Hydraulic systems store fluid under 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
Oil adheres to the skin. 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.
This operator was burned when a hydraulic hose, neglected during maintenance, burst and spewed hydraulic oil, at normal operating temperature, over his entire body.
The frequency of fires involving hydraulic fluids has prompted the introduction of fire-resistant fluids for hydraulic systems. Is your company using them?
RISK ASSESSMENT
For every 1 degree in heat applied to trapped hydraulic oil, the pressure rises 50to 60-pounds-per-square-inch.
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.
Pipe being pressure-tested in rig with OM15 aircraft hydraulic oil, held at 6,000psi As operator reached inside Perspex box to operate pressure relief valve, hand brushed against pipe to valve, just as the pipe split. Fine jet of oil made a -inch cut in hand, with -inch circle of lifted skin around it. Felt like being punched in the palm. No pain
Rushed to hospital in company security van Pain increasing; intravenous pain relief 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
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
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 2 years of physiotherapy Marriage break-up
Wash off affected skin, eyes, and protective clothing immediately. Remove contaminated clothing, and launder or dry-clean it before reuse. After contact with hydraulic oil (and especially before breaks and meals, and at the end of shifts), always cleanse skin with a waterless hand cleanser, and then wash with soap and water.
Block, secure or lower to the ground components that may move, rotate or fall. Use test equipment designed for higher pressures than the system being repaired. Use of gauges, lines, connectors, etc., designed for lower pressures can result in bursting or equipment damage. Start with high pressure gauges and work down. (A good rule is to use equipment rated at twice what is expected. Example: For a 2500 psi system, use a 5000 psi gauge.) Relieve system pressures. DO NOT USE FINGERS OR HANDS to find leaks. Check for leaks using a piece of cardboard or wood.
Always use safety glasses. Use extreme caution when disconnecting hydraulic lines. Severe burns from hot fluid can result. 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. AVOID HEATING NEAR PRESSURISED FLUID LINES.
Hydraulics Maintenance
All hydraulic hoses, tube lines and fittings should be periodically inspected. Any deterioration should be carefully examined to determine whether further use of the component would constitute a hazard.
Conditions such as the following should be sufficient for consideration of replacement: a. Any evidence of hydraulic oil leakage at the surface of a flexible hose or its junction with the metal and couplings; b. Any blistering or abnormal deformation to the outer covering of a hydraulic hose; c. Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal tightening or recommended procedures
and/or d. Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or hydraulic fitting.
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 not only to test-bed engineers, but to maintenance fitters, forklift and lorry fitters, millwrights, platers and welders and to anyone whose work entails the operation of machines whether they be milling machines or bulldozers that use hydraulic pressure systems.
RISK ASSESSMENT
All maintenance work should be visually examined when Risk Assessed. All "hot work" should be visually examined when Risk Assessed. the presence of a hydraulic system is a hazard the presence of hydraulic hoses is a hazard
Remember?
Step 1: Look for the hazards Step 2: Decide who might be harmed and how Step 3: Evaluate the risks and decide whether the existing precautions are adequate or whether more should be done Step 4: Record your findings Step 5: Review your assessment and revise it if necessary
HSE, 5 Steps to Risk Assessment, INDG 163
Poor skills, not poor employees, are the root-cause of most accidents associated with hydraulics. There is no tool more effective at eliminating poor skills and hence, work-related accidents, than training.
Ensure that only trained, authorised persons carry out hydraulic system service, repair and troubleshooting. Encourage discussion in management and in safety committees on the need for training that will prevent these kinds of accidents occurring to those to work near or with hydraulic systems.
Get training for competency in hydraulics Get training - not in the theory of hydraulics but in the hazards of hydraulics
Thank you
Dennis Mac HandS UK Health & Safety Resources