Risk assess the bulk fuel pump seal replacement

What is going on

Delivery pump P2 on the Wodonga bulk fuel installation has a weeping seal. The pump is isolated, a drip tray is in place and the hazard is recorded in the WHS Incident and Hazard Register with an open work order. Leanne Cowell wants the seal replaced before the exercise support period starts. The task involves draining and opening a pump that has held diesel, working inside a bunded area with limited access around the pump skid, handling a heavy pump head and managing ignition sources, static and spills. Tom Whitlock wants a full risk assessment and a job safety analysis before the maintenance crew signs on.

Your brief

Produce a risk assessment and job safety analysis for the P2 seal replacement that identifies every hazard, applies the hierarchy of controls, names responsible persons and links to the hazard and work order records so the crew can start safely.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the Work Health and Safety Policy, the Job Safety Analysis Template and the hazard entry for pump P2 in the WHS Incident and Hazard Register.
• Walk the task with Bec Halloran and break it into steps from isolation and draining to testing and return to service.
• Identify the hazards of each step, including fuel vapour, ignition sources, static, spill, manual handling, restricted access and heat, and decide whether the bunded area meets the definition of a confined space.
• Assess each risk and select controls using the hierarchy of controls, recording elimination and engineering controls before administrative controls and personal protective equipment.
• Complete the Job Safety Analysis Template with steps, hazards, controls and the responsible person for each control, and state the permits required.
• Update the pump P2 hazard entry in the register with the risk assessment reference and the controls agreed, and note the work order number.
• Prepare a written toolbox talk brief for the crew covering the hazards and controls agreed, and record the attendees at sign on.

What someone in this role would produce

• Completed risk assessment
• Completed Job Safety Analysis
• Updated register entry for pump P2
• Toolbox talk brief and attendance record