Industrial Hydraulic Safety Hazards

Industrial Hydraulic Safety
1
Hydraulic systems store fluid under very high

pressure – typically, at 2,000 pounds per square
inch…
Hazards:
 stored energy
• flailing hydraulic hose, ejected components
• maintenance conducted without releasing pressure
• maintenance conducted after incorrectly releasing pressure
 temperature
 ignition
 injection
Skin will scald at 120°F
Two to three minutes at that temperature will

result in a 2nd degree burn.
The average operating temperature of a

hydraulic system of 140°F
will cause a 2nd degree burn in
½ to 1 second.
3
• Oil adheres to the skin and the
longer the contact, the deeper the burn.
• Burn injuries are the worst type of
injury from a rehabilitation point of view.
• The rule of thumb is: one day in hospital for each 1% of
body area burned.
Employee was burned when a hydraulic hose,

neglected during maintenance, burst and spewed
hydraulic oil, at normal operating temperature,
over his entire body.
4
Fire and Explosion Risks
of Hydraulic Fluid
• High flash point: 300-600°F

• Under pressure, atomised spray of droplets
may travel a considerable distance from the
break
• Ignites readily by heat source
• Resulting fire is torch-like with very high heat
release rate
• Mist in confined area can explode violently
Never use hands or fingers

to find leaks.
Fluid under high pressure can be

injected into the skin causing
extreme injury, serious infection
– gangrene –
and amputation
6
Fluid Injection wound and the extent of

surgery needed to treat it
7
Always inspect equipment before

each use.
Also have a periodic maintenance

plan in place for extensive inspection
and replacement of parts at end of
their service life.
8
Hydraulic Fluid Injection Case

•Pipe being pressure-tested on drilling rig at
6,000 psi
•As operator reached inside an enclosure box
to operate pressure relief valve, hand brushed
against pipe to valve, just as the pipe split.
•Fine jet of oil made a ¼-inch cut in hand, with
½-inch circle of lifted skin around it.
•Felt like being punched in the palm.
•No pain
9

• Rushed to hospital
• Pain increasing
• In surgery 5 hours after incident, began
removing oil
• After surgery, morphine ineffective for pain
relief
• With local anaesthetic to hand, undid stitches
and searched for more oil
• Second surgery on day three
10

• Skin turned black on little finger
• Carpal tunnel opened to relieve pressure
• Massive swelling crushing nerves
• Cut away side of hand “eaten” by oil
• Third surgery on day five
• More flesh cut away and grafts begun
• Drugs for pain finally working
11
12
• 14 days in hospital
• Weekly physiotherapy
• 3 months later, fourth surgery to release little
finger that had curled into palm
• 9 months later, fifth surgery
• Off work for six months
• 3 skin grafts with scarring to thigh and arm
13
Hydraulic Fluid Injection After Recovery
14
Inspect Hydraulic Equipment
Defective Hydraulic Hoses
Hydraulic hoses should be inspected daily 15

Always Relieve Hydraulic Pressure
Before Performing Maintenance
16
Hydraulic Hose Whip
17
Industrial Accident – High Pressure Line Whip Cut
18
Working with Hydraulic Oils

• Avoid prolonged breathing of its vapor, mist, and fumes.
• Avoid prolonged or repeated skin contact.
• Use chemical-resistant gloves, splash goggles and a
chemical-resistant apron
• Wash off affected skin, eyes, and protective clothing
immediately. Remove contaminated clothing, and
launder before reuse.
• After contact with hydraulic oil always cleanse skin with
a waterless hand cleanser, and then wash with soap
and water.
19
Working with Hydraulic Systems

• Never begin work on a hydraulic system until fully
trained.
• Carefully review the manuals on equipment before
beginning work and ask questions about anything you do
not fully understand.
• Review all Material Safety Data Sheets (MSDS) for all
chemicals used.
• Use all required personal protective equipment.
– Safety goggles "and" face shield
– Protective apron
– Protective gloves
– Hard hat
– Steel toes leather shoes
20
Working with Hydraulic Systems

• Always relieve pressure before performing any
maintenance on a hydraulic system
• Use extreme caution when disconnecting hydraulic lines.
• Clean up spills immediately. Hydraulic fluid can cause
slips, falls and resulting injuries.
• Do not work under equipment / apparatus being
supported by hydraulics.
– Stops, safety pins, etc, must be in place before repairs begin.
21
Summary
• The risks of work with hydraulic systems are not
only of high-pressure puncture accidents, but of
fire, lacerations, severe burns, crushing and
death.
• These risks apply to maintenance workers,
forklift and other hydraulic equipment,
millwrights, and welders, etc.
• Anyone whose work entails the operation of
machines – whether they be milling machines
or bulldozers – that use hydraulic pressure
systems.
22

Industrial Hydraulic Safety Hazards

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Industrial Hydraulic Safety

Industrial Hydraulic Safety

Hydraulic systems store fluid under very high

Skin will scald at 120°F

Two to three minutes at that temperature will

The average operating temperature of a

Employee was burned when a hydraulic hose,

• High flash point: 300-600°F

Never use hands or fingers

Fluid under high pressure can be

Fluid Injection wound and the extent of

Always inspect equipment before

Also have a periodic maintenance

Hydraulic Fluid Injection Case

Hydraulic Fluid Injection Case

Hydraulic Fluid Injection Case

Hydraulic Fluid Injection Case

Hydraulic Fluid Injection After Recovery

Hydraulic hoses should be inspected daily 15

Working with Hydraulic Oils

Working with Hydraulic Systems

Working with Hydraulic Systems

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