Stay Safe during Hydraulic Hose Repairs

Hydraulics systems are important for many operations, from agriculture to construction and industrial plants. Unfortunately, they can also pose serious and even life-threatening hazards if proper care is not taken. This is especially important when repairing hoses, as this requires workers to be in close proximity to the equipment.

At Hoseright, we’re concerned for the safety of all workers. That’s why we’ve put together this article to help you learn about the potential hazards of hydraulic systems and how to repair and maintain them. If you still feel unsure about working on the hydraulics yourself, you can call our friendly team about our hydraulic hose repair services.

Hydraulic Hazards

Hydraulic systems and hydraulic fluid can present serious hazards in a number of scenarios:

1.Pinhole Leaks

Hydraulic fluid is highly pressurised and the compressed liquid can jet out through tiny leaks, penetrating a worker’s skin or eyes. These are called ‘injection injuries’. They can cause severe injuries ranging from gangrene to blindness. Injection injuries require immediate medical attention and can often result in amputation of the affected limb.

2. Injuries from Hot Fluid

The pressurised fluid in a hydraulic system can also be very hot. If a worker is exposed to hydraulic fluid while removing or adjusting components, or if a hose bursts, they may sustain burns, bruises, cuts, and abrasions.

3.Hose Problems

When an unrestrained hose fails while under pressure it flails around until the hydraulic pressure is exhausted. A whipping hose increases the likelihood of contact with the hot hydraulic fluid. The hose itself can also cause striking injuries. These include concussions, lacerations, and broken bones.

Staying Safe around Hydraulics

Proper maintenance is critical for making sure your hydraulics assembly remains functional and safe. Here are some safety measures to keep you protected when checking, maintaining, and repairing hydraulic hoses.

• Regularly examine the hydraulic lines for leaks and wear.
• When looking for leaks, never run your hand along a hydraulic line –this puts you at risk of injection injuries. Instead, use a piece of cardboard or plexiglass to locate leaks.
• Always wear personal protective equipment (PPE) when performing maintenance on hydraulic systems, including gloves and eye protection.
• Do not rely solely on the hydraulic lift if you work on hydraulic components with the system raised. Set the working unit on blocks as a precautionary measure.
• Unless you are bleeding the hydraulic system, do not run the machine engine when you are servicing it.
• Let the hydraulic system cool before changing lines, connections, filters, or fittings.
• Coat the cylinder rods with a lubricant that provides rust protection.
• Periodically replace filters, and keep hydraulic oil away from contaminants – dirt is the biggest culprit in hydraulic system damage.
• Before removing the cylinders from working units, make sure that the units are resting on the ground, safety stands, or safety blocks and that the engine is shut off.
• Use a chain hoist, floor jack, or another type of assistive device if you need to remove heavy hydraulic pumps or control valves. Many workplace injuries result from people simply trying to lift or move things that are far too heavy for manual labour.

For further assistance with your hydraulic system maintenance, contact the team at Hoseright. We are Perth and Regional WA’s experts in hydraulic hose fittings.

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Hydraulic Hose Maintenance

It’s never a good idea to wait for something to fail before worrying about maintenance – and with hydraulic hoses – the financial, environmental and safety stakes are so high that neglecting maintenance is extremely irresponsible.

Dangers of Hydraulic Hose Failure Health and Safety

The primary concern of any workplace should be the safety of its workers. If you don’t take adequate care of your project’s hydraulic hoses and fittings, you are putting them at grave risk.

Environmental

Whether through sudden catastrophic failures or incremental leakage over time, hydraulic systems have the potential to cause great environmental damage. Hydraulic equipment leakage in the mining industry alone sees 370 million litres of hydraulic fluid deposited into topsoil, rivers, and forests annually.

Financial Loss

If a hose in your operation explodes or becomes uncoupled, you will also be facing huge financial loss as well as safety and environmental risks. Incremental fluid leakage is also a huge cost – the 370 million litres mentioned above represents an annual loss of around $1 billion worth of hydraulic oil!

Prevention Is Better Than Cure

Of course, even with the best maintenance in the world, leaks and failures will still sometimes occur in your industrial hoses and fittings. However, according to a 2015 study by the Australasian Mine Safety Journal (AMSJ), the majority of problems can be mitigated by regular, targeted maintenance and improved work protocols.

Scheduled Maintenance

The single most important factor is carrying out a regular, scheduled check and maintenance on all hydraulic equipment. The appropriate schedule for maintaining your equipment will be found in your user manual. Up to 50% of equipment failures in the AMSJ study were caused by hose or fitting failures that could be avoided through proper maintenance and inspection.

Maintenance Checklist

Exact maintenance procedures will vary slightly for specific hydraulic products; but as a general rule, the following checklist should be followed and safety guidelines must be rigorously adhered to:

1.Always turn off the equipment’s power and release pressure in hoses before carrying out any maintenance on hydraulic systems.

2.Place equipment and components in a safe or neutral position using a lock and tag procedure to ensure safety for the duration of the inspection.

3.Remove access panels and inspect hoses and fittings for the following signs of damage or leaks:

• Abrasion, nicks, cuts, cracks, hardness, or colour changes in the hose cover.
• Signs of leakage, such as puddles of fluid, low fluid levels in reservoir, leakage around the hydraulic fittings, or a greasy or dirty hose.
• If you suspect pressurised leaks, check for them using a piece of cardboard or plexiglass, never your hand!

4. Repair or replace damaged hoses and other components as necessary.
5. Safely inspect other hydraulic components like valves, pumps, and cylinders for leaks and damage.

6.Once your maintenance check is complete and all faulty parts are repaired or replaced, reinstall the system’s access panels.
7. Now you can safely turn the power back on.
8. Don’t become complacent, pay attention to your hydraulics system in between scheduled checks. Look and listen for anything unusual, and familiarise yourself with the common signs of compromised industrial hoses and fittings.

Hose Replacements and 24/7 Service

If you need a hose replaced and lack the personnel for the job, get in touch with the experts at Hoseright about our replacement and repair services. We offer 24/7 mobile service in Perth and the surrounding areas.

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