Safe Work Procedure: Unplugging a Pump and Pipelines with Hot Water

Document Number: [SWP-NUMBER]
Revision Date: [DATE]
Next Review Date: [NEXT REVIEW DATE]
Department: [DEPARTMENT NAME]

1. Scope

This procedure covers the safe unplugging of pumps and pipelines using hot water. It applies to maintenance and cleaning operations where blockages in pipelines need to be cleared using hot water. This procedure is applicable in environments where pressurized systems are used and where there is a risk of exposure to hot water and steam.

This procedure should be used in conjunction with the company's lockout/tagout procedures and any other relevant safety protocols.

2. Definitions

Lockout/Tagout (LOTO)
A safety procedure used to ensure that machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work.

Pressurized System
A system that operates under pressure, such as pipelines or vessels containing fluids or gases.

Hot Water Unplugging
The process of using hot water to clear blockages in pipelines.

3. Responsibilities

3.1 Supervisors

Ensure all workers are trained in this procedure.
Verify that all safety equipment and PPE are available and in good condition.
Conduct regular safety audits to ensure compliance with this procedure.

3.2 Workers

Follow the safe work procedure as outlined.
Use all required PPE and safety equipment.
Report any unsafe conditions or incidents to the supervisor immediately.

3.3 Health and Safety Representative

Monitor compliance with safety procedures.
Provide feedback and recommendations for improving safety practices.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Hot water and steam	Burns and scalds	Use appropriate PPE, including gloves and face shields [1]
Pressurized systems	Sudden release of pressure causing injury	Ensure systems are depressurized before maintenance [1]
Electrical equipment	Electric shock	Follow lockout/tagout procedures [2]

5. Personal Protective Equipment (PPE)

Proper PPE is essential to protect against burns, scalds, and other injuries.

Heat-resistant gloves - Protect hands from hot surfaces and water.
Face shield - Protect face from splashes of hot water.
Safety goggles - Protect eyes from steam and hot water.
Protective clothing - Long sleeves and pants to protect skin from hot water.
Safety boots - Non-slip and heat-resistant to protect feet.

Inspect PPE before use and replace any damaged items.

6. Equipment and Tools

Using the correct equipment and tools is crucial for safety and efficiency.

Pressure relief valves - Ensure they are functioning to prevent overpressure.
Hot water hoses - Rated for high temperatures and pressures.
Lockout/tagout devices - For securing energy sources.
Thermometers - To monitor water temperature.
Pressure gauges - To monitor system pressure.

Inspect equipment regularly and maintain according to manufacturer guidelines.

7. Pre-Job Requirements

7.1 Training and Competency

Workers must be trained in lockout/tagout procedures and the use of PPE.

7.2 Pre-Job Briefing

Discuss the procedure, potential hazards, and emergency response actions with all team members.

7.3 Work Area Preparation

Ensure the area is clear of unnecessary personnel and equipment. Set up barriers and warning signs.

8. Safe Work Procedure Steps

Step 1: Preparation

Ensure all necessary equipment and PPE are available and in good condition.

Verify that the system is depressurized.
Confirm that lockout/tagout procedures are in place.
Check that all safety devices are operational.

Step 2: Unplugging

Carefully introduce hot water into the system to clear blockages.

Gradually increase water temperature and pressure.
Monitor pressure gauges to avoid overpressure.
Use thermometers to ensure water temperature is within safe limits.

Step 3: Completion

Once the blockage is cleared, safely shut down the system.

Depressurize the system completely.
Remove lockout/tagout devices following proper procedures.
Conduct a final inspection to ensure the system is safe for operation.

9. Precautions and Safety Measures

Monitor Pressure - Continuously monitor system pressure to prevent overpressure.
Temperature Control - Ensure water temperature does not exceed safe limits.
Communication - Maintain clear communication with all team members.
Emergency Preparedness - Be prepared to respond to any emergencies.
Regular Inspections - Conduct regular inspections of equipment and PPE.

10. Emergency Procedures

10.1 General Emergency Response

In case of an emergency, immediately stop all work and follow emergency protocols.

10.2 Specific Emergency Scenarios

Burns or Scalds - Cool the affected area with water and seek medical attention.
Pressure Release - Evacuate the area and notify emergency services.
Electrical Shock - Disconnect power and provide first aid if safe to do so.

10.3 Emergency Contact Information

[List of emergency contacts and their phone numbers]

11. Incident Reporting and Investigation

Report all incidents, near-misses, and hazards to the supervisor immediately. Follow the company's incident investigation procedures to determine root causes and implement corrective actions.

12. References and Related Documents

OSHA 29 CFR 1910 [2]
CAT Excavator Operation and Maintenance Manuals [1]

Approved by: [NAME AND POSITION]
Date: [APPROVAL DATE]