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
Pressure 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
Create Flow Control Flow/ Perform
Pressure Work Energy

Pump/Compressor Control Valve Actuators

(Cylinders/Motors)
Fluid power or specifically – ‘hydraulic’ systems operate on the following
basic premises:
If we create a FLOW of fluid and then RESTRICT that flow, we will
generate a pressure!
If we place ‘ACTUATORS’ in the FLOW of fluid then those actuators will
convert this flow into movement!
OR! …..
FLOW makes it GO!
PRESSURE 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

Ensure you have a thorough knowledge of the subject.

Ensure you have a diagram of the circuit and you can read, and understand the circuit.
Ensure the circuit is hosed correctly and all the protection equipment is in place and
correctly set.
NEVER 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 procedure’s 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……….
 Falls  Sticks  Energised
 Slips  Jams  Sharp
 Breaks  Ignites  Pressurized
 Spills  Leaks  Poisonous
 Drops  Too Heavy  Incorrectly
 Shifts  Too Big/Small Labeled
 Doesn’t fit  Hot  The wrong one
I’m He/She/They
 Wrong
 Confused
 In need of
assistance
 Not strong enough
 Too slow
 Don’t understand
 Let go
 Need Help
 Make an error
ASSESS THE RISK
Is it possible?
 Improbable
 Frequent
 Occasional
 Remote
 Injury
 Environmental
Impact
 Property Damage
 Business
Interruption
MAKE THE CHANGES Control & Communicate
 Remove the hazard
 Isolate the hazard
 Barricade the hazard
 People behavior
 Use low gear, wear PPE Etc
 Systems (Permits, JSA etc)

DO THE JOB SAFELY

 ISOLATE – 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 Physical Abuse
Route to avoid tensile loads
Side loads
Flattening
Kinking
Damage to threads & sealing surfaces
Abrasion, and twisting
Exceeding minimum bend radius
Don’t 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 Shock 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 60C 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
Don’t 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 +/-
Tolerance.
Up to and Including 300mm 3mm

300mm up to and including 5mm

400mm
400mm up to and including 7mm
900mm
Over 900mm 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 Angular

when two elbows are Toleranc
fitted e.
Lengths up to 600mm ± 3°
(24”)
Lengths over 600mm ± 5°
(24”)
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)