🛠️ Hydraulic Safety Essentials: A Quick Recap! 1. Stored Energy Risks: - Hydraulic systems store energy; be cautious of potential hazards. - Risks include burns, injection injuries, fire hazards, and unexpected equipment movements. 2. Fluid Power Dangers: - Hydraulic control is powerful but can be dangerous. - Fluid temperatures can cause burns; leaks near heat sources may lead to fires. 3. Stored Energy Regulations: - Know the regulations for devices like accumulators storing energy under pressure. - Follow guidelines like PED, PER, PESR, and PSSR during maintenance. 4. Component Failures: - Continued operation at high pressure may stress components. - Pressure test new equipment and reduce frequency oscillations for prolonged component life. 5. Safe Isolation Procedures: - Follow positive isolation before starting any work. - Prioritize safe start-up and shut-down procedures, and always wear appropriate safety gear. 6. Fluid Leakage Risks: - Keep fluid leaks to a minimum to avoid spillage, slips, and skin contact. - Use retaining walls and barriers, especially near heat sources, to prevent fire risks. 7. Hydraulic Hose Safety: - Regularly check and replace hydraulic hoses. - Avoid whiplash risks by correctly installing and restraining hoses. 8. Fluid Injection Dangers: - Stay clear of pressurized hydraulic systems; injection injuries are severe. - Urgent medical attention is crucial in case of fluid injection. 9. Heat Source Cautions: - Be cautious around heat sources; hydraulic fluid and solenoids can reach high temperatures. - Control fluid temperature within limits to avoid burns and reduce energy consumption. 10. Actuator Maintenance Tips: - Securely remove and fix actuators, following proper depressurization and safety precautions. - Always consult manuals, seek expert advice, and prioritize safety in all hydraulic maintenance.

1. INDUSTRIAL
HYDRAULIC
SAFETY
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2. INTRODUCTION Hydraulic systems store fluid under
very high pressure- typically at
2000 pounds per square inch
01
02
Hydraulic equipments and systems are
designed to accomplish work using
confined liquid pressure to produce a
greater mechanical force.
Hydraulic control makes
machines move faster and
more precisely boosting
efficiency in various tasks.
Hydraulic
equipment stores
formidable energy
capable of
propelling failed
components with
bullet-like impact.
BEST POWER & FLEXIBILITY TEMPERATURE CHALLENGES
Fluid temperatures can
surpass scalding levels,
presenting operational
challenges.
FIRE SAFETY CONSIDERATIONS
Fluid leaks near heat
sources pose fire risks,
necessitating proactive
measures & vigilant
monitoring.
BE AWARE OF DANGERS
While powerful, hydraulic
systems have risks, so it's
important to have strong
safety measures.
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3. Design systems that automatically
discharge pressure and support loads
safely, when inactive.
Exception: Accumulator safety blocks
needing certified relief valves.
STORED ENERGY RISKS
Hydraulic systems that retain
stored energy while the power
supply is turned off, brings an
increased risk.
COMMON RISKS
Hydraulic accumulators retaining
pressure even after fluid release.
Hydraulic cylinders maintaining
pressure while supporting loads.
Actuators feeding energy back
into systems.
good practise
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4. Air compressibility in pneumatics poses
risks of uncontrolled movements or unsafe
releases.
Compressed air volumes may require
additional safety measures.
STORED ENERGY RISKS
Considerations with Pneumatics
Hydraulic fluid is
considered to be
incompressible.
It is actually slightly
compressible and will
change volume with
temperature.
Trapped fluid can cause thermal expansion
failures or dangerous releases when
pressure is not released before removing
fittings.
fluid dynamics in hydraulics
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5. Working at high pressure, especially
with cyclic loads, can surpass
recommended component lifetimes.
HIGH PRESSURE RISKS: COMPONENT
FAILURES
Load induced pressure Ensure all equipment is
commissioned by an
experienced hydraulics
engineer.
Incorrect operation or system failures
can overstress components, leading
to potential failures over time.
Overstressing risks
Pressure test new hydraulic
equipment to 1.5 times working
pressure using a low-energy device
before startup.
Reduce frequency oscillations or
use ramped accelerations and
decelerations to remove harshness
in direction changes, extending
component life.
pressure testing
managing operations
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6. Start-up or shutdown phases pose significant dangers, especially
during first-time start-ups or after extensive maintenance
shutdowns.
SAFE ISOLATION PROCEDURE
Critical Times
for Safety
Importance of
understanding
procedures
It's crucial to comprehend and follow safe start-up and shutdown
isolation procedures before conducting any work near hydraulic
equipment.
Risks of not following isolation procedures
Uncontrolled
movements
Dangerous loads Premature power
restoration
Pressure
entrapment
Negative
pressures
Fluid loss Contamination
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7. Ensure all isolators, especially tank return and drain line isolators,
are open before system activation.
Fully isolate and tag or lock the main power supply to prevent
unauthorized restarts.
SAFE ISOLATION PROCEDURE
Typical procedures
Check before
startup
Isolations
measures
Unload the
system
Use the system relief valve to unload the system before starting.
Motor check Power electric motors briefly to confirm correct wiring and flow
direction
Accumulator
discharge
Discharge all accumulators before beginning any equipment work.
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8. Physically support elevated loads before releasing pressure.
Stand behind a shield during start-up, especially near
working hydraulic equipment.
Turn off hydraulic power before adjusting valve settings.
Powerup electrical controls before applying hydraulic power to
actuators
Safety
measures
Sequential
activation
Appropriate
attire
Wear proper clothing, including glasses, steel-capped boots,
protective gloves, and overalls for enhanced safety.
Apply common sense at all times to ensure safety
Follow correct start-up and shut-down procedures outlined in your
'Safe Operating Procedure'
SAFE ISOLATION PROCEDURE
Typical procedures
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9. Keeping the risk of fluid leaks to an absolute minimum is crucial for safety.
FLUID LEAKAGE RISKS
Potential
hazards
risk
reduction
actions
Install retaining walls around
hydraulic equipment to prevent
fluid leaks onto walkways or the
environment.
Provide physical barriers to
prevent fluid jets from coming
into contact with the workforce
Spillage Slip & fall Skin contact Inhalation
Ingestion
Retaining walls Physical barriers
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10. FLUID LEAKAGE RISKS
risk
reduction
actions
Exercise caution in areas where hydraulic systems operate near
heat sources.
Hydraulic fluid is combustible, and high-pressure leaks forming a
mist near heat sources increase the risk of fire.
Address the increased fire risk by using appropriate guarding or fire-
resistant fluid in such areas.
Special consideration for heat sources
Fire risk mitigation
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11. HYDRAULIC HOSE FAILURES
Correct
installation
Ensure hoses are correctly installed with appropriate end fittings
Hydraulic hoses are prone to failures, making them a critical component
in need of special attention and safety precautions.
Safety measures
Physical
restraint
If people are within the range of loose hoses, physically restrain end
fittings to prevent whiplash from flying, broken hose ends.
Monitoring
dates
Regularly check hose dates within predicted life limits (typically 5-7
years, but environment and application dependent).
Critical
hoses
Pay special attention to hoses retaining load pressure, as their failure
could lead to a dangerous falling load.
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12. HYDRAULIC HOSE FAILURES
Replacement
protocol
Replace hoses immediately upon detecting damage or wear on the
outer surface.
Safety measures
No re-ending Never attempt to re-end a failed hose; replace it instead.
Adhering to these safety measures is essential to mitigate the risks associated with
hydraulic hose failures.
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13. HEAT SOURCES RISKS
hydraulic
fluid
Exercise utmost care
when working around
hydraulic equipment
due to the potential
for serious burns.
Utilize large volume reservoirs and effective
offline cooling to control fluid temperature and
avoid extreme highs.
Solenoid require more power to switch positions than
to hold valves in place.
Implement controls that reduce power to the
solenoid after switching to lower temperature and
reduce energy consumption.
posing a burn risk to the skin.
operates at
40-50°C
electrical
solenoids
can reach
70-100°C
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14. FLUID INJECTION INJURIES
Hydraulic injection injury occurs when the outer layer of skin is broken by a jet of
fluid under pressure.
Reported cases range
from pressures
over 100 bar
(1450 psi)
Tiny holes in hose skin, loose fittings, or
fractured pipes can result in fluid jets injecting
under the skin.
These injuries may have minimal visible signs
but can lead to severe consequences if not
treated promptly.
Injuries can cause
mechanical pressurized
penetration and trauma to
surrounding tissue.
Toxicity of injected fluid
adds another layer of harm.
Severity varies based on pressure, proximity,
and jet size during the injury.
Anecdotal evidence suggesting
risks at pressures as low as
7 bar
(101.5 psi)
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15. Keep any part of your skin at least 100 mm away from any part
of a pressurized hydraulic system.
Prompt action is essential following any injection
injury to prevent severe consequences.
FLUID INJECTION INJURIES
Neglected injuries may lead to amputation of
affected parts, highlighting the critical need for
proper care.
Without timely medical treatment, intense throbbing pain
unresponsive to medication can occur within
four to six hours
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16. Common hydraulic system injuries often result from pinhole leaks in hoses.
PINHOLE LEAK INJURY
Detecting these leaks is challenging as they may appear as damp, oily, or
dirty areas near hydraulic lines.
A risky practice is running hands or fingers
along the line to find the leak, which can
result in fluid injection into the skin.
Immediate symptoms include a slight
stinging sensation, but severe pain develops
hours later.
Delay in seeking medical attention may lead to the loss of a finger or entire
arm.
To reduce the risk of such injuries, use a non-contact method like running
wood or cardboard along the hose to detect leaks.
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17. Hazards arise from improper coupling of hydraulic components, especially
between low and high-pressure systems.
IMPROPER COUPLING
Never connect a high-pressure
pump to a low-pressure system or
incorporate low-pressure
components into high-pressure
systems.
Such improper coupling can lead to
ruptures in components, hoses, or
fittings.
Ensure pressure relief valves are integrated into the hydraulic
system to avoid pressure buildups during use.
Regularly clean and test these valves to ensure correct operation and prevent
potential accidents.
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18. GENERAL SAFETY PRECAUTIONS
DURING MAINTENANCE OF HYDRAULIC SYSTEM
Before starting any hydraulic work, follow the designated isolation
procedure.
Depressurize the system, and consider local isolation if necessary.
Never initiate work without proper training and a comprehensive
risk assessment.
Review equipment manuals thoroughly and ask questions for
clarity.
Read Material Safety Data Sheets (MSDS) for chemicals used in
the system.
Utilize all required safety equipment during maintenance tasks.
POSITIVE ISOLATION
PROCEDURE
Document and practice de-energizing procedures for each circuit.
Drain pressure lines and accumulators before maintenance work.
Avoid hammering during the tightening of pressurized lines.
PRE-WORK
PREPARATION
DE-ENERGIZING &
LOAD LOCKING
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19. GENERAL SAFETY PRECAUTIONS
DURING MAINTENANCE OF HYDRAULIC SYSTEM
Test hydraulic pipes and cylinders at 1.5 times working pressure.
Check components' ratings before replacement.
Use caution during testing to avoid injury due to potential system
failures.
Do not use bare hands to check hydraulic leakage; use a non-
porous material.
Avoid hot work like welding near hydraulic pipelines or tanks.
POST-REPAIR
TESTING &START-UP
Any modifications to the hydraulic system should be approved by a
competent authority.
FLUID LEAK CHECK
MODIFICATION
APPROVAL
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20. THANK YOU
FOR YOUR
ATTENTION
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