Hydraulic Safety Induction

8/6/2019 Hydraulic Safety Induction

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InductionInduction in inFluid Power Fluid Power

A fluid is defined as a substance whichchanges its shape easily and adapts to theshape of its container.


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ObjectiveObjective - - LearningLearningOutcomesOutcomes

B asic Hydraulic circuit & ComponentsRecognise HazardsWork safely with pressure & forceUnderstand Fluid Transfer (hoses, piping,fittings & fluids)


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Pascals LawPascals Lawressure applied to confined

fluid is transmittedundiminished in every

direction and acts with equalforce on equal areas and at

right angles to them.


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Counterbalance valveCounterbalance valve


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Actuators Actuators


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Accidents can happen if Accidents can happen if

we are not aware of we are not aware of Hydraulic System power Hydraulic System power

This following person did not realise he had an injury (whichwas a pin hole in size) until the following day. This displaysgraphically fluid power at its destructive best.

BE WAR E


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HYDRAULIC INJECTIONINCIDENT

A warning to us all

Aberdeen


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Hydraulic Injection caused a pinprick intrusion to the IPs hand.

Hydraulic Fluid in use wasa Mineral Oil Unknown atpresentPressure of fluid was630B ar (approx 9,150psi)Eq uipment in use: Scissor cutters used at Road Traffic Accidents to releaseoccupants.

Location of Accident: FireService Training GroundRisk Assessments were inplace and Full PP E wasworn.


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Events

Training Session under controlledconditions within Brigade TrainingPremisesIP was to cut through samplevehicle using scissors.Normal practise at time was for the h ydraulic hose to be run over operators shoulder to tool in use.Hose ruptured at ferrule arearesulting in release of fluid through

PP E (Leather gauntlets) to IPshand.


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W hat Happened Next

IP went to A&E and initial prognosiswas keep clean and rest.By chance a specialist observedand intervened.Mineral Oil had alread y started toeat awa y fatt y tissues in hand andbegan travelling through the hand

and up the arm.IP had 5 operations to cut awa y oildeposits and was on his last chancebefore losing arm. It was successfulWound could not be sutured due totissue damage b y oil so wound wasgraduall y closed over weeks.


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Results

IP was eventuall y medicall y discharged from force and is severel y disabled in this hand.Fire Brigade has passed learning's on to its associated Brigades.Litigation is in place:

IP to BrigadeBrigade to Eq uipment Manufacturers.

IP awaits final outcomeTimescale: 2 years and counting


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W ear appropriate PPEW ear appropriate PPE


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W ork Alcohol and DrugW ork Alcohol and Drug

FreeFree


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Awareness

Safet y procedures for maintenance and operation of heav y e quipment begin with theunderstanding that an yone who works with h ydraulic machiner y must be aware of the potential

hazards involved.The simplicit y of control of man y hydraulic s ystems tends to belie the sometimes awesomepower and mechanical forces associated with the e quipment. One fraction of a second of

carelessness, b y a simple oversight, can result in serious injur y and sometimes death.The 2000 Occupational Health & Safet y Act outlines the obligations of both the Emplo yer & the

Emplo yee. Their obligations are as follows:The Emplo yer must Provide & Maintain:

Safe Plant & Eq uipmentSafe s ystems at workInformation & Training

PP ESafe Working Environment

The Emplo yee must take reasonable care to:Ensure their own safet y at work

Avoid adversel y effecting the safet y or health of an y other personsUse PP E provided

Report hazards and potentiall y serious conse quences


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P ower Unit

E nergy

Create Flow Control Flow/P ressure

Use Flow/P ressure toP erformWork E nergy

Hydraulic Systems A confined fluid is one of the most versatile means of modifying motion and transmitting power.

Pump/Compressor Control Valve Actuators(Cylinders/Motors)

Fluid power or specifically hydraulic systems operate on the following basic premises:

y If we create a FLOW of fluid and then R ES TR ICT that flow, we willgenerate a pressure!

y If we place ACTUATOR

Sin the FLOW of fluid then those actuators willconvert this flow into movement!

OR! ..y FLOW makes it GO!

y P R ESS UR E will result in FORC E being applied to the actuator!*FLOW MAK ES IT GO!

*R ES TICTED FLOW G ENE RAT ES P R ESS UR E !

FLOW A ND

P

R ESS

UR E

P

ROD

UCE

ME

CHA N I

CAL WORK IFHAR NESSED / CO N TROLL ED / D IR E CTED


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Before Working On Any Hydraulic Circuit

y E nsure you have a thorough knowledge of the subject.y E nsure you have a diagram of the circuit and you can read, and understand the circuit.y E nsure the circuit is hosed correctly and all the protection equipment is in place andcorrectly set.y NEVER use the part of the hydraulic circuit for another task for which it was not intended.ALL hoses must be connected.Isolate the circuit fully before working on it.


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EQUIPMENT SHUT DOWN PROCEDURE

After operating EQUIPMENT there is a certain safety shutdown procedure that MUST be observed: Park the machine on level ground and apply the park brake.

DO NOT UNDER ANY CIRCUMSTANCE LEAVE EQUIPMENT WITH THEIMPLEMENTS RAISED, AND/OR UNSUPPORTED.

THENLower all implements so that there is no hydraulic actuator force required for support. If

unsupported, chock or follow OEM instructions. THEN

Turn off the engine or isolate the prime mover so that the system is inoperative. THEN

Operate all the directional control valves through all possible positions to relieve entrapped pressurein the system.

THENIf maintenance or repair work is required on the machine, all actuators and implements must be

securely blocked to prevent movement. If an accumulator is fitted, the bleed valve must be openedand correctly tagged.

NEVER Rely on Gauge pressure readings


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Lo ad Lock Valves E ven though load-lock valves are fitted to boom lift cylinders on continuous miners and shuttles cars ALWAYS use the mechanical stops provided when working under raised booms.Hydraulic Cylinders-ActuatorsO n assembly and testing, ensure all connections and hoses are properly fitted.

Blockages in return flow lines can cause over-pressurization and intensification well beyond designed system pressure.


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SPOT TH E HAZA RD

Look CloseLook Wide

Look AboveMachinesMethodsMaterials

Personal FactorsEnvironment


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LOCK OUT IS OL A T I ON

You MUST be aware of the SIT E tagging and Isolation Procedure

TAGGING PROCEDURE

Personal Danger TagsOut of Service Tags

Information Tags

Tags provide important information. Failure to read and follow the instructions on a tag attached to any equipment could result in the deatinjury of yourself or workmates.


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Personal Danger Tags

Personal Danger Tags are used to ensure that individuals working on equipment itemscan do so in safety. The Personal Danger Tag is your insurance against injury E nsure

you use Personal Danger Tags appropriately and in accordance with procedures Do not start or operate any item of equipment which has a Personal Danger Tag

attached to its isolation point.

Out of Service Tags

O ut of Service Tags are placed on isolation point/s of defective equipment which, if operated, could cause personal injury, equipment damage, or adversely affect some

part of the operation.Do NOT use Out of Service Tags in place of Personal Danger Tags


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Ensure Isolation From:Ensure Isolation From:

ElectricityElectricityPressurePressureMotionMotion


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IF I N DOU BT CH E CK IT OUT !IF you are unfamiliar with the isolation procedures for a given task or work area or if you are skeptical abou

procedures effectiveness, do not proceed with the job. Consult your supervisor or obtain clarification.

JO B SAF E TY A NALYSIS or TAK E FI VE THINK THROUGH THE TASK Have a clear plan in mind

Understand the jobRight information

Procedure to follow Right tools & equipment

Right permitsPeople or systems affected

Safe accessNearby Equipment

What could go wrong Alternative methods


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W hat if ?It.

y Fallsy

Slipsy Breaksy Spillsy Dropsy Shiftsy Doesnt fit

y Sticksy

Jamsy Ignitesy Leaksy Too Heavyy Too Big/Smally Hot

y E nergisedy

Sharpy Pressurizedy Poisonousy Incorrectly

Labeledy The wrong one

I m He/She/Theyy W rong

y Confusedy In need of

assistancey Not strong enoughy

Too slowy Dont understandy Let goy Need Helpy M ake an error


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ASSESS THE R SK

Is it possible?y Improbabley F requenty Occ asionaly R emotey Injuryy E nvironmental

Impa c ty P roperty Damagey usiness

Interruption


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MAKE THE CHANGES Control & Communicate

y Remove the hazardy Is olate the hazardy Barricade the hazardy eople behaviory U s e low gear, wear PPE Etcy Sy s tem s (Permit s , J SA etc)

D O THED O THEJ OB J OB

SAFELY SAFELY


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I S O LATE h VENT

Mechanisms Controlled By Fluid PowerObjects may fall or machines may loose brakes or steering


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I NSPECT I O N Inspection Requirement

Consult Operator. They often are able to reduce time required in determining functions not

satisfactory operating.Check manufacturers requirementsInspect for leaks in hoses or fittings

Damaged, cut or abraded coverExposed reinforcement

Kinked, Crushed or Flattened or twisted hose

Hard Stiff or heat cracked Charred hoseBlistered Soft degraded or loose coverCracked, damaged or corroded fittings

Fitting Slippage on hoseOther signs of significant deterioration

Leaking ports

Damaged or missing Hose clamps, Guards & ShieldsExcessive dirt or Debris around fittingsSystem fluid including

Level Type

Contamination

Condition and Air entrapment.


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Hose Deteri o rati on:H oses may deteriorate when exposed to:

UV LightSalt Water

Air Pollutants Temperature

OzoneChemicalsElectricity Abrasion

Application of external forces onto the hoses for which they are not designed ie Walk on or Drivenover


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Ex ternal P ys ical Abus eRoute to avoid tensile loads

Side loadsFlattening Kinking

Damage to threads & sealing surfaces Abrasion, and twisting

Exceeding minimum bend radiusDont clamp together High & low pressure hoses

Consider hose flexing as it becomes energized

Avoid Multiple planes of motion Avoid twisting


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INSP E CTIO NS OF HY DR AULIC SYST E M SB e particularly conscious of the following when inspecting a hydraulic system.

Hydraulic LinesKinked or chafed hosesDented pipe lines

Hoses too close to heat sourcesHoses tangling with moving parts

Leaks, Weeps and S pills Which Could I ndicateLoose or cracked fittings or pipesBrown O rings or seals

Excessive pressure in circuit causing components or hose lines to become stressed Wrong fittings or hoses being used

Condition of Oil for S mell, Colour and solid ContentDark colour together with almond smell usually indicates overheating

Milky appearance could indicate water inclusion


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U n usu al V i b rati o ns o r No ises This could be due to a mechanical fault

Fault within the hydraulic systemCavitation conditions

J erk y o r U nresp o nsi v e O perati o nsNormally due to air entrapped within the hydraulic system

Faulty accumulator

Ex cessi v e S o ck in the Sy stem Could indicate incorrect relief valve setting

Mechanical faultOperation fault


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O PERAT I NG FL U IDPersonal Safety

Reduce skin contamination to a minimumUse suitable equipment and work methods

Do not allow oil to soak into floor benches-clean up spills immediately.Use protective clothing including gloves

Barrier cream may be used for prolonged periods.

Avoid breathing oil mist or vapours.Oils in a hydraulic system are under high pressure and are also hot so beware of leaking hoses,

pipes, pipes, etc. These should be reported/repaired as soon as possible. A pin-hole in a hydraulic line operating at 13.7 Mpa ( 2000 psi) will create an oil exit velocity of

approximately 1500 kilometres per hour (946 miles per hour) which could easily penetrate the skinand enter the blood stream.

Oil temperature is normally in the vicinity of 60rC depending on the system design. Some mobileapplications often operate at temperatures much hotter than this, sometimes approaching the boiling

point of water. Oil burns are painful, serious, and long lasting.

Oil trapped in the tissue cannot be easily removed and instances of gangrene have often occurred I t is important


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Oil trapped in the tissue cannot be easily removed and instances of gangrene have often occurred. I t is importanttherefore not to put your finger over a jet of oil which may be observed coming from a faulty hose or fitting.

Fluid escaping from a small hole can be almostinvisible.S earching for oil leaks by F EE L is adangerous practice and may result in injury tofingers or even your hand. Use a piece of cardboard or wood, instead of your hands, tosearch for suspected leaks.

Components released under pressure may be propelled at high velocity


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Accumulator

An accumulator looks like and can act like a bomb if not treated properly. Many hydraulic systems are fitted with an accumulator whichis a specially designed pressure vessel and is one of the most potentiallydangerous components in the system. The accumulator can be used to

absorb shock or pressure in the situation of a power failure or it can beused to absorb shock or pressure surges due to sudden stopping or reversing of oil flow.


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Hydraulic ApparatusUse extreme care when removing the breather, filler connection, or hose to a reservoir. Many units are

pressurized to prevent the ingress of contaminationsand will discharge hot oil unless properly relieved.

Faulty Control ValvesI t is possible that a faulty pressure or directional valve may cause an actuator to respond without having been given acommand signal.


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Ho seHo se

RE PAI R


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RE PAI R

Hose S electionWhen selecting hoses remember the following

S ize: Use a N omogram or similar to determine hose diameter Temperature: Fluid and Ambient temperature must be consideredApplications or Approvals: I s a M S HA or D OT or other approval

required?Medium: Fluid must be compatible with Liner P ressure: Rated working pressure must not exceeded.E nds: S elect the right ends considering pressure rating of fitting &

type

Use only M SHA ( M ine Safety Health Authority) or F R AS FireR esistant Anti-Static) marked hose. If it is NOT marked it is NOTapproved.


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Prior To Assembly Inspect For:Style & TypeCleanliness

Damage to fittingsDamage to hose

SizeInside obstructions

LengthBlistersBurrs

Assembly Eq uipmentDO NOT - mix hose fitting or Hose from different manufacturers without written permission from

BOTH manufacturers.DO NOT -

Assemble a hose not listed for that fitting.DO NOT - Assemble a hose fitting on to a hose without following the manufacturers printedinstructions

DO NOT - crimp with anything but the proper crimper and DiesDO NOT - re-use a reusable fitting that was blown or pulled off

DO NOT - Reuse permanent hose fittings or part of them


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Hose Cleanliness

Clean out hose assemblies so that debris will Not clog or damage:PumpsCylinders ValvesFilters

When Installing Check:

Routing Correct style, size & length

Non conformities & damaged sealing surfacesReplacement is of equal quality to original

Dont kink or bend Avoid twisting, & kinking of hose

Assembly Torque. Do not over-tighten.Route to avoid rubbing together or against something which may abrade hose.

Do not clamp High & Low pressure hoses together


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V ariables in a hose:V ariables in a hose:

Hose LengthHose LengthHose T ypeHose T ypeHose SizeHose SizeCoupling T ypeCoupling T ypeCoupling OrientationCoupling OrientationHose ProtectionHose ProtectionOuter Cover PiercingOuter Cover Piercing

Extra AdaptorsExtra Adaptors


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W hen it comes toW hen it comes tospecifying a hose, a clear specifying a hose, a clear language is needed thatlanguage is needed thatis well understood by allis well understood by all

parties.parties.


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Ov erall LengthOv erall Length


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Seat to SeatSeat to Seat


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Hose Cut LengthHose Cut Length


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Ov erall V ersus Seat toOv erall V ersus Seat to

SeatSeat


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SAE J517 Tolerances for SAE J517 Tolerances for Length:Length:

Hose LengthHose Length + /+ / --Tolerance.Tolerance.

Up to and Including 300mmUp to and Including 300mm 3mm3mm300mm up to and including300mm up to and including400mm400mm

5mm5mm

400mm up to and including400mm up to and including900mm900mm

7mm7mm

Over 900mmOver 900mm 1% of 1% of lengthlength


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Fitting O rientationFitting O rientation

Orientation isOrientation ismeasured in ameasured in a

clockwise directionclockwise directionbetween the fittingbetween the fittingfurthest from thefurthest from theviewer, to the fittingviewer, to the fittingnearest the viewer.nearest the viewer.


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SAE J517 Tolerances for SAE J517 Tolerances for Angles:Angles:

Orientation ToleranceOrientation Tolerancewhen two elbows arewhen two elbows are

fittedfitted

Angular Angular TolerancToleranc

e.e.Lengths up to 600mmLengths up to 600mm

(24)(24)33

Lengths over 600mmLengths over 600mm(24)(24)

55


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O rdering or specifying aO rdering or specifying a

hose:hose:1.1. Hose T ypeHose T ype2.2. Hose protection or extra operations.Hose protection or extra operations.

3.3. Hose Assembl y LengthHose Assembl y LengthBlank for Seat to SeatBlank for Seat to SeatO/ A for Overall LengthO/ A for Overall LengthCL for Cut LengthCL for Cut Length

4.4. Part No. End 1Part No. End 15.5. Part No. End 2Part No. End 26.6. Angle of Orientation Angle of Orientation

7.7. Extra partsExtra parts


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Always use Swept Bends if spaceAlways use Swept Bends if spaceallows.allows.


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High ambient temperatures and radiantHigh ambient temperatures and radiantheat shorten hose life. Insulate hoses.heat shorten hose life. Insulate hoses.


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W hen installing a hose, make sure it isW hen installing a hose, make sure it isnot twisted. Pressure applied to anot twisted. Pressure applied to atwisted hose will cause prematuretwisted hose will cause prematurefailure, or loosen connectors.failure, or loosen connectors.


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Allow for length changes when pressureAllow for length changes when pressureis applied. Do not clamp at bends.is applied. Do not clamp at bends.


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W hen the radius is below the requiredW hen the radius is below the required

minimum, use an angled adaptor tominimum, use an angled adaptor toimpro v e the radius and a v oid sharpimpro v e the radius and a v oid sharpbends.bends.


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Use angled adaptors and couplings to

Use angled adaptors and couplings toa v oid sharp bends or twists.a v oid sharp bends or twists.


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Learning O utcomes

Basic Hydraulic circuit &ComponentsRecognise HazardsW ork safely with pressure &forceU nderstand Fluid Transfer (hoses, piping, fittings & fluids)

Hydraulic Safety Induction

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