Pumping unit safety

Pumping units, as process equipment, fall under OSHA's mechanical integrity requirements, which include written procedures, training, inspections, and quality assurance to ensure their ongoing integrity. Employers must establish and implement written procedures to maintain the integrity of process equipment, including pumps. [1] [2] [3]

Training is essential for employees involved in maintaining pump integrity, covering process overview, hazards, and safe job performance. Employers need to train each employee involved in maintaining the ongoing integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner. Refresher training should be provided at least every three years to ensure employees understand and adhere to current operating procedures. [1] [2] [4] [5]

Regular inspections and tests must be conducted on process equipment, following recognized engineering practices and manufacturer recommendations. The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience. Each inspection and test performed on process equipment should be documented, including the date, inspector's name, equipment identifier, description of the inspection, and results. [1] [1] [1] [1] [2] [2] [2] [2]

Deficiencies in equipment that fall outside acceptable limits must be corrected before further use, or in a safe and timely manner with necessary precautions. The employer shall correct deficiencies in equipment that are outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation. [1] [2]

Operating procedures must include steps for emergency shutdown, including conditions that trigger it and assigned responsibilities. The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements: Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. [4] [5]

Operating procedures should address safety and health considerations, including chemical properties and hazards, exposure precautions (engineering, administrative controls, and PPE), control measures for contact or exposure, and any special hazards. Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment. [4] [5]

PPE should be used in conjunction with guards, engineering controls, and sound manufacturing practices. A hazard assessment should be conducted to identify potential hazards and the appropriate PPE. To assess the need for PPE a walk-through survey of the areas in question should be conducted to identify sources of hazards to workers and co-workers, and basic hazard categories. [6] [6]