01
Hazard
Unexpected rotation
Potential Consequence
Entanglement or amputation
Persons at Risk
Maintenance workers
Existing Controls
LOTO and mechanical blocking
Additional Controls
Verify mechanical energy at zero
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Ready Risk AssessmentMaintenance9 Hazards
Rotating Equipment Maintenance Risk Assessment
Review the critical hazards, potential consequences, persons at risk and recommended control measures for Rotating Equipment Maintenance in one professional HSE workspace.
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Rotating Equipment Maintenance Hazards & Controls
Review the key hazards, consequences and control measures for Rotating Equipment Maintenance in a structured professional HSE format.
02
Hazard
Guard removal
Potential Consequence
Exposure to moving parts
Persons at Risk
Maintenance personnel
Existing Controls
Energy isolation
Additional Controls
Do not test-run before guards are reinstalled
03
Hazard
Handling heavy rotor or coupling
Potential Consequence
Crushing or muscle injury
Persons at Risk
Maintenance team
Existing Controls
Suitable lifting equipment
Additional Controls
Verify component center of gravity and weight
04
Hazard
Unexpected rotor movement
Potential Consequence
Crushing or limb injury
Persons at Risk
Maintenance workers
Existing Controls
LOTO and mechanical blocking
Additional Controls
Verify rotor is fully stopped and restrained
05
Hazard
Pinch points during coupling alignment
Potential Consequence
Hand or finger injury
Persons at Risk
Maintenance personnel
Existing Controls
Suitable alignment equipment
Additional Controls
Keep hands clear of couplings and movable components
06
Hazard
Incorrect guard installation
Potential Consequence
Contact with rotating parts
Persons at Risk
Operations and maintenance personnel
Existing Controls
Pre-start guard inspection
Additional Controls
Verify all guards are complete and secure before startup
07
Hazard
Stored mechanical energy in rotor
Potential Consequence
Sudden movement or entrapment
Persons at Risk
Maintenance personnel
Existing Controls
LOTO and mechanical blocking
Additional Controls
Verify the rotor is fully stopped and mechanically restrained
08
Hazard
Hand entrapment during coupling alignment
Potential Consequence
Hand or finger injury
Persons at Risk
Maintenance workers
Existing Controls
Alignment tools and controlled working
Additional Controls
Use suitable alignment equipment without placing hands between couplings
09
Hazard
Incomplete reinstallation of guard
Potential Consequence
Contact with rotating parts
Persons at Risk
Operations and maintenance personnel
Existing Controls
Pre-start inspection
Additional Controls
Verify all guards are complete and secure before startup
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