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# Hydraulic Safety

Hydraulic Safety. Colorado Mine Safety Training Program John Barton CMSP. Our Demonstration Consists of 1 DA ram and 1 porta power. Notice each end has a pressure gauge and the “rod end” of the cylinder only has a gauge. Watch as we apply pressure to the closed end of the cylinder. 400. 775.

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## Hydraulic Safety

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1. Hydraulic Safety Colorado Mine Safety Training Program John Barton CMSP

2. Our Demonstration Consists of 1 DA ram and 1 porta power

3. Notice each end has a pressure gauge and the “rod end” of the cylinder only has a gauge.

4. Watch as we apply pressure to the closed end of the cylinder

5. 400

6. 775

7. 1000

8. 1500

9. 2000

10. 2400

11. What Happened?Why did the 2 pressure gauges read different?

12. Hydraulic Pressure Intensification

13. A typical single rod single acting hydraulic cylinder

14. Fluid under pressure enters the closed end...

15. Forcing the piston and rod out of the rod end

16. A typical single rod double acting hydraulic cylinder

17. Fluid under pressure can enter either side of the cylinder thus moving the piston and rod in either direction

18. Extending the rod...

19. Or retracting the rod

20. The problem occurs, when the rod end port orline of a single rod double acting cylinder is restricted and system pressure is applied to the closed end.

21. A Few Fundamentals: Force Area Pressure Force is expressed in lbs. Area is expressed in in² Pressure is expressed in PSI

22. The FORCE of the cylinder in lbs. Is the system pressure multiplied by piston area…remember this area is round The area of a circle is: A = π r² Lets assume this cylinder is 4” in diameter The area of this PISTON is 3.14 x 4 or 12.5 sq. in Lets assume the system pressure is 1000 psi This cylinder WILL produce 1000 x 12.5 or 12500 lbs of FORCE! This area is known as the major area

23. If Force = Pressure x Area then Pressure = Force ÷ Area With this 4” diameter cylinder, the rod diameter is 2” We must subtract the rod Area from the Piston Area To obtain the MINOR Area! 12.5 - 3 = 9.5 in² Minor Area Major Area is 12.5 in² Rod Area is 3 in²

24. When system pressure is applied to the closed end and the rod end is restricted, pressure intensification occurs Area = 9.5 in² Pressure = 1000 PSI Pressure = Force ÷ Area 12500 ÷ 9.5 = ?? 12500 lbs of Force X

25. 1325PSI is within the rod end of this cylinder when the rod end port is restricted and system pressure is applied to the closed end of the cylinder! 1325 PSI 1000 PSI 1325 PSI

26. Another Scenario

27. 5 “ cylinder 4 “ rod working under 2200 PSI Major Area = 19.6 Rod Area = 12.5 Minor Area = 7.1 Force = 19.6 x 2200 or 43120 lbs Intensified Pressure = 43120 ÷ 7.1 or ?? X

28. 6073 PSI 2200 PSI Would you like to be working near this cylinder if this condition existed? Where might you find this type of cylinder? What could cause a rod end port to be restricted?

29. Types of restrictions include: Hose restriction\complete blockage Hard pipe damage Ball valve or gate valve INSTALLATION Foreign objects/contamination What can WE do to minimize exposure to this HAZARD?

30. Be thorough when making Equipment Examinations Repair or replace damaged components immediately Don’t wait until the maintenance shift NEVER use a ball valve for controlling a hydraulic cylinder circuit Don’t adjust any circuits’ pressure relief valve you may be setting yourself up for disaster

31. The Accident

32. A mechanic with no formal training in hydraulics was attempting to test a hydraulic boom lifting cylinder for leaks while attached to a large front end loader. He used a uni-directional (one way) inline flow meter. He installed the flow meter in series with the cylinder between the cylinder and the directional control valve in the rod end hose. Asking the operator for assistance, the mechanic instructed the operator to retract the cylinder until it stalled against the base of the cylinder and to hold full pressure. The mechanic observed the flow meter and saw no indication of leakage. He signaled to the operator to extend the cylinder a short distance to repeat the test.

33. Uni-directional Flow meter To directional control valve (valve bank)

34. As the cylinder began to extend there was a loud explosion. At the same instance the flow meter assembly, still attached to one end of the hose, came flying across the machine and skimmed across the top of the mechanics head. The hose end had ruptured at the crimp connection near the flow meter. Hot oil escaping from the severed hose sprayed his face and neck. He was treated for minor burns. He narrowly escaped Disaster He did not understand that a uni-directional flow meter contains an internal check valve

35. Hydraulic accidents frequently occur and for the most part are not understood. Treat hydraulic systems with the same respect you would electrical systems. They ARE as potentially hazardous.

36. Colorado Division of Mining Reclamation and Safety Mine Safety Training Program

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