Case Study - PUWER Assessments for a National Water Treatment Company

Client Overview

Carn Engineering was appointed by a leading UK water and wastewater treatment company to deliver a comprehensive PUWER (Provision and Use of Work Equipment Regulations 1998) compliance assessment across multiple treatment facilities.

The client operates large-scale treatment plants, pumping stations, and sludge-handling centres nationwide, supporting critical water infrastructure for domestic, industrial, and environmental supply networks.

Objective

To ensure all key process machinery and equipment were safe, compliant, and suitable for ongoing operation under PUWER 1998, while strengthening the client’s overall machinery safety management and maintenance strategy.

Scope of Work

Carn Engineering’s PUWER Assessment covered a wide range of water and wastewater treatment machinery, equipment and the immediate workspaces, including:

• Raw water intake screens and conveyors.

• Centrifugal and progressive cavity pumps.

• Chemical dosing skids and chlorination systems.

• Sludge dewatering presses, centrifuges, and thickeners.

• Mixers, agitators, and aeration blowers.

• Grit classifiers, screw conveyors, and screens.

• Motor control centres, electrical panels, and instrumentation systems.

• Access platforms, valve manifolds, and automated control systems.

Our Approach

Carn Engineering’s team of qualified mechanical and electrical engineers conducted detailed site inspections and compliance reviews, which included:

• Inspection of equipment guards, emergency stops, and control systems.

• Review of CE/UKCA markings, Declarations of Conformity, and manufacturer documentation.

• Assessment of emergency isolation systems, lock-off procedures, and maintenance safety protocols.

• PUWER-based hazard identification and risk evaluation against applicable British and harmonised standards.

• Review of operator competence, training records, and Safe Systems of Work (SSoW).

Key Findings

The assessment identified several areas for improvement to enhance safety and compliance:

• Guarding & Enclosures: Open drive systems on pumps, conveyors, and centrifuges required additional guarding to meet current safety standards.

• Emergency Stop Systems: Inconsistent emergency stop arrangements were found across chemical dosing and sludge treatment areas.

• Documentation: While most equipment was CE/UKCA marked, Declarations of Conformity and manufacturer safety instructions were not consistently retained.

• Training & Competence: Operator training records and task-specific risk assessments were incomplete in several locations.

• Maintenance & Inspection: Preventive maintenance and inspection schedules were not fully documented for all process equipment.

Hazard Insightsout

Carn Engineering’s PUWER assessment highlighted key risk categories typical of water and wastewater operations:

• Mechanical Hazards: Entanglement and crushing risks around rotating equipment such as pumps, centrifuges, and screw conveyors.

• Electrical Hazards: Potential for electric shock due to unsecured control panel covers and unlabelled cabling.

• Chemical & Thermal Hazards: Risks associated with dust, chemical dosing systems and hot equipment surfaces during sludge processing.

• Access Hazards: Several access, fall-prevention and rescue concerns were highlighted around raised platforms, tank edges, and screw conveyors.

• Noise & Vibration: Elevated noise from blowers and centrifuges required consistent hearing protection; vibration exposure required review.

• Ergonomic Risks: Manual handling issues were identified during access and maintenance of pumps and mixers in confined areas.

Outcome

Carn Engineering provided a detailed PUWER compliance roadmap outlining both short-term corrective actions and long-term compliance improvements. This included:

• Prioritised safety upgrades to mechanical guarding and control systems.

• Improved documentation and certification management. • Enhanced operator training and competency frameworks.

• Enhanced operator safety through elimination of key fall, entanglement, and electrical hazards.

• Improved PUWER and Work at Height compliance, with access systems to meet design standards.

• Site-wide PUWER compliance monitoring and review procedures.

• Reduced maintenance downtime due to safer, more accessible equipment layouts.

• Improved workforce confidence and safety culture, supported by clear signage and visible risk controls.

• Long-term cost benefits, as engineered access solutions and standardised guarding reduced future modification and inspection requirements.

Through our structured assessment approach, the client achieved a measurable improvement in machinery safety, regulatory compliance, and maintenance efficiency across its operations.

Why Choose Carn Engineering for PUWER Assessments

Carn Engineering delivers expert PUWER assessments and machinery safety compliance services for clients in all commercial and industrial sectors. Our engineers combine technical expertise with a deep understanding of industry operations - helping ensure your assets are safe, compliant, and fully aligned with HSE/HSA and PUWER requirements.

Need a PUWER compliance review for your assets?

Contact Carn Engineering to speak with our PUWER specialists and schedule your site assessment.

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