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Safety Around Hydraulic Equipment

Caught In Between | OSHA Fatal Four

The Problem

Hydraulic equipment is essential on many job sites, but it also presents significant risks. High-pressure systems, faulty hoses, and improper handling can lead to serious injuries, such as injection injuries, burns, and crushing incidents. Today, we’ll discuss the hazards of hydraulic equipment and how to work with it safely to prevent accidents.

Identify the Hazards

  • High-Pressure Leaks: Hydraulic fluid under pressure can penetrate the skin, leading to injection injuries that require immediate medical attention.
  • Hose Failures: Damaged or worn hoses can rupture, spraying hot or flammable hydraulic fluid.
  • Improper Lockout/Tagout: Accidental activation during maintenance can cause crushing or amputation injuries.‍
  • Stored Energy: Even when equipment is off, pressurized systems may store energy that can cause unexpected movement or discharge.

Safety Practices and Preventative Measures

To address these hazards, always follow these safety measures:

  1. Inspect Hydraulic Equipment Regularly:

    • Check hoses, connections, and seals for wear, leaks, or damage.
    • Ensure protective covers and guards are intact.
    • Report any defects to your supervisor immediately and tag out faulty equipment.
  2. Handle High-Pressure Systems with Care:

    • Never attempt to check for leaks with your hands. Use a piece of cardboard or wood to locate leaks safely.
    • Wear appropriate PPE, including gloves, safety goggles, and protective clothing, when working near hydraulic systems.
  3. Follow Proper Lockout/Tagout Procedures:

    • De-energize and depressurize hydraulic systems before performing any maintenance.
    • Lock and tag out the equipment to prevent accidental reactivation.
  4. Store and Use Hoses Safely:

    • Avoid kinking, twisting, or exposing hoses to excessive heat or chemicals.
    • Use hoses rated for the system's pressure and replace them if they show signs of wear or damage.
  5. Be Aware of Stored Energy:

    • Release pressure from hydraulic systems before disconnecting or performing maintenance.
    • Use equipment with built-in pressure relief valves to prevent unexpected discharge.
  6. Respond to Hydraulic Fluid Injuries Immediately:

    • Injection injuries require immediate medical treatment. Do not delay seeking help, as these injuries can quickly worsen.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. Here’s an example of why these precautions matter: A worker once tried to locate a hydraulic fluid leak with their hand. The pressurized fluid penetrated their skin, causing an injection injury. They delayed seeking medical attention, resulting in severe infection and permanent damage. This could have been prevented by using a safe detection method and prompt treatment.

Employee Responsibilities

  • Inspect equipment before use and report defects.
  • Wear appropriate PPE when working with hydraulic systems.
  • Follow proper Lockout/Tagout procedures during maintenance.
  • Use only approved hoses and components for repairs or replacements.

Employer Responsibilities

  • Provide training on hydraulic equipment safety.
  • Ensure regular inspections and maintenance of hydraulic systems.
  • Supply appropriate PPE and replacement parts for worn or damaged components.
  • Enforce Lockout/Tagout procedures to protect employees.

Discussion & Questions

  • "What are some hazards you’ve encountered when working with hydraulic equipment?"
  • "Do you have concerns about the condition of any hydraulic systems on this site?"

Encourage employees to share experiences and ask questions.

Commitment/Action Plan

Let’s commit to inspecting all hydraulic equipment before use and strictly following safety procedures. If you see any issues, tag the equipment and report it immediately. Together, we can prevent accidents and ensure a safe job site.

Wrap-Up

Hydraulic equipment is powerful, but it comes with serious risks. By following these safety practices, we can protect ourselves and our coworkers. Thank you for making safety a priority.

Standards Overview

  • OSHA regulations require hydraulic systems to be maintained and operated according to manufacturer instructions (OSHA 1926.600).
  • Employers must provide training on safe operation and ensure systems are inspected regularly.
  • Lockout/Tagout procedures (OSHA 1910.147) are required during equipment maintenance to prevent accidental activation.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
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It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
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Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

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