Hydraulic Systems Safety

Paul D. Ayers, Colorado State University

Quick Facts About Hydraulic Systems Safety…

Hydraulic systems must store fluid under high pressure. Three kinds of hazards exist: burns from the hot, high-pressure spray of fluid; bruises, cuts, or abrasions from flailing hydraulic lines; and injection of fluid into the skin. Hydraulic systems safety and performance requires general maintenance. Proper coupling of high and low-pressure hydraulic components and pressure relief valves are important safety measures.

Hydraulic systems are popular on many types of agricultural equipment because they reduce the need for complex mechanical linkages and allow remote control of numerous operations. Hydraulic systems are used to lift implements, such as plows; to change the position of implement components, such as a combine header or bulldozer blade; to operate remote hydraulic motors; and to assist steering and braking.

To do their work, hydraulic systems must store fluid under high pressure, typically 2,000 pounds or more per square inch. One hazard comes from removing or adjusting components without releasing the pressure. The fluid, under tremendous pressure, is also hot. The worker then is exposed to three kinds of hazards: burns from hot, high-pressure fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin.

Many systems store hydraulic energy in accumulators. These accumulators are designed to store oil under pressure when the hydraulic pump cannot keep up with demand, when the engine is shut down, or when the hydraulic pump malfunctions. Even though the pump may be stopped or an implement disconnected, the system is still under pressure. To work on the system safely, relieve the pressure first.

Pinhole Leak Injuries

Probably the most common injury associated with hydraulic systems is the result of pinhole leaks in hoses. These leaks are difficult to locate. A person may notice a damp, oily, dirty place near a hydraulic line. Not seeing the leak, the person runs a hand or finger along the line to find it. When the pinhole is reached, the fluid can be injected into the skin as if from a hypodermic syringe.

Immediately after the injection, the person experiences only a slight stinging sensation and may not think much about it. Several hours later, however, the wound begins to throb and severe pain begins. By the time a doctor is seen, it is often too late, and the individual loses a finger or entire arm.

Unfortunately, this kind of accident is not uncommon. To reduce the chances of this type of injury, run a piece of wood or cardboard along the hose (rather than fingers) to detect the leak (see Figure 1).

Figure 1: Detecting pinhole leaks in a hydraulic system.

Improper Coupling

Another hazard is improper coupling of low- and high-pressure hydraulic components. Do not connect a high-pressure pump to a low-pressure system. Do not incorporate a low-pressure component, hose or fitting into a high-pressure system. Component, hose or fitting ruptures are likely to occur.

Pressure relief valves incorporated into the hydraulic system will avoid pressure buildups during use. Keep these valves clean and test them periodically to ensure correct operation.

Maintenance

An improperly maintained hydraulic system can lead to component failures. Safe hydraulic system performance requires general maintenance.

Periodically check for oil leaks and worn hoses.
Keep contaminants from hydraulic oil and replace filters periodically.
Coat cylinder rods with protective lubricants to avoid rusting.

Tips for Safe Operation

Follow these rules for safe hydraulics operation:

Always lower the hydraulic working units to the ground before leaving the machine.
Park the machinery where children cannot reach it.
Block up the working units when you must work on the system while raised; do not rely on the hydraulic lift.
Never service the hydraulic system while the machine engine is running unless absolutely necessary (bleeding the system).
Do not remove cylinders until the working units are resting on the ground or securely on safety stands or blocks; shut off the engine.
When transporting the machine, lock the cylinder stops to hold the working units solidly in place.
Before disconnecting oil lines, relieve all hydraulic pressure and discharge the accumulator (if used).
Be sure all line connections are tight and lines are not damaged; escaping oil under pressure is a fire hazard and can cause personal injury.
Some hydraulic pumps and control valves are heavy. Before removing them, provide a means of support such as a chain hoist, floor jack or blocks.
When washing parts, use a nonvolatile cleaning solvent.
To ensure control of the unit, keep the hydraulics in proper adjustment.

For more information read this Hydraulic System preventative maintenance checklist.

Download the full pdf.

Paul D. Ayers, Colorado State University

Improving Safety: 10 Tips, Tricks, Rules and Suggestions

According to the U.S. Bureau of Labor Statistics, workers sustained a collective 2.9 million workplace injuries and illnesses in 2015, and nearly 5,000 workers were killed on the job—an average of 13 employees every day. As employers try to curtail those shocking numbers and improve safety throughout their facility, it’s important to examine the relationship between a safer workplace and ensuring uptime, reliability and quality asset performance.

Confined Space Entry Safety

Confined space entry safety. A confined space is anywhere not normally meant for human habitation in which access maybe restricted and the conditions in the confinement may be inadequate to support life or could cause engulfment. Obvious places are tanks, vessels, silos and below ground pits. The less obvious ones are cold rooms, areas of plant sandwiched between machinery and equipment, tip truck trays and open pit mines.

Leveraging Inspection Forms for Job Hazard Analysis (JHA)

Performing the daily and job specific hazard analysis (JHA) with your crew has been a long-standing element of your safety culture.

Plant Safety - Avoid Pitfalls of New and Untrained Plant Employees

For management, new and untrained employees present a different set of costly challenges. For example, productivity will drop due to lost time, there may be overtime expenses, insurance costs will rise and there can be potential lost customer sales. Worker's compensation claims will also increase and lead to higher premiums. How can these problems be avoided? What are some steps that can be put in place to help alleviate these concerns for new and untrained workers already in the workforce? Ideally, health and safety programs that offer basic training will fit the bill quite nicely. New and untrained workers need to learn about personal protective equipment (PPE), back-injury prevention, health and safety regulations and hazard recognition.

Work / Job Safety – Part 2

One aspect of safety is the reminder to be safe! Just the actual reminder might save someone’s life. It’s not unreasonable to have a safety moment every day. It could be one or two minutes. At some companies, when they have any meeting, they always start with a safety moment. In maintenance, there’s usually a five- or 10-minute section on safety during the daily toolbox meeting in the morning; nothing really elaborate. If you’re going to address a bigger safety topic, it might be a half hour or an hour with a slide presentation.

Trade-Offs in Drone Technology: High-Performance vs. Data Security

The rapid advancements in drone technology have brought high-performance drones to the forefront in several industries, leading to enhanced efficiencies and improved outcomes. However, the persistent concerns surrounding drone data security cannot be simply wished away. Organizations need to find a middle ground, one where they can acquire drones that deliver on their operational mandate, are cost-effective but also secure the data they hold. Because the tech is only going to get more powerful – but it doesn’t have to be at the expense of integrity and security of user data.

Hydraulic Systems Safety