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.
Plant Safety Inspection (PSI)
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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.
Plant Safety Inspection (PSI)
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Plant Safety Inspection (PSI)
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