HandS Hydraulics Safety Awareness
Transcript of HandS Hydraulics Safety Awareness
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Hydraulics
Safety
Awareness
Dennis Mac
HandS UK Health & Safety Resources
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Hydraulics is no t
a recognisedoccupational
hazard Unless there is a lost time injury or a death,
hydraulic "accidents" go unreported
Result = no data
No data = no recognised problem
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But there isa problem.
Each of the cases illustrated here is an
accident that could well occur in your
company.
The first step in preventing these, as withall types of accidents, is training.
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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 incorrectlyreleasing pressure
temperature
ignition injection
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Employee Killed By Forklift Boom
Employee #1 was unloading a piece of steel with his forklift. His supervisorleaned down to unhook a chain and saw hydraulic fluid dripping from the
joint at the main cylinder; he told Employee #1 to take the forklift to be fixedby the maintenance man. The employee parked the forklift in themaintenance area and raised the forks. Employee #1 was standing underthe forks when the hydraulic fitting to the mast failed, resulting in a suddenrelease of the fluid and descent of the mast. Employee #1 was killed. Noone saw the accident. He may have been attempting to pinpoint the leak'slocation prior to summoning the maintenance man. There was a wrench onthe floor near the body, and it is likely that Employee #1 was attempting totighten the fitting to stop the leak, but instead stripped the threads, causinga complete failure.
OSHA Accident: 515205
Report ID: 0625700 -- Event Date: 09/18/1990
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Skin will scald at 48C (120F)
Two to three minutes at that temperature will
result in a 2nd degree burn.
The average operating temperature of a
hydraulic system of 60C
will cause a 2nd degree burn in
to 1 second.
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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.
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This operator was burned when a hydraulic hose,
neglected during maintenance, burst and spewed
hydraulic oil, at normal operating temperature,
over his entire body.
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Fire and Explosion Risks
High flash point: 145-315C (300-600F)
High auto-ignition: 260-400C (500-750F)
Under pressure, atomised spray of droplets
may extend 10 metres from the break Ignited readily by heat source
Resulting fire is torch-like with very high heat
release rate Mist in confined area can explode violently
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Welder Strikes Hydraulic Fluid And Is
Burned To Death
Employee #1 was arc welding in the forward ballast tank of theAmerican Trader vessel, working approximately 68 feet from theupper deck in an enclosed space. His welding rod struck a pipeline
containing hydraulic fluid, which was under approximately 600 psigat the time, and ignited a fire. Employee #1 became engulfed inflames, and sustained thermo-cutaneous burns over 80 percent ofhis body from which he died.
OSHA Accident: 967430
Report ID: 0932000 -- Event Date: 07/18/1991
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Two Employees Burned In Flash Fire
Employees #1 and #2, both press operators, were operating an
aluminum extrusion press when a hydraulic hose developed a leak.
Hydraulic fluid sprayed out in a small stream under pressure and
then partially vapourised. The heat and flame from a nearby oven
ignited the fluid, resulting in a flash fire. Employees #1 and #2
sustained second- and third-degree burns.
OSHA Accident: 170587760
Report ID: 0950631 -- Event Date: 02/19/1996
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Imagine a chip pan fireProjected from a high-pressure nozzle
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The frequency of fires involving
hydraulic fluids has prompted theintroduction of fire-resistant fluids
for hydraulic systems.
Is your company using them?
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Employee Dies In Oil Drum
Explosion
Employee #1 was cutting the top out of a 55 gallon metal drum that
had contained hydraulic oil. The drum exploded, killing the
employee.
OSHA Accident: 170568448
Report ID: 0751910 -- Event Date: 06/09/1995
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Never use hands or fingers
to find leaks.
Fluid under high pressure can be
injected into the skin causing
extreme injury, serious infection
gangreneand amputation.
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Accidental Injection of Hydraulic Oil
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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
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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
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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
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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
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Pipe, retrieved from dismantled test rig
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Avoid prolonged breathing of its vapour, mist, andfumes.
Avoid prolonged or repeated skin contact.
Use chemical-resistant gloves, splash goggles and a
chemical-resistant apron
Elevated processing temperatures may cause
release of toxic vapours which are harmful if inhaled.
Before working with hydraulic oil, know the location of
the nearest emergency shower and eyewash station.
Working with Hydraulic Oils
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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.
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Working with Hydraulic Systems
Never begin work on a hydraulic system until fullytrained.
Never begin work on a hydraulic system without
a Risk Assessment.
Carefully review the manuals on equipment beforebeginning work. Ask questions about anything you donot fully understand.
Review all Material Safety Data Sheets (MSDS) for allchemicals used.
Maintain a clean work area free of slipping hazards anddebris.
Use all required safety equipment.
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Block, secure or lower to the ground components thatmay move, rotate or fall.
Use test equipment designed for higher pressures thanthe system being repaired. Use of gauges, lines,connectors, etc., designed for lower pressures can resultin bursting or equipment damage. Start with highpressure 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 HANDSto find leaks.Check for leaks using a piece of cardboard or wood.
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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 beingsupported by hydraulics. Stops, safety pins, etc, must be
in place before repairs begin.
AVOID HEATING NEAR PRESSURISED FLUID LINES.
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Hydraulics Maintenance
All hydraulic hoses, tube lines and fittingsshould be periodically inspected.
Any deterioration should be carefully examined
to determine whether further use of thecomponent would constitute a hazard.
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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 bynormal tightening or recommended procedures
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and/or
d. Evidence of excessive abrasion or
scrubbing on the outer surface of a
hose, rigid tube, or hydraulic fitting.
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Summary
The risks of work with hydraulic systems are notonly of high-pressure puncture accidents, but offire, lacerations, severe burns, crushing anddeath.
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 machineswhether they be milling machines or bulldozersthat use hydraulic pressure systems.
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All maintenance work should be visually examinedwhen Risk Assessed.
All "hot work" should be visually examined whenRisk Assessed.
the presence of a hydraulic system is a hazard
the presence of hydraulic hoses is a hazard
RISK ASSESSMENT
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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 whethermore should be done
Step 4: Record your findings
Step 5: Review your assessment and revise it ifnecessary
HSE, 5 Steps to Risk Assessment, INDG 163
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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.
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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 tothose to work near or with hydraulic systems.
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Get trainingfor competency in hydraulics
Get training
- not in the theoryof hydraulics -
but in the hazardsof hydraulics
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Hydraulics
Safety
Awareness
Dennis Mac
HandS UK Health & Safety Resources
Thank you