Induction in

Fluid Power


A fluid is defined as a substance which changes its shape easily and adapts to the shape of its container.

Objective - Learning Outcomes

Basic Hydraulic circuit & Components  Recognise Hazards  Work safely with pressure & force  Understand Fluid Transfer (hoses, piping, fittings & fluids)


Pascals Law
ressure applied to confined fluid is transmitted undiminished in every direction and acts with equal force on equal areas and at right angles to them.

Counterbalance valve

Actuators

Accidents can happen if we are not aware of Hydraulic System power

This following person did not realise he had an injury (which was a pin hole in size) until the following day. This displays graphically fluid power at its destructive best. BEWARE

HYDRAULIC INJECTION INCIDENT

A warning to us all Aberdeen

Hydraulic Injection caused a pinprick intrusion to the IPs hand.

 

Hydraulic Fluid in use was a Mineral Oil Unknown at present Pressure of fluid was 630Bar (approx 9,150 psi) Equipment in use: Scissor cutters used at Road Traffic Accidents to release occupants. Location of Accident: Fire Service Training Ground Risk Assessments were in place and Full PPE was worn.

Events

 

Training Session under controlled conditions within Brigade Training Premises IP was to cut through sample vehicle using scissors. Normal practise at time was for the hydraulic hose to be run over operators shoulder to tool in use. Hose ruptured at ferrule area resulting in release of fluid through PPE (Leather gauntlets) to IPs hand.

What Happened Next

IP went to A&E and initial prognosis was keep clean and rest. By chance a specialist observed and intervened. Mineral Oil had already started to eat away fatty tissues in hand and began travelling through the hand and up the arm. IP had 5 operations to cut away oil deposits and was on his last chance before losing arm. It was successful Wound could not be sutured due to tissue damage by oil so wound was gradually closed over weeks.

  

Results
  

IP was eventually medically discharged from force and is severely disabled in this hand. Fire Brigade has passed learning's on to its associated Brigades. Litigation is in place:
 

IP to Brigade Brigade to Equipment Manufacturers.

 

IP awaits final outcome Timescale: 2 years and counting

Wear appropriate PPE

Work Alcohol and Drug Free

Awareness
Safety procedures for maintenance and operation of heavy equipment begin with the understanding that anyone who works with hydraulic machinery must be aware of the potential hazards involved. The simplicity of control of many hydraulic systems tends to belie the sometimes awesome power and mechanical forces associated with the equipment. One fraction of a second of carelessness, by a simple oversight, can result in serious injury and sometimes death. The 2000 Occupational Health & Safety Act outlines the obligations of both the Employer & the Employee. Their obligations are as follows: The Employer must Provide & Maintain:

Safe Plant & Equipment Safe systems at work Information & Training PPE Safe Working Environment

The Employee must take reasonable care to: Ensure their own safety at work Avoid adversely effecting the safety or health of any other persons Use PPE provided Report hazards and potentially serious consequences

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

Power Unit Use Flow/ Pressure to Perform Work

Create Flow

Control Flow/ Pressure

Energy

Pump/Compressor

Control Valve Actuators (Cylinders/Motors) Fluid power or specifically hydraulic systems operate on the following basic premises: yIf we create a FLOW of fluid and then RESTRICT that flow, we will generate a pressure! yIf we place ACTUATORS in the FLOW of fluid then those actuators will convert this flow into movement! OR! .. yFLOW makes it GO! yPRESSURE will result in FORCE being applied to the actuator! *FLOW MAKES IT GO! *RESTICTED FLOW GENERATES PRESSURE! FLOW AND PRESSURE PRODUCE MECHANICAL WORK IF HARNESSED/ CONTROLLED/ DIRECTED

Before Working On Any Hydraulic Circuit

yEnsure you have a thorough knowledge of the subject. yEnsure you have a diagram of the circuit and you can read, and understand the circuit. yEnsure the circuit is hosed correctly and all the protection equipment is in place and correctly set. yNEVER 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.

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 THE IMPLEMENTS RAISED, AND/OR UNSUPPORTED. THEN Lower 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 pressure in the system. THEN If 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 opened and correctly tagged. NEVER Rely on Gauge pressure readings

Load Lock Valves

Even 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-Actuators On 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.

SPOT THE HAZARD

Look Close Look Wide Look Above Machines Methods Materials Personal Factors Environment

LOCK OUT ISOLATION

You MUST be aware of the SITE tagging and Isolation Procedure TAGGING PROCEDURE Personal Danger Tags Out 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 death or injury of yourself or workmates.

Personal Danger Tags

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

Out 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

Ensure Isolation From:

  

Electricity Pressure Motion

IF IN DOUBT CHECK IT OUT !

IF you are unfamiliar with the isolation procedures for a given task or work area or if you are skeptical about the procedures effectiveness, do not proceed with the job. Consult your supervisor or obtain clarification.

JOB SAFETY ANALYSIS or TAKE FIVE

THINK THROUGH THE TASK Have a clear plan in mind Understand the job Right information Procedure to follow Right tools & equipment Right permits People or systems affected Safe access Nearby Equipment What could go wrong Alternative methods

What if ? It. y Falls y Slips y Breaks y Spills y Drops y Shifts y Doesnt fit Im He/She/They y Wrong y Confused y In need of assistance y Not strong enough y Too slow y Dont understand y Let go y Need Help y Make an error

y y y y y y y

Sticks Jams Ignites Leaks Too Heavy Too Big/Small Hot

y y y y y y

Energised Sharp Pressurized Poisonous Incorrectly Labeled The wrong one

ASSESS THE R SK
Is it possible? y Improbable y Frequent y Occasional y Remote y Injury y Environmental Impact y Property Damage usiness y Interruption

MAKE THE CHANGES Control & Communicate

y y y y y y

Remove the hazard Isolate the hazard Barricade the hazard eople behavior Use low gear, wear PPE Etc Systems (Permits, JSA etc)

DO THE JOB SAFELY

ISOLATE h VENT
Mechanisms Controlled By Fluid Power Objects may fall or machines may loose brakes or steering

INSPECTION
Inspection Requirement Consult Operator. They often are able to reduce time required in determining functions not satisfactory operating. Check manufacturers requirements Inspect for leaks in hoses or fittings Damaged, cut or abraded cover Exposed reinforcement Kinked, Crushed or Flattened or twisted hose Hard Stiff or heat cracked Charred hose Blistered Soft degraded or loose cover Cracked, damaged or corroded fittings Fitting Slippage on hose Other signs of significant deterioration Leaking ports Damaged or missing Hose clamps, Guards & Shields Excessive dirt or Debris around fittings System fluid including Level Type Contamination Condition and Air entrapment.

Hose Deterioration:
Hoses may deteriorate when exposed to: UV Light Salt Water Air Pollutants Temperature Ozone Chemicals Electricity Abrasion Application of external forces onto the hoses for which they are not designed ie Walk on or Driven over

External P

ysical Abuse

Route to avoid tensile loads Side loads Flattening Kinking Damage to threads & sealing surfaces Abrasion, and twisting Exceeding minimum bend radius Dont clamp together High & low pressure hoses Consider hose flexing as it becomes energized Avoid Multiple planes of motion Avoid twisting

INSPECTIONS OF HYDRAULIC SYSTEMS

Be particularly conscious of the following when inspecting a hydraulic system. Hydraulic Lines Kinked or chafed hoses Dented pipe lines Hoses too close to heat sources Hoses tangling with moving parts

Leaks, Weeps and Spills Which Could Indicate

Loose or cracked fittings or pipes Brown 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 Smell, Colour and solid Content

Dark colour together with almond smell usually indicates overheating Milky appearance could indicate water inclusion

Unusual Vibrations or Noises

This could be due to a mechanical fault Fault within the hydraulic system Cavitation conditions

Jerky or Unresponsive Operations

Normally due to air entrapped within the hydraulic system Faulty accumulator

Excessive S

ock in the System

Could indicate incorrect relief valve setting Mechanical fault Operation fault

OPERATING FLUID
Personal Safety Reduce skin contamination to a minimum Use 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 skin and enter the blood stream.  Oil temperature is normally in the vicinity of 60rC depending on the system design. Some mobile applications 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. It is important therefore 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 almost invisible. Searching for oil leaks by FEEL is a dangerous practice and may result in injury to fingers or even your hand. Use a piece of cardboard or wood, instead of your hands, to search for suspected leaks.

Components released under pressure may be propelled at high velocity

Accumulator
An accumulator looks like and can act like a bomb if not treated properly. Many hydraulic systems are fitted with an accumulator which is a specially designed pressure vessel and is one of the most potentially dangerous components in the system. The accumulator can be used to absorb shock or pressure in the situation of a power failure or it can be used to absorb shock or pressure surges due to sudden stopping or reversing of oil flow.

EXTREME DANGER AN ACCUMULATOR CAN OPERATE AN HYDRAULIC SYSTEM NORMALLY EVEN WHEN THE SYSTEM IS SHUT DOWN AND ISOLATED.
As a word of CAUTION the accumulator must be blocked out of the circuit or completely discharged before attempting to disconnect any hydraulic component. A specific procedure is required. If at all unsure, do not proceed with the work.

NEVER try to disassemble an accumulator without releasing the pre-charge gas. If the accumulator is removed from the circuit without depressurising, oil can be discharged at an uncontrolled rate, and this may cause the accumulator to behave like a projectile launching its heavy steel case into the nearest person or object with disastrous results. An important function of the accumulator is that it requires a pressurized inert gas (nitrogen) to function properly. Nitrogen gas when discharged in a reasonably confined space can cause an oxygen deficient atmosphere. Atmospheres containing less than 18% oxygen are extremely dangerous and at less than 10% will certainly cause brain damage and often death. Also, while Nitrogen is non toxic, in high concentrations it is an effective asphyxiant.

Hydraulic Apparatus Use extreme care when removing the breather, filler connection, or hose to a reservoir. Many units are pressurized to prevent the ingress of contaminations and will discharge hot oil unless properly relieved.

Faulty Control Valves It is possible that a faulty pressure or directional valve may cause an actuator to respond without having been given a command signal.

Hose

REPAIR
Hose Selection When selecting hoses remember the following  Size: Use a Nomogram or similar to determine hose diameter  Temperature: Fluid and Ambient temperature must be considered  Applications or Approvals: Is a MSHA or DOT or other approval required?  Medium: Fluid must be compatible with Liner  Pressure: Rated working pressure must not exceeded.  Ends: Select the right ends considering pressure rating of fitting & type Use only MSHA (Mine Safety Health Authority) or FRAS Fire Resistant Anti-Static) marked hose. If it is NOT marked it is NOT approved.

Prior To Assembly Inspect For:

Style & Type Cleanliness Damage to fittings Damage to hose Size Inside obstructions Length Blisters Burrs

Assembly Equipment DO 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 printed instructions DO NOT - crimp with anything but the proper crimper and Dies DO NOT - re-use a reusable fitting that was blown or pulled off DO NOT - Reuse permanent hose fittings or part of them

Hose Cleanliness
Clean out hose assemblies so that debris will Not clog or damage: Pumps Cylinders Valves Filters

When Installing Check:

Routing Correct style, size & length Non conformities & damaged sealing surfaces Replacement 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

Variables in a hose:
       
Hose Length Hose Type Hose Size Coupling Type Coupling Orientation Hose Protection Outer Cover Piercing Extra Adaptors

When it comes to specifying a hose, a clear language is needed that is well understood by all parties.

Hose Assembly Length can be specified in 3 ways:

 Overall length  Seat to Seat  Hose Cut Length

Overall Length

Seat to Seat

Hose Cut Length

Overall Versus Seat to Seat

SAE J517 Tolerances for Length:

Hose Length Up to and Including 300mm 300mm up to and including 400mm 400mm up to and including 900mm Over 900mm +/Tolerance. 3mm 5mm 7mm 1% of length

Fitting Orientation
 Orientation is measured in a clockwise direction between the fitting furthest from the viewer, to the fitting nearest the viewer.

SAE J517 Tolerances for Angles:

Orientation Tolerance when two elbows are fitted Lengths up to 600mm (24) Lengths over 600mm (24)

Angular Toleranc e. 3 5

Ordering or specifying a hose:

1. Hose Type 2. Hose protection or extra operations. 3. Hose Assembly Length Blank for Seat to Seat O/A for Overall Length CL for Cut Length 4. Part No. End 1 5. Part No. End 2 6. Angle of Orientation 7. Extra parts

Adequate hose length is necessary to distribute movement on flexing applications, and to avoid abrasion.

Always use Swept Bends if space allows.

High ambient temperatures and radiant heat shorten hose life. Insulate hoses.

When installing a hose, make sure it is not twisted. Pressure applied to a twisted hose will cause premature failure, or loosen connectors.

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

When the radius is below the required minimum, use an angled adaptor to improve the radius and avoid sharp bends.

Use angled adaptors and couplings to avoid sharp bends or twists.

Approve appearance and excessive lengths by using angled couplings and adaptors.

Ryco Hose Assembly Video 25 minutes

Learning Outcomes
Basic Hydraulic circuit & Components Recognise Hazards Work safely with pressure & force Understand Fluid Transfer (hoses, piping, fittings & fluids)