Product Overview

Summary: This Bearings and Seals Inspection Safe Operating Procedure sets out a clear, repeatable method for safely inspecting rotating equipment components in Australian workplaces. It helps maintenance teams detect wear, contamination and failure risks early, reducing breakdowns, improving plant reliability and ensuring compliance with WHS obligations around plant and equipment.

Bearings and seals are critical components in rotating plant such as conveyors, pumps, fans, gearboxes and motors. When they are not inspected systematically, the result can be sudden equipment failure, overheating, loss of containment, fire risk and serious injury to workers. This Safe Operating Procedure provides a structured, WHS-aligned approach for inspecting bearings and seals, from pre-start isolation and guarding checks through to detailed visual, functional and condition assessments.

Developed for Australian industrial, manufacturing, mining, utilities and agricultural environments, the SOP supports businesses to move away from ad‑hoc inspections and towards a documented, defensible inspection regime. It helps teams identify early signs of wear, misalignment, lubrication issues, seal damage and contamination that can lead to catastrophic failure. By implementing this procedure, organisations can extend asset life, reduce unplanned downtime, protect workers from rotating plant hazards, and demonstrate due diligence under Australian WHS plant and equipment requirements.

Key Benefits

• Reduce unplanned breakdowns and costly production stoppages by identifying bearing and seal defects before failure.
• Improve worker safety around rotating machinery through clear isolation, guarding and inspection controls.
• Ensure consistent inspection quality across shifts and sites with a standardised, step-by-step method.
• Extend equipment life and optimise maintenance spend by detecting lubrication, alignment and contamination issues early.
• Demonstrate compliance with Australian WHS plant and equipment obligations through documented inspection records and sign‑offs.

Who is this for?

• Maintenance Fitters
• Mechanical Technicians
• Plant Operators
• Maintenance Planners
• Reliability Engineers
• Workshop Supervisors
• WHS Managers
• Engineering Managers
• Asset Managers
• Operations Managers

Hazards Addressed

• Entanglement and contact with rotating shafts, couplings and exposed moving parts during inspection
• Crush and pinch injuries from unexpected start-up or movement of plant
• Burns and heat stress from overheated bearings and housings
• Fire and explosion risks from bearing failure, frictional heating and loss of lubrication
• Slip hazards from leaking seals causing oil, grease or product spills
• Exposure to hazardous substances from leaking seals (e.g. oils, chemicals, process fluids)
• Manual handling injuries from handling heavy housings, guards or components
• Eye injuries from ejected debris, failed components or pressurised lubricant
• Noise and vibration exposure from deteriorated bearings and misaligned rotating equipment
• Environmental contamination from uncontrolled lubricant or process fluid leaks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Bearings, Seals, Rotating Plant, OEM, Isolation, etc.)
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Authorisation Requirements
• 5.0 Applicable Legislation, Standards and Reference Documents
• 6.0 Tools, Instruments and Inspection Aids (e.g. stethoscopes, IR thermometers, vibration tools)
• 7.0 Required Personal Protective Equipment (PPE)
• 8.0 Pre-Inspection Planning and Risk Assessment (JSA/SWMS)
• 9.0 Isolation, Lockout/Tagout and Verification of Zero Energy
• 10.0 Access, Guarding and Housekeeping Requirements
• 11.0 Step-by-Step Bearing Inspection Procedure
• 12.0 Step-by-Step Seal Inspection Procedure
• 13.0 Lubrication, Contamination and Leakage Checks
• 14.0 Vibration, Noise and Temperature Condition Checks
• 15.0 Criteria for Defect Classification and Follow-Up Actions
• 16.0 Reassembly, Guard Replacement and Return-to-Service Checks
• 17.0 Recording, Reporting and Maintenance System Entry (CMMS)
• 18.0 Emergency Response and Escalation for Critical Findings
• 19.0 Environmental Controls for Spills and Waste Lubricants
• 20.0 Continuous Improvement, Review and Audit of the Procedure
• 21.0 Document Control and Revision History

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Part 4.2: Duties of persons conducting businesses or undertakings involving management of plant
• Safe Work Australia – Managing risks of plant in the workplace: Code of Practice
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace: Code of Practice (where lubricants or process fluids are hazardous chemicals)
• AS/NZS 4024 series: Safety of machinery
• AS 1735 series: Lifts, escalators and moving walks (where relevant plant uses bearings and seals)
• AS/NZS ISO 31000: Risk management – Guidelines
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems; relevant for aligning procedures)
• Manufacturer-specific OEM maintenance and inspection guidelines for bearings and seals