all

procedures and safety rules at all times.


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Types of Inspection (Contd.)(4)Special InspectionsCertain occasions or situations

may require special inspections: New building or plant

New equipment or process

Any plant change or modification

Scaffolding Machine guards

Illumination

Noise

Health and hygiene, etc.Noise Meter

Lux Meter


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Inspection Procedure Persons carrying out inspections should be

competent and familiar with the process,

equipment and operations, associatedhazards and the precautions to be taken.

They should also be familiar with thecompanys OH&S policy, the safety rules and

all applicable statutes dealing with OH&S.


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Inspection Procedure (Contd.) Checklists can be very useful.

Should be prepared by knowledgeable

and experienced persons. It eliminates chances of forgetting or

overlooking certain aspects of inspection.

Checklist is a means of transferring

experience to less experiencedpersons.
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Inspection Procedure (Contd.) Prepare an inspection report and give

recommendations, where necessary.

Indicate responsibility and the target date forimplementation against each recommendation.

Report should be clear and concise.

Distribute copy of the report to all concerned

for implementation of recommendations. Have a periodic review and follow up the

progress of implementation of approvedrecommendations.


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Thank you foryour attention

p 4 [1 05]=psi plant safety inspection (35) jul.2012

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