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Hydraulic Leaks and Risk Every Drop Counts in Safety Are you really trained Many occupational Standards and regulations explicitly require the employer to train employees in the safety and health aspects of their jobs. OH&S standards make it the employer’s legal responsibility to limit certain tasks to employees who are “certified”, “competent” or “qualified” – meaning that they have had special previous training to perform specific duties and are made aware of related hazards. Training must be part of every employer’s safety and health program for protecting workers from injuries and illnesses. Research concludes that those who are new on the job have a higher rate of incidents and injuries compared to more experienced workers. DO WE OR I : A). Use hydraulics in our facility for plant processes. B). Have mobile or construction equipment. C). Have personnel that maintain equipment that utilizes hydraulics. D). Have employees who work within 1 meter of a hydraulic system or component. E). Have personnel who operate equipment that utilizes hydraulics, in public areas. F). Operate hydraulic equipment in fragile ecosystems. Once the employees training needs have been identified; the employee should enrolled in the best suited level of training. Ok where are all the Hydraulic Hoses? How are you Exposed • Now apply our risk matrix? In your walk around's You want to look for: • hydraulic leaks, leaks are component failure which can become catastrophic • hydraulic hoses that have wear from abrasion • hydraulic hoses that have bubbles forming on the outer covering • cylinder gland nut unthreading • cylinder pins bushings and retainers are in place and in proper condition • Fluid containment and absorbents are available and identified • Fire suppression or extinguishers are available • Low pressure adapters in a high pressure system • hose pressure ratings; do the hoses have a safe working pressure identified on them? • Are accumulators identified with hazard labels and have components integrated for discharging stored energy? Visual inspections should also include assessing risk behaviour such as: • how workers interact with equipment when performing their own inspection • how workers perform lockout and control hydraulic energy for maintenance tasks • is there a comprehensive lockout procedure for venting residual energy? • Are they supporting loads normally supported by hydraulic cylinders? • is the safe work procedures task based? Control Bleeding Should Never be allowed In large industrial systems lockable isolation devices are common, such as ball valves. Isolating in an area of a circuit to perform maintenance also requires specific procedures for isolation, lockout, monitoring, bleeding, and reintroduction of hydraulic energy. Each written procedure should include details of each of these items. Redundancy of isolation devices and monitoring is very important when energy exists beyond isolation devices. Hose burst protection system as described is known as a counter balance valve. The valve is designed to prevent the free fall of the boom (load) in the event of a connecting hose failure. The valve is also designed to control descending (runaway) loads including overpressure relieving capabilities. To be most effective in protection of hose failure, the valve must be mounted having reduced failure points. This is commonly achieved by mounting the valve directly to the cylinder port. In some cases it is welded directly or has a connection which is of rigid pipe or tube or steel adapter. The most common are bolted pad mounted valves, which the two surfaces are sealed with and elastomeric seal (oring). The fluid between the actuator (cylinder piston in this case) and the counter balance valve is isolated and will not pass the counter balance valve until pilot pressure from the directional control valve pilots the valve to open. Without pilot pressure or over pressure the fluid remains isolated. It is this isolated volume under pressure which must be identified and controlled safely. For each piece of equipment at work Write a safe work procedure specific to each task to include details on; • -Supporting components to prevent movement when fluid is vented • -Instruction for safe use of integrated monitoring and venting devices • -Monitoring of energy hazards throughout the duration of the task • -How to perform a hazard assessment specific to the task • -PPE requirements If you become injured/infected Thermal Expansion in Tanks When adding hydraulic fluid to a reservoir, NEVER FILL TO THE TOP! Oil expanding under working temperatures will overflow the reservoir I think there is a leak A severe NEAR MISS Lets Talk Risk in a big way! Is your Worker WITHIN CLOSE PROXIMITY Clean up Spills IMMEDIATELY $5. to $5000. in Seconds LOOK for Blisters Don’t Johnny Rig Leaks Think Confined Energy Hydraulic Fluid Is Very FLAMMABLE Change this Out Now Seems Tiny But a HUGE Hazard Simple Don’t Inspect by Hand Burns and Hot Surfaces ARE EVERYWHERE 150-F or 65-C High Pressure Bullets Lock out Tag Out Verify Zero Energy Don’t Mix Adapter Know the Difference Always THINK Environmental Protection Got a spill? Control it NOW!
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