Field Level Hazard Assessment (FLHA) for Routine Maintenance

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This Field Level Hazard Assessment (FLHA) covers all tasks performed during routine maintenance activities. It includes the identification of potential hazards, assessment of risks, and implementation of control measures to ensure the safety of all personnel involved. Excluded from this assessment are emergency repair activities, which require a separate, specific risk assessment at the time of the event.

2. Risk Assessment Methodology

This FLHA employs a semi-quantitative risk assessment method using a 5x5 risk matrix to determine risk levels. The matrix considers likelihood (Rare, Unlikely, Possible, Likely, Almost Certain) and severity (Negligible, Minor, Moderate, Major, Catastrophic) to assign a risk rating (Low, Medium, High, Extreme). Control measures are selected based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, PPE) to reduce risks to acceptable levels. [1]

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Moderate	Moderate
Major	Low	Moderate	Moderate	High	High
Moderate	Low	Moderate	High	High	Extreme
Minor	Moderate	High	High	Extreme	Extreme
Negligible	Moderate	High	Extreme	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Use of damaged or defective tools

Potential Consequences: Cuts, lacerations, punctures, or blunt force trauma

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Eliminate the use of the damaged tool.
• Substitute with a tool in good working condition.
• Implement regular inspection of tools before and after use.
• Provide training on proper tool use and maintenance.
• Require the use of safety glasses and gloves.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

2. Electrical shock from contact with live electrical components

Potential Consequences: Electrical burns, cardiac arrest, death

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• De-energize and lockout/tagout equipment before maintenance.
• Verify isolation of energy sources.
• Use insulated tools and equipment.
• Provide training on electrical safety and lockout/tagout procedures.
• Wear appropriate electrical PPE (e.g., insulated gloves, safety shoes).

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

3. Musculoskeletal injuries from manual lifting and awkward postures

Potential Consequences: Strains, sprains, back injuries, hernias [3]

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Use mechanical lifting aids (e.g., hoists, cranes) for heavy items.
• Provide training on proper lifting techniques.
• Reduce the weight of items to be lifted.
• Implement team lifting for heavy or awkward items.
• Use personal protective equipment (PPE) such as back supports and gloves.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

4. Entanglement in moving machinery parts

Potential Consequences: Lacerations, fractures, amputations

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Install machine guards to prevent contact with moving parts.
• Ensure guards are in place and functioning correctly.
• Provide training on machine guarding and safe operating procedures.
• Implement lockout/tagout procedures during maintenance.
• Use awareness barriers and signage.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

5. Exposure to hazardous chemicals (e.g., cleaning solvents, lubricants)

Potential Consequences: Skin irritation, respiratory problems, chemical burns, poisoning

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Provide adequate ventilation to remove fumes and dust.
• Use respiratory protection (e.g., respirators) when ventilation is insufficient.
• Substitute hazardous chemicals with less hazardous alternatives.
• Provide training on chemical handling and SDS information.
• Store chemicals properly and use appropriate PPE (e.g., gloves, eye protection).

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

6. Slips, trips, and falls due to spills, clutter, or uneven surfaces

Potential Consequences: Bruises, sprains, fractures [2]

Affected Persons: Maintenance workers, visitors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	Medium

Control Measures

• Ensure proper lighting in work areas.
• Keep walkways clear of obstructions.
• Use slip-resistant footwear.
• Provide training on slip, trip, and fall hazards.
• Implement a regular inspection and cleaning schedule.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Low

7. Fire or explosion during hot work (e.g., welding, cutting)

Potential Consequences: Burns, explosions, property damage

Affected Persons: Maintenance workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Implement a permit-to-work system for hot work.
• Ensure fire extinguishers are readily available.
• Provide training on fire safety and hot work procedures.
• Clear flammable materials from the work area.
• Use fire-resistant barriers and PPE (e.g., welding helmets, gloves).

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

5. General Control Measures

• Conduct regular safety meetings to discuss potential hazards and review safety procedures.

Schedule meetings weekly or before the start of each shift.

• Maintain a clean and organized work environment to prevent slips, trips, and falls.

Implement a daily housekeeping checklist.

• Ensure all equipment is regularly inspected and maintained according to manufacturer's recommendations.

Keep detailed maintenance logs and schedules.

6. Emergency Preparedness

• Ensure readily available spill kits and appropriate PPE for chemical spills.
• Establish and communicate evacuation routes and assembly points in case of fire or explosion.
• Provide first aid training and readily accessible first aid kits for injuries.

7. Training Requirements

• Personal Protective Equipment (PPE) Training: Training on the proper selection, use, maintenance, and storage of PPE.
  • Ensure proper fit and compatibility of PPE.
  • Regularly inspect PPE for damage.
  • Replace worn or damaged PPE immediately.
• Hazardous Materials Handling Training: Training on the identification of hazardous materials, proper handling techniques, and emergency response procedures.
  • Review Safety Data Sheets (SDS) for all chemicals.
  • Use appropriate PPE when handling chemicals.
  • Properly store and dispose of hazardous materials.
• Lockout/Tagout (LOTO) Training: Training on the procedures for safely isolating energy sources and preventing accidental start-up during maintenance activities.
  • Identify all energy sources.
  • Properly apply and remove LOTO devices.
  • Verify isolation of energy sources.

8. Monitoring and Review

Review Frequency: Annually, and after any incident or significant change in procedures

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Maintenance Supervisor	Regular inspections of tools and equipment to ensure they are in good working condition.
Incident Review	Monthly	Safety Officer	Review of incident reports and near-miss reports to identify trends and areas for improvement.
Direct Observation	Monthly	Maintenance Supervisor	Observation of maintenance tasks to ensure adherence to safety procedures.

9. Special Circumstances

• Adverse weather conditions (e.g., rain, snow, extreme temperatures) can increase the risk of slips, falls, and equipment malfunction.
• Night work reduces visibility and increases the risk of accidents.
• Lone work increases the time to get help in case of an emergency.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, and after any incident or significant change in procedures or when significant changes occur.

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