Job Safety Analysis: Lift Station Pump Replacement

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Step Potential Hazard Control
Assess work area Traffic exposure, uneven ground, standing water, electrical hazards Conduct site assessment; set up MUTCD compliant work zone; ensure stable footing; assign lookout
Inspect tools, lifting devices, and PPE Equipment failure, improper rigging, damaged PPE Inspect hoist, chains, slings, and rigging hardware; inspect gas monitor; replace defective equipment
Don required PPE Sewer exposure, splash hazards, aerosols Wear gloves, face shield, protective clothing, high visibility vest, respirator if needed
Test and monitor air in wet well Hydrogen sulfide, methane, low oxygen Use gas monitor at top, mid, and lower levels; do not proceed if readings are unsafe
Lockout tagout electrical sources Pump start up, electrical shock Shut down pump power; apply lockout tagout; verify no power at control panel
Ventilate wet well Toxic gases, poor oxygen Use blower and ducting; ventilate continuously during operation
Open wet well hatch Fall hazards, dropped objects Secure hatch open; set barriers around opening; ensure surface is clear
Set up lifting system over pump rails Hoist failure, pinch points Position davit or tripod securely; confirm lifting capacity exceeds pump weight; attach retrieval line properly
Disconnect pump electrical connections Shock hazard, water contact Confirm lockout is applied; disconnect using insulated tools; keep connections clear of water
Disconnect pump from discharge piping or guide rails Pinch points, splash hazards Use appropriate tools; stand to side of connection; avoid sudden pump movement
Lift pump from wet well Dropped loads, rigging failure, splash exposure Raise pump slowly; keep all workers clear of suspended load; use guide rope to control swing
Move pump to safe work area Struck by swinging pump, slips Place pump onto stable surface; maintain communication between workers
Install replacement pump Pinch points, muscle strain, misalignment Inspect new pump and rails; use mechanical lifting device; avoid placing hands between pump and guides
Lower pump into wet well Dropped load, rigging hazards, alignment issues Lower slowly; guide into rails; ensure pump seats correctly on discharge connection
Reconnect electrical components Shock hazard, miswired connections Use insulated tools; verify wiring diagram; keep connections dry
Restore power and test pump Unexpected movement, water surge Stand clear during startup; run pump manually; confirm flow and proper operation
Close and secure hatch Pinch points, unseated lid Lower hatch carefully; ensure latch is engaged; remove surrounding barriers
Clean and disinfect equipment Cross contamination, splash hazards Rinse hoist, tools, and PPE; bag disposable items; wash hands thoroughly
Final inspection Improper seating, leaks, missed hazards Verify pump cycles correctly; check for abnormal noise or vibration; confirm site is clean and safe
Remove traffic control Exposure to traffic Remove signs and cones in reverse order; keep PPE on; use lookout

Suggested Personal Protective Equipment

  • Hard hat

  • Safety glasses or face shield

  • High visibility vest or jacket

  • Steel toe boots

  • Chemical resistant gloves (nitrile or neoprene)

  • Waterproof boots or waders

  • Long pants and long sleeves

  • Hearing protection near pumps or generators

  • Respirator for sewer gases or aerosols

  • Disposable coveralls when contamination is heavy

Always have a complete, well-stocked first aid kit available.

JSA Category: Water and Sewer Department Operations

* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.

Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.

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Job Safety Analysis
Step Potential Hazard Control
Assess work area Traffic exposure, uneven ground, standing water, electrical hazards Conduct site assessment; set up MUTCD compliant work zone; ensure stable footing; assign lookout
Inspect tools, lifting devices, and PPE Equipment failure, improper rigging, damaged PPE Inspect hoist, chains, slings, and rigging hardware; inspect gas monitor; replace defective equipment
Don required PPE Sewer exposure, splash hazards, aerosols Wear gloves, face shield, protective clothing, high visibility vest, respirator if needed
Test and monitor air in wet well Hydrogen sulfide, methane, low oxygen Use gas monitor at top, mid, and lower levels; do not proceed if readings are unsafe
Lockout tagout electrical sources Pump start up, electrical shock Shut down pump power; apply lockout tagout; verify no power at control panel
Ventilate wet well Toxic gases, poor oxygen Use blower and ducting; ventilate continuously during operation
Open wet well hatch Fall hazards, dropped objects Secure hatch open; set barriers around opening; ensure surface is clear
Set up lifting system over pump rails Hoist failure, pinch points Position davit or tripod securely; confirm lifting capacity exceeds pump weight; attach retrieval line properly
Disconnect pump electrical connections Shock hazard, water contact Confirm lockout is applied; disconnect using insulated tools; keep connections clear of water
Disconnect pump from discharge piping or guide rails Pinch points, splash hazards Use appropriate tools; stand to side of connection; avoid sudden pump movement
Lift pump from wet well Dropped loads, rigging failure, splash exposure Raise pump slowly; keep all workers clear of suspended load; use guide rope to control swing
Move pump to safe work area Struck by swinging pump, slips Place pump onto stable surface; maintain communication between workers
Install replacement pump Pinch points, muscle strain, misalignment Inspect new pump and rails; use mechanical lifting device; avoid placing hands between pump and guides
Lower pump into wet well Dropped load, rigging hazards, alignment issues Lower slowly; guide into rails; ensure pump seats correctly on discharge connection
Reconnect electrical components Shock hazard, miswired connections Use insulated tools; verify wiring diagram; keep connections dry
Restore power and test pump Unexpected movement, water surge Stand clear during startup; run pump manually; confirm flow and proper operation
Close and secure hatch Pinch points, unseated lid Lower hatch carefully; ensure latch is engaged; remove surrounding barriers
Clean and disinfect equipment Cross contamination, splash hazards Rinse hoist, tools, and PPE; bag disposable items; wash hands thoroughly
Final inspection Improper seating, leaks, missed hazards Verify pump cycles correctly; check for abnormal noise or vibration; confirm site is clean and safe
Remove traffic control Exposure to traffic Remove signs and cones in reverse order; keep PPE on; use lookout
Suggested Personal Protective Equipment