1) Why daily inspection is mandatory
Daily rounds are not “walk-throughs”—they are a legal and safety requirement to catch issues early and prevent incidents. For hazardous chemical operations and petrochemical plants, typical requirements include:
Frequency: At least two rounds per day by electrical/instrument teams; hourly patrols for key equipment and major hazard zones.
Communication: Inspectors must carry two-way radios or equivalent comms to stay in contact with the control room.
Maintenance discipline: Safety-critical equipment must be maintained and periodically tested; records must be traceable.
2) Pre-job preparation (don’t skip)
Personal protective equipment (PPE)
Hard hat, safety shoes, anti-static workwear, goggles, multi-gas personal monitor.
Entering toxic areas: carry a portable gas detector and respirator; use SCBA when required.
Readiness check
Instruments/equipment tagged and legible; area clean; no leaks/spills/drips.
Local indicators and HMI/PLC/DCS show normal; no active alarms without work orders.
3) What to inspect (by system)
A) Valves & pneumatic equipment
Air leaks: listen/feel for leakage along tubing, fittings, and positioners.
Actuation: cycle where allowed; no sticking, no abnormal noise.
Shutdown valves: verify command vs. position indication match.
B) Temperature / Pressure / Flow / Level instruments
Tightness: glands, impulse lines, manifolds, and process connections tight & dry.
Heat-trace & insulation: intact and energized when required (winter focus).
Reasonableness check: reconcile local gauges/sights with DCS values; investigate discrepancies.
C) Alarms & analyzers
Gas detectors: powered, healthy, and alarm path tested per plan.
Online analyzers: verify sample flow/pressure/temperature in spec; no condensate or plugging.
D) Seasonal & weather-driven checks
Winter: heat-trace continuity, insulation condition, condensate traps.
Summer: enclosure cooling fans, clean filters, MCC/PLC room temperature & RH.
After storms (rain/wind/snow): outdoor equipment covers, Ex integrity, water ingress, cable tray condition.
4) If you find a problem
Fix now if safe: e.g., tighten fittings, reseat a connector, clear a blocked filter.
If not resolvable on the spot: record details immediately, escalate to shift lead/dispatcher, and track to closure.
Increase patrol frequency for abnormal conditions or when learning from nearby incidents.
5) Documentation—make it traceable
Every round should log time, area/unit, items checked, findings, actions, person.
Use a standardized template for easy retrieval and audits; sign/acknowledge.
6) Quick daily checklist (printable)
Shift/Date: ____ / ____ Unit/Area: __________ Inspector: __________
| Item | Checkpoints | OK | Issue/Notes | Action | Completed by / Time |
|---|---|---|---|---|---|
| PPE readiness | Helmet, shoes, anti-static wear, goggles, gas monitor | ☐ | |||
| Comms | Radio functional; control room contact verified | ☐ | |||
| Housekeeping | Tags legible; no leaks/spills; clear access | ☐ | |||
| Valves/Actuators | Air leaks; stroke/position; shutdown valve indication | ☐ | |||
| Temp/Press/Flow/Level | Connections tight; heat-trace/insulation; values align with DCS | ☐ | |||
| Analyzers/Detectors | Power healthy; sample flow/pressure/temp OK; alarm path | ☐ | |||
| Seasonal focus | Winter: heat-trace/insulation; Summer: fans/filters; After storms: ingress/Ex | ☐ | |||
| Findings escalated | Work orders raised; watch-list updated; patrol freq adjusted | ☐ |
7) Summary
Daily inspection is your plant’s first line of defense. Looking, listening, touching, and comparing readings—every shift, without exception—prevents small deviations from becoming incidents. A disciplined route, clear escalation, and auditable records protect people, assets, and compliance.