INDUSTRIAL

HYDRAULIC
SAFETY

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INTRODUCTION Hydraulic systems store fluid under
Hydraulic equipments and systems are very high pressure- typically at
designed to accomplish work using 2000 pounds per square inch
confined liquid pressure to produce a
greater mechanical force.
BEST POWER & FLEXIBILITY TEMPERATURE CHALLENGES
Hydraulic control makes Fluid temperatures can
machines move faster and surpass scalding levels, Hydraulic
more precisely boosting presenting
02 operational equipment stores
01
efficiency in various tasks. challenges. formidable energy
capable of
FIRE SAFETY CONSIDERATIONS BE AWARE OF DANGERS propelling failed
components with
Fluid leaks near heat While powerful, hydraulic bullet-like impact.
sources pose fire risks, systems have risks, so it's
necessitating proactive important to have strong
measures & vigilant safety measures.
monitoring.
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STORED ENERGY RISKS

Hydraulic systems that retain COMMON RISKS

stored energy while the power
supply is turned off, brings an Hydraulic accumulators retaining
increased risk. pressure even after fluid release.

Hydraulic cylinders maintaining

good practise pressure while supporting loads.

Design systems that automatically Actuators feeding energy back

discharge pressure and support loads into systems.
safely, when inactive.
Exception: Accumulator safety blocks
needing certified relief valves.

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STORED ENERGY RISKS
Considerations with Pneumatics
Air compressibility in pneumatics poses
risks of uncontrolled movements or unsafe
releases.
Compressed air volumes may require Hydraulic fluid is
additional safety measures. considered to be
incompressible.
fluid dynamics in hydraulics It is actually slightly
compressible and will
change volume with
Trapped fluid can cause thermal expansion
temperature.
failures or dangerous releases when
pressure is not released before removing
fittings.

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HIGH PRESSURE RISKS: COMPONENT
FAILURES
Load induced pressure Ensure all equipment is
Working at high pressure, especially commissioned by an
with cyclic loads, can surpass experienced hydraulics
recommended component lifetimes. engineer.

Overstressing risks
Incorrect operation or system failures managing operations
can overstress components, leading Reduce frequency oscillations or
to potential failures over time. use ramped accelerations and
decelerations to remove harshness
pressure testing in direction changes, extending
component life.
Pressure test new hydraulic
equipment to 1.5 times working
pressure using a low-energy device
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 SAFE ISOLATION PROCEDURE
Critical Times Start-up or shutdown phases pose significant dangers, especially
for Safety during first-time start-ups or after extensive maintenance
shutdowns.
Importance of It's crucial to comprehend and follow safe start-up and shutdown
understanding isolation procedures before conducting any work near hydraulic
procedures equipment.
Risks of not following isolation procedures
Uncontrolled Premature power
Dangerous loads
movements restoration
Negative Pressure
Fluid loss Contamination entrapment
pressures
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 SAFE ISOLATION PROCEDURE
Typical procedures
Isolations Fully isolate and tag or lock the main power supply to prevent
measures unauthorized restarts.

Check before Ensure all isolators, especially tank return and drain line isolators,
startup are open before system activation.

Unload the Use the system relief valve to unload the system before starting.
system
Motor check Power electric motors briefly to confirm correct wiring and flow
direction
Accumulator Discharge all accumulators before beginning any equipment work.
discharge
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SAFE ISOLATION PROCEDURE
Typical procedures
Sequential Powerup electrical controls before applying hydraulic power to
activation actuators

Safety Physically support elevated loads before releasing pressure.

measures Stand behind a shield during start-up, especially near
working hydraulic equipment.
Turn off hydraulic power before adjusting valve settings.

Appropriate Wear proper clothing, including glasses, steel-capped boots,

attire 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'
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 FLUID LEAKAGE RISKS
Keeping the risk of fluid leaks to an absolute minimum is crucial for safety.

Potential
hazards

Spillage Slip & fall Skin contact Inhalation

Ingestion
risk Retaining walls Physical barriers
Install retaining walls around
reduction hydraulic equipment to prevent Provide physical barriers to
prevent fluid jets from coming
actions fluid leaks onto walkways or the into contact with the workforce
environment.
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 FLUID LEAKAGE RISKS

risk Special consideration for heat sources

reduction Exercise caution in areas where hydraulic systems operate near
heat sources.
actions Hydraulic fluid is combustible, and high-pressure leaks forming a
mist near heat sources increase the risk of fire.

Fire risk mitigation

Address the increased fire risk by using appropriate guarding or fire-
resistant fluid in such areas.

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 HYDRAULIC HOSE FAILURES
Hydraulic hoses are prone to failures, making them a critical component
in need of special attention and safety precautions.
Safety measures
Correct Ensure hoses are correctly installed with appropriate end fittings
installation
Physical If people are within the range of loose hoses, physically restrain end
restraint fittings to prevent whiplash from flying, broken hose ends.
Monitoring Regularly check hose dates within predicted life limits (typically 5-7
dates years, but environment and application dependent).
Critical Pay special attention to hoses retaining load pressure, as their failure
hoses could lead to a dangerous falling load.
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 HYDRAULIC HOSE FAILURES
Safety measures
Replacement Replace hoses immediately upon detecting damage or wear on the
protocol outer surface.
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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HEAT SOURCES RISKS
hydraulic operates at can reach electrical
fluid 40-50°C 70-100°C solenoids
posing a burn risk to the skin.

Utilize large volume reservoirs and effective

offline cooling to control fluid temperature and Exercise utmost care
avoid extreme highs. when working around
hydraulic equipment
Solenoid require more power to switch positions than due to the potential
to hold valves in place. for serious burns.
Implement controls that reduce power to the
solenoid after switching to lower temperature and
reduce energy consumption.

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 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 Anecdotal evidence suggesting
from pressures risks at pressures as low as
over 100 bar 7 bar
(1450 psi) (101.5 psi)

Tiny holes in hose skin, loose fittings, or

fractured pipes can result in fluid jets injecting Injuries can cause
under the skin. mechanical pressurized
These injuries may have minimal visible signs penetration and trauma to
but can lead to severe consequences if not surrounding tissue.
treated promptly. Toxicity of injected fluid
adds another layer of harm.
Severity varies based on pressure, proximity,
and jet size during the injury.
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FLUID INJECTION INJURIES
Prompt action is essential following any injection
injury to prevent severe consequences.

Without timely medical treatment, intense throbbing pain

unresponsive to medication can occur within
four to six hours

Neglected injuries may lead to amputation of

affected parts, highlighting the critical need for
proper care.

Keep any part of your skin at least 100 mm away from any part
of a pressurized hydraulic system.
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PINHOLE LEAK INJURY
Common hydraulic system injuries often result from pinhole leaks in hoses.
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.
To reduce the risk of such injuries, use a non-contact method like running
wood or cardboard along the hose to detect leaks.
Delay in seeking medical attention may lead to the loss of a finger or entire
arm.
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IMPROPER COUPLING
Hazards arise from improper coupling of hydraulic components, especially
between low and high-pressure systems.

Never connect a high-pressure Such improper coupling can lead to

pump to a low-pressure system or ruptures in components, hoses, or
incorporate low-pressure fittings.
components into high-pressure
systems.

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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GENERAL SAFETY PRECAUTIONS
DURING MAINTENANCE OF HYDRAULIC SYSTEM
Before starting any hydraulic work, follow the designated isolation
procedure.
POSITIVE ISOLATION Depressurize the system, and consider local isolation if necessary.
PROCEDURE
Never initiate work without proper training and a comprehensive
risk assessment.
Review equipment manuals thoroughly and ask questions for
clarity.
PRE-WORK Read Material Safety Data Sheets (MSDS) for chemicals used in
PREPARATION
the system.
Utilize all required safety equipment during maintenance tasks.

Document and practice de-energizing procedures for each circuit.

DE-ENERGIZING & Drain pressure lines and accumulators before maintenance work.
LOAD LOCKING
Avoid hammering during the tightening of pressurized lines.
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GENERAL SAFETY PRECAUTIONS
DURING MAINTENANCE OF HYDRAULIC SYSTEM

Test hydraulic pipes and cylinders at 1.5 times working pressure.

POST-REPAIR Check components' ratings before replacement.
TESTING &START-UP Use caution during testing to avoid injury due to potential system
failures.
Do not use bare hands to check hydraulic leakage; use a non-
FLUID LEAK CHECK porous material.
Avoid hot work like welding near hydraulic pipelines or tanks.

MODIFICATION Any modifications to the hydraulic system should be approved by a

APPROVAL competent authority.

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THANK YOU
FOR YOUR
ATTENTION

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