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Safety Hazard Prevention and Control in Centrifugal Pump Factories - News - Athena Engineering S.r.l.

I. Mechanical Operation Hazards: Risks from Rotating Parts and Vibration

The impeller of a centrifugal pump rotates at high speed (usually over 2900 rpm). If the protective cover is missing, loose, or not locked, operators' limbs may be caught in the rotation, causing lacerations or fractures.

Misalignment of the pump shaft, unbalanced impeller, or loose foundation can cause severe vibration, leading to loose bolts, pipeline rupture, or even pump body overturning.

II. Electrical and Explosion-Proof Hazards: Leakage and Spark Risks

When the motor insulation ages, the junction box is waterlogged, or the grounding is poor, the casing may carry mains voltage (220V/380V), causing electric shock if touched by operators. The risk of leakage is higher in humid environments (such as coal washing plants).

When transporting flammable media such as gasoline or ethanol, static electricity accumulation and discharge on the pump body, or a motor that does not meet explosion-proof standards (e.g., non-Ex certified), may ignite the vapor mixture.

III. Medium Leakage and Toxic Hazards: Corrosion, Combustion, and Poisoning

Wear of mechanical seals, aging of O-rings, or cracks in the pump body can lead to medium leakage. If concentrated hydrochloric acid is transported, leakage will corrode equipment and personnel's skin; if liquefied petroleum gas is transported, leakage may cause combustion and explosion.

When transporting toxic media such as aniline or formaldehyde, trace leakage of volatile gases inhaled may cause chronic poisoning of operators.

IV. Overpressure and Idling: Equipment Overload and Explosion Hazards

If the outlet valve is fully closed when starting the centrifugal pump, the liquid in the pump will heat up due to high-speed rotation, and the pressure can surge to 2-3 times the design pressure, causing the pump body to rupture.

When the pump idles without medium, the impeller rubs against the pump casing, generating heat (temperature can reach over 300℃), which may burn the impeller or even ignite residual media.

V. High Temperature and Noise: Physical Injury Hazards

When transporting heat-conducting oil (temperature ≥ 200℃) or steam condensate, the pump body surface temperature is high, and operators touching it will suffer second-degree burns.

The operating noise of centrifugal pumps usually reaches 85-100dB, and long-term exposure (8 hours per day) will cause permanent hearing loss.

VI. Safety Blind Spots in Maintenance and Repair

Failing to cut off the motor power and lock the label during maintenance, and other personnel mistakenly closing the switch to start the equipment, which may cause injury to maintenance personnel by rotating parts.

Failing to replace the media in the pump before maintenance, residual strong acids, alkalis, or flammable liquids may burn the skin or explode when encountering open flame.

VII. Environmental and Management Hazards: Poor Ventilation and Operation Errors

When the pump is installed in a closed pump room or underground tank area, gases volatilized from medium leakage (such as carbon dioxide) may accumulate, causing the oxygen concentration to drop (< 19.5%), leading to personnel asphyxiation.

Misoperation by untrained personnel (such as backflow startup, frequent start-stop) will accelerate equipment damage and cause safety accidents.