Risk Level

Task/Step Potential Hazards Control Measures

(Low/Med/High)
- Electric shock
- Strictly follow Lockout-Tagout (LOTO)
from power not
procedures for electrical isolation
fully isolated
- Incorrect valve
isolation causing - Confirm isolation with operations team
1. System unexpected fluid before proceeding
release High
Isolation
- Ensure double block and bleed for valve
isolation where possible
- Use personal protective equipment (PPE)
including insulated gloves and lockout devices
for electrical isolation.
- Exposure to hot - Drain pump and piping slowly to release
condensate pressure
- Leaks or spills
- Wear heat-resistant gloves and protective
causing slip
clothing
hazards
- Burns or scalding
2. Draining - Use containment trays or catchment devices
from steam or hot
Pump and Medium to control spills
fluids
Lines
- Allow system to cool down before draining,
if possible.
- Have a spill kit readily available to handle
any leaks.
- Post signs indicating wet/slippery areas.
- Exposure to
- Verify that all pressure is relieved from the
residual pressure
system before disconnection
or fluid
- Injuries from
- Use proper tools and lifting aids for flange
handling heavy
handling
flanges or tools
- Gasket removal
3. may release
Disconnect Medium - Wear gloves, goggles, and face shield to
trapped
Piping protect from splashes
condensate or
chemicals
- Place blanking caps on disconnected piping
to prevent spills or contamination

- Use proper ergonomics and team lifting

techniques for heavy parts.
4. - Electric shock - Strict adherence to LOTO procedure and
High
Disconnect from improper ensure zero voltage check using a voltmeter
 isolation
- Damage to - Wear insulated gloves and use non-
electrical wiring conductive tools
- Cutting or
abrasion injuries - Ensure that disconnected wiring is properly
Electrical from exposed labeled and safely secured
wires
- Use barriers to protect against inadvertent
contact with exposed wires
- Involve qualified electricians for electrical
work.
- Pinch points from
- Use proper tools such as coupling pullers to
coupling
avoid sudden release of tension
disassembly
- Misalignment
- Ensure proper alignment markings during
leading to difficulty
dismantling for easier reassembly
in reinstallation
5. - Injuries from
Dismantling sudden release of Medium - Wear hand protection to avoid pinch
Coupling injuries
tension
- Verify that the coupling is supported
properly before disassembly to prevent it
from falling or shifting.

- Communicate with team members.

- Crushing injuries
- Use a certified crane or hoist with properly
from improper
rated slings and chains
lifting
- Load shifting - Inspect lifting gear (slings, shackles, hooks)
during lifting before use
- Equipment falling - Ensure the load is balanced and evenly
6. Lifting
or dropping distributed
Pump and High
Motor - Establish a clear exclusion zone during
lifting to keep personnel at a safe distance

- Use spotters for safe maneuvering

- Follow lifting plan carefully.

- Secure the pump and motor properly on the

7. - Load shifting
transport vehicle with ratchet straps or other
Transport during transport
Medium securing devices
to
- Injuries from - Use padding or protective covers to avoid
Workshop
equipment falling damage during transport
 off vehicle
- Damage to pump
- Plan and clear transport route to ensure no
or motor during
obstructions
transport
- Use proper manual handling techniques
when securing and unloading equipment.

- Ensure stable offloading in workshop.

General Hazards and Controls

1. Slips, Trips, and Falls:

o Hazards: Wet or oily surfaces from condensate or lubricants.
o Control Measures:
 Keep the work area clean and dry.
 Use spill containment measures and clean up any leaks immediately.
 Wear slip-resistant footwear.
2. Manual Handling:
o Hazards: Back strain or muscle injuries from lifting heavy components.
o Control Measures:
 Use mechanical aids (cranes, hoists) for heavy lifting.
 Train workers in proper lifting techniques.
 Ensure team lifting is done for large or heavy parts.
3. Confined Spaces:
o Hazards: Oxygen deficiency, heat stress, or toxic gases if the pump is in a
confined space.
o Control Measures:
 Obtain a confined space entry permit and ensure ventilation.
 Use gas detection equipment and wear proper PPE (e.g., respirators) if
necessary.
4. Chemical Exposure:
o Hazards: Exposure to chemicals (e.g., cleaning agents, residual process fluids)
during disassembly.
o Control Measures:
 Wear appropriate chemical-resistant PPE.
 Follow Material Safety Data Sheet (MSDS) guidelines for handling
chemicals.
 Use proper containment for any hazardous liquids.
5. Noise Hazards:
o Hazards: High noise levels from operating nearby equipment or power tools.
o Control Measures:
 Wear hearing protection (earplugs or earmuffs) in high-noise areas.

Emergency Preparedness
  First Aid Kits: Ensure first aid kits are readily available and workers know their
locations.
 Emergency Evacuation Plan: Have an emergency plan in place in case of incidents
(e.g., spills, injuries).
 Fire Extinguishers: Check that fire extinguishers are present and in working order in
case of electrical or mechanical fires.

Risk Levels and Priority of Control

 High Risk: Immediate control measures needed (e.g., LOTO, crane lifting).
 Medium Risk: Controls to be applied and monitored (e.g., manual handling, slip
hazards).
 Low Risk: Standard controls are sufficient but should be reviewed regularly (e.g., noise,
minor leaks).