hands hydraulics safety awareness

8/13/2019 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.




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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.




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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.




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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

hands hydraulics safety awareness

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