Safety Around Hydraulic Equipment
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, pressurised systems may store energy that can cause unexpected movement or discharge.
Safety Practices and Preventative Measures
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.
Handle High-Pressure Systems with Care:
- Never attempt to check for leaks with your hands. Use a piece of cardboard or wood to safely detect leaks.
- Wear appropriate PPE, including gloves, safety goggles, and protective clothing when working near hydraulic systems.
Follow Proper Lockout/Tagout Procedures:
- De-energise and depressurise hydraulic systems before performing any maintenance.
- Lock and tag out the equipment to prevent accidental reactivation.
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.
Be Aware of Stored Energy:
- Release pressure from hydraulic systems before disconnecting or working on them.
- Use equipment with built-in pressure relief valves to prevent unexpected discharge.
Respond to Hydraulic Fluid Injuries Immediately:
- Injection injuries require urgent medical treatment. Do not delay seeking help, as these injuries can quickly worsen.
Real-Life Case or Scenario
A worker once tried to locate a hydraulic fluid leak with their hand. The pressurised fluid penetrated their skin, causing an injection injury. They delayed seeking medical attention, resulting in a 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 co-workers. Thank you for making safety a priority.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA), WorkSafe New Zealand requires PCBUs (Persons Conducting a Business or Undertaking) to eliminate or minimise risks associated with plant and machinery, including hydraulic systems.
Key expectations include:
- Maintaining and operating hydraulic systems according to manufacturer specifications
- Providing training on safe use and maintenance
- Conducting regular inspections
- Applying lockout/tagout (LOTO) procedures during servicing to prevent accidental activation
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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