Inspection frequencies - Chemicals/Petrochemicals/Pharmaceuticals

Chemical/ Petrochemical/ Pharmaceutical Industries

A guide to inspection frequencies

Employers have a duty of care to ensure the health, safety and welfare of their employees. Periodic inspections and/or thorough examinations on their plant and equipment form part of this vital duty, whilst also ensuring employer conformity to applicable health and safety legislation.

Manufacturers rely on a wide range of equipment and process plant for their day-to-day operations, with various work processes occurring depending on the type of business operation.

Plant and equipment within the workplace needs to be examined and properly maintained to ensure it is safe to operate, and that it complies with applicable health and safety legislation; requiring statutory examinations at specific intervals, which exist outside normal equipment maintenance and servicing procedures.

Regular inspections may also serve as a good preventative maintenance programme to ensure the integrity of plant and equipment; helping to minimise machinery breakdowns and production downtime.

Inspection frequencies

Different types and categories of equipment have varying inspection frequencies according to applicable health and safety legislation.

Typical equipment and installations found within the chemical, petrochemical and pharmaceutical industries are listed below, together with the applicable legislation.

UK

Lifting

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months)
Lifting Operations and Lifting Equipment Regulations 1998	Mobile crane (goods only)	12
	Forklift truck (goods only)	12
	Forklift truck: lifting attachments	12
	Jib crane (manual/powered)	12
	Mobile elevating work platform (MEWP)	6
	Trolley	12
	Miscellaneous lifting accessories	6
	Fall protection equipment (harness with lanyard)	6

(1) For Northern Ireland, similar statutory equipment legislation is applicable.

Boiler/Pressure

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months) (2)
Pressure System Safety Regulations 2000	Boiler	14
	Cryogenic vessels	60
	Jacketed vessels	14/26
	Steam pipework and manifolds	14
	Other pipework and manifolds	Dependent on risk assessment
Provision and Use of Work Equipment Regulations 1998	Compressed air vessel	12

(1) For Northern Ireland, similar statutory equipment legislation is applicable. (2) Examination intervals for statutory pressure systems are dictated by a Written Scheme of Examination; a legal document that details the items within the pressure system, including protective devices, and outlines the inspection frequency and requirements.

Electrical/Mechanical Plant

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months)
Provision and Use of Work Equipment 1998	General mechanical and electrical plant (e.g. motors, pumps)	12
	Process machinery	12

(1) For Northern Ireland, similar statutory equipment legislation is applicable.

Local Exhaust Ventilation

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months)
The Control of Substances Hazardous to Health Regulations 2002	Fume extraction	14
	Dust extraction (metallic)	6/14 (2)
	Dust extraction (non-metallic)	14

(1) For Northern Ireland, similar statutory equipment legislation is applicable. (2) 6-month frequency if used for more than 12 hours per week. Otherwise, a 14-month frequency.

Storage of hazardous substances

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months)
Control Of Major Accident Hazards Regulations 2015	Storage tank	Dependent on risk assessment

(1) For Northern Ireland, similar statutory equipment legislation is applicable.

Electrical Systems

Applicable legislation (1)	Typical equipment	Inspection/thorough examination frequency (months) (2)
Electricity at Work Regulations 1989	Low voltage electrical installations: general areas	12/36: dependent on risk assessment
	Low voltage electrical installations: petroleum	12
	Portable appliances	12

(1) For Northern Ireland, similar statutory equipment legislation is applicable. (2) The frequency of period inspection for electrical systems, installations and equipment covered by the Electricity at Work Regululations 1989 is dependent on the type and use of the installation, the quality and frequency of maintenance and any external influences which the installation may be subject to.

Ireland

Lifting

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months)
S.I. No. 299 of 2007: Safety, Health and Welfare at Work (General Application) Regulations 2007	Mobile crane (goods only)	12
	Forklift truck (goods only)	12
	Forklift truck: lifting attachments	12
	Jib crane (manual/powered)	12
	Mobile elevating work platform (MEWP)	6
	Trolley	12
	Miscellaneous lifting accessories	6
	Fall protection equipment (harness with lanyard)	6

Boiler/Pressure

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months)
S.I. No. 445 of 2012: Safety, Health and Welfare at Work (General Application) (Amendment) Regulations 2012	Boiler	14
	Cryogenic vessels	36/60
	Jacketed vessels	14/26
	Steam pipework and manifolds	14
	Other pipework and manifolds	Dependent on risk assessment
S.I. No. 299 of 2007 (Regulation 30): Safety, Health and Welfare at Work (General Application) Regulations 2007	Compressed air vessel	12

Electrical/Mechanical Plant

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months)
S.I. No. 299 of 2007 (Regulation 30): Safety, Health and Welfare at Work (General Application) Regulations 2007	General mechanical and electrical plant (e.g. motors, pumps)	12
	Process machinery	12

Local Exhaust Ventilation

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months) (1)
Health & Safety Authority: Local Exhaust Ventilation (LEV) Guidance document	Fume extraction	12
	Dust extraction (metallic)	12
	Dust extraction (non-metallic)	12

(1) Unless specified otherwise by the manufacturer.

Storage of hazardous substances

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months)
S.I. No. 209 of 2015: Chemicals Act (Control of Major Accident Hazards involving Dangerous Substances) Regulations 2015	Storage tank	Dependent on risk assessment

Electrical systems

Applicable legislation	Typical equipment	Inspection/thorough examination frequency (months)
S.I. No. 299 of 2007 (Part 3): Safety, Health and Welfare at Work (General Application) Regulations 2007	Low voltage electrical installations: general areas	12-60 - Dependent on risk assessment
	Low voltage electrical installations: petroleum	36 - Retail and private (1)
		12 - Bulk storage areas (1)
	Portable appliances	3-60 (2)

(1) Unless specified otherwise by a risk assessment/the manufacturer. (2) A general guide, unless specified otherwise by a risk assessment/the manufacturer.

How HSB can help

HSB Inspection Services: Our network of competent, multi-skilled Engineer Surveyors help customers throughout the UK and Ireland to maintain workplace equipment safety, optimise the efficiency of plant and equipment, and comply with applicable health and safety legislation; covering boiler/pressure, lifting, electrical/mechanical, dust and fume extraction, power press equipment, and fixed wiring installations.

HSB Risk Management Solutions: We can help businesses to reduce risks, costs, and deliver compliance via improved analysis of their equipment and health and safety practices. Consisting of three services, each service is further split into modules, allowing customers to build them to fit their business.

HSB Inspection Services HSB Risk Management Solutions