01
Hazard
Unexpected equipment movement
Potential Consequence
Pinch or crush injury
Persons at Risk
Maintenance workers
Existing Controls
LOTO
Additional Controls
Do not test-run before alignment work is complete
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Ready Risk AssessmentMaintenance9 Hazards
Pump Alignment Risk Assessment
Review the critical hazards, potential consequences, persons at risk and recommended control measures for Pump Alignment in one professional HSE workspace.
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Pump Alignment Hazards & Controls
Review the key hazards, consequences and control measures for Pump Alignment in a structured professional HSE format.
02
Hazard
Hand pinch at coupling
Potential Consequence
Hand injury
Persons at Risk
Maintenance personnel
Existing Controls
Safe hand positioning
Additional Controls
Use controlled adjustment methods at coupling
03
Hazard
Movement of heavy motor or pump
Potential Consequence
Crushing injury
Persons at Risk
Maintenance crew
Existing Controls
Jacking or suitable lifting equipment
Additional Controls
Do not place hands beneath equipment without secure support
04
Hazard
Pinch point between couplings
Potential Consequence
Hand or finger injury
Persons at Risk
Maintenance workers
Existing Controls
LOTO and suitable alignment tools
Additional Controls
Keep hands clear between couplings during alignment
05
Hazard
Unexpected equipment rotation
Potential Consequence
Entrapment or serious injury
Persons at Risk
Maintenance personnel
Existing Controls
LOTO and mechanical control
Additional Controls
Verify isolation of motor and driven equipment separately
06
Hazard
Incorrect alignment causing equipment failure
Potential Consequence
Vibration, mechanical failure or component release
Persons at Risk
Operations and maintenance personnel
Existing Controls
Alignment measurement and tolerance verification
Additional Controls
Verify manufacturer tolerances before startup
07
Hazard
Hand or finger entrapment at coupling
Potential Consequence
Hand or finger crushing injury
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Do not align couplings by hand and use suitable alignment equipment
08
Hazard
Unexpected pump startup during alignment
Potential Consequence
Serious injury from contact with moving parts
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Verify electrical and mechanical isolation before alignment
09
Hazard
Alignment measuring equipment inadequately secured
Potential Consequence
Dropped or ejected device or incorrect measurement
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Secure measuring devices in accordance with manufacturer instructions
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