01
Hazard
Unexpected pump startup
Potential Consequence
Crushing or serious injury
Persons at Risk
Maintenance workers
Existing Controls
LOTO and zero-energy verification
Additional Controls
Verify all energy sources using a checklist
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Ready Risk AssessmentMaintenance9 Hazards
Pump Maintenance Risk Assessment
Review the critical hazards, potential consequences, persons at risk and recommended control measures for Pump Maintenance in one professional HSE workspace.
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Pump Maintenance Hazards & Controls
Review the key hazards, consequences and control measures for Pump Maintenance in a structured professional HSE format.
02
Hazard
Process fluid release
Potential Consequence
Chemical exposure or slip hazard
Persons at Risk
Maintenance crew
Existing Controls
Isolation and draining
Additional Controls
Provide catch trays and spill kit
03
Hazard
Handling heavy pump components
Potential Consequence
Crushing or musculoskeletal injury
Persons at Risk
Maintenance personnel
Existing Controls
Lifting equipment and suitable rigging
Additional Controls
Verify component weight before lifting
04
Hazard
Unexpected pump startup
Potential Consequence
Crushing, cutting or fatality
Persons at Risk
Maintenance personnel
Existing Controls
LOTO and zero-energy verification
Additional Controls
Independently verify electrical and process isolation before maintenance
05
Hazard
Hot or hazardous fluid remaining in pump
Potential Consequence
Burn or chemical exposure
Persons at Risk
Maintenance workers
Existing Controls
Drainage, flushing and process isolation
Additional Controls
Verify contents and temperature before opening the pump casing
06
Hazard
Contact with coupling or rotating parts
Potential Consequence
Hand or limb injury
Persons at Risk
Maintenance and operations personnel
Existing Controls
Guarding and controlled test run
Additional Controls
Do not operate equipment with guards removed and control the test area
07
Hazard
Residual process material when opening pump casing
Potential Consequence
Chemical or thermal injury
Persons at Risk
Maintenance personnel
Existing Controls
Drainage, flushing and isolation
Additional Controls
Verify zero pressure and safe temperature before opening the casing
08
Hazard
Unexpected pump rotor movement
Potential Consequence
Entrapment or laceration
Persons at Risk
Maintenance workers
Existing Controls
LOTO and mechanical restraint
Additional Controls
Verify isolation of motor and driven equipment separately
09
Hazard
Manual lifting of heavy pump components
Potential Consequence
Musculoskeletal or crushing injury
Persons at Risk
Maintenance crew
Existing Controls
Mechanical lifting and team handling
Additional Controls
Use suitable lifting equipment for casing, impeller or motor components
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