Pre-Task Plan: Changing out a PSV

Date: [DATE] Work Area: [WORK AREA] Task Supervisor: [SUPERVISOR NAME]

1. Task Description

Replace the Pressure Safety Valve (PSV) on the hydraulic system.

2. Task Duration

Estimated Start: [START TIME] Estimated Completion: [END TIME]

3. Personnel Involved

• [ROLE 1]
• [ROLE 2]
• [ROLE 3]

4. Task-Specific Hazards and Controls

Hazard	Risk	Control Measures
Hot oil and components	Burns	Allow the machine to cool down before starting work. Wear appropriate PPE, including gloves and long sleeves 1, 11, 13.
Pressurized hydraulic system	Injury from sudden release of oil	Relieve hydraulic tank pressure by slowly turning the cap to the secondary stop with the engine off 1, 2, 3, 6, 7. Ensure pressure is fully released before disconnecting any components.
Heavy components	Musculoskeletal injuries, crushing injuries	Use proper lifting techniques and equipment. Ensure components are properly supported during removal and installation.
Fluid spillage	Slips, environmental contamination	Use drip pans to collect any spilled oil. Have spill cleanup materials readily available 6, 7.

5. Required PPE for Today's Task

• Safety glasses
• Gloves
• Long sleeves
• Steel-toe boots

6. Tools and Equipment Needed

• New PSV
• Wrenches
• Sockets
• Torque wrench
• Drip pans
• Cleaning supplies

7. Pre-Start Checklist

Area Preparation

• Ensure the machine is parked on a level surface 1, 9.
• Barricade the work area to prevent unauthorized access.
• Ensure adequate lighting is available.

Equipment Checks

• Inspect all tools and equipment for proper function.
• Verify the correct replacement PSV is available.
• Check that spill cleanup materials are on hand.

Communication

• Review the task steps and potential hazards with all personnel involved.
• Establish clear communication signals between team members.

8. Task Steps Overview

1. Park the machine on a level surface and engage the parking brake 1, 9.
2. Allow the machine to cool down.
3. Relieve the pressure in the hydraulic system 1, 2, 3, 6, 7.
4. Carefully remove the old PSV.
5. Install the new PSV and torque to the correct specification.
6. Check the hydraulic oil level 2, 3, 11, 13.

9. Emergency Response for This Task

• Hydraulic oil spill → Stop work, contain the spill, and clean up the area.
• Personal injury → Provide first aid and seek medical attention if needed.

10. Task-Specific Precautions

• Do not smoke or use open flames near the hydraulic system 17, 18.
• Dispose of used parts and fluids properly.
• Keep the work area clean and organized.

Pre-Task Briefing Confirmation

All workers understand the task, associated hazards, and required controls.

Team Lead Initials: [___] Date: [DATE] Time: [TIME]

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