Safety First-The Importance of Inspecting and Replacing Hydraulic Lines

Hydraulic systems might seem like minor details, operating behind the scenes - but the reality is that they're the backbone of countless industrial and construction operations, powering everything from heavy machinery to more intricate manufacturing processes.

But the very systems that boost efficiency and productivity (thereby making your job so much easier) can also pose significant risks if they're not properly maintained. In this post, we'll take a closer look at why inspecting and replacing hydraulic lines is so important.

These are must-read tips for anyone, at any time, and in any industry, but we underscore their importance in June, which is National Safety Month in the US.

So whether you're an equipment operator, an industrial maintenance technician, or even a CEO, you can do your part to recognize the importance of hydraulic maintenance for safety this June by taking the time to read this guide.

Why Is Inspecting and Replacing Hydraulic Lines Important?

Hydraulic systems are the lifeblood of many industrial and construction operations. They're powerful, efficient, and reliable - but only if they're well-maintained. A compromised hydraulic line is dangerous for everyone, from operators to bystanders and even equipment.

Here's why it's so important:

Safety Risks

A leaking hydraulic line can create slippery surfaces, leading to accidents or injuries. Imagine working on a wet surface where every step could lead to a fall - definitely not something you want to subject yourself (or your employees) to.

Not only that, but hydraulic fluid is often pressurized. A sudden equipment failure caused by a leak can result in unexpected malfunctions and put your team in harm's way. The consequences can be severe, including burns from high-temperature fluid or skin irritation from fluid additives.

Remember, hydraulic systems can operate at temperatures exceeding 200°F and pressures ranging from 2,000 to 10,000 PSI. Cracking a fitting or dealing with old, brittle hoses that burst can result in fluid sprays that end up causing severe injuries.

Injuries also occur because of improper repairs or the lack of adequate preventative maintenance (PM) procedures. Workers have suffered severe consequences from equipment failure due to neglected hydraulic lines.

Equipment Damage

Beyond human safety, neglecting hydraulic line leaks can lead to extensive equipment damage over time. Unattended leaks stress the system, potentially leading to component failures or entire system breakdowns. The cost of such repairs often far exceeds the expense of fixing a leaky line early on.

Both stationary industrial equipment and mobile construction machinery rely on hydraulic systems. Neglecting maintenance can cause these systems to fail, and the cost of replacing or repairing them is significantly higher than the cost of regular inspections and timely replacements.

Electrical Hazards

Another concern is the interaction between hydraulic systems and electrical components.

Accidental contact with live wires or improper grounding can cause electrical shocks or fires. The stored energy within hydraulic systems only adds to the substantial risks.

Pinhole Leaks

Pinhole leaks in hydraulic lines can also be dangerous. Pressurized hydraulic fluid can forcefully escape through small openings, resulting in fluid injection injuries, burns, and other hazards.

Immediate action to relieve hydraulic pressure and repair leaks is crucial, but it’s even better to inspect and replace lines before they reach this point.

Unexpected Release of Pressure

Understanding the risks associated with removing or adjusting components in hydraulic systems is just as vital. Working with pressurized hydraulic equipment can be very dangerous. Components like valves, connectors, or hoses might unexpectedly release hydraulic pressure, causing sudden movements or injuries.

Before removing or adjusting any parts, it's essential to relieve hydraulic pressure and follow all safety protocols.

When Should You Inspect Your Hydraulic Hoses?

Now, you hopefully know that regular inspection is key to maintaining the safety and efficiency of hydraulic systems. But how often should you inspect your hoses?

While the exact timeline will probably vary depending on your industry and the frequency of use, here is a good general schedule to follow:

●     Daily: A quick visual check for obvious signs of wear, leaks, or damage.

●     Weekly: A more thorough inspection, including checking connections and ensuring there are no signs of wear and tear.

●     Monthly: A comprehensive inspection, including pressure testing and checking for pinhole leaks.

Tips for Safely Inspecting and Replacing Hydraulic Hoses

When it comes to safely inspecting and replacing hydraulic hoses, there are several helpful tips you'll want to keep in mind.

First and foremost, always make sure that the machinery is turned off and properly isolated before beginning any maintenance work. This step can prevent the accidental exposure to high-pressure fluids that have the ability to cause serious injuries.

Next, visually inspect the hoses for signs of wear and tear, such as cracks, abrasions, or leaks. Pay close attention to the hose fittings and connectors, as these areas are prone to damage. It's also important to check for any kinks or twists in the hose, which can compromise its performance and safety.

After inspecting, if you find any damage or other potential issues, replace the hose immediately. Always use the manufacturer-recommended replacement hoses and fittings to ensure compatibility and reliability. When you're installing new hoses, make sure they're routed correctly to avoid sharp bends and contact with moving parts, which can lead to premature failure.

Remember, the key takeaway here is that regularly scheduled maintenance and inspections should be part of your routine. This can help you catch potential problems early and extend the lifespan of your hydraulic systems.

When you carry out this maintenance, be sure to properly document all inspections and replacements - that way, you can track the history and performance of your equipment over time.

Routine Inspections Provide Optimal Performance

When it comes to maintaining the efficiency and safety of your hydraulic systems, there's truly no substitute for regular inspections. These need to be scheduled and conducted at consistent intervals and tailored to the specific needs and usage of the system.

During each inspection, focus on identifying signs of wear and tear, verifying the integrity of seals and hoses, and making sure fluid levels are adequately maintained.

By adhering to a routine inspection schedule, you can identify and address potential issues before they escalate - and in doing so, hopefully extend the lifespan of the system and prevent costly downtime.

Inspecting and replacing hydraulic lines isn't just about maintaining equipment - it's about safeguarding your team.

Ready to take your hydraulic maintenance to the next level? Browse the Hose and Fittings catalog for a wide range of hydraulic components and feel free to reach out with any questions. We'll help you find the information and supplies you need to keep everyone safe - and your equipment functioning exactly as it should.

FAQ

What are the safety precautions that need to be taken when working with hydraulic systems?

Always remember to follow safety protocols like using insulated tools, proper lockout/tagout procedures, and making sure everything is well grounded to steer clear of any electrical mishaps.

What should be inspected for in hydraulic lines?

During inspections of hydraulic lines, keep an eye out for leaks, wear and tear, damage, or any signs of deterioration to identify and address potential issues early and to keep your system running smoothly.

How often should hydraulic lines be replaced?

The frequency of replacing hydraulic lines can vary based on factors like usage, environmental conditions, and manufacturer recommendations, but as a rule of thumb, consider replacement if you spot significant wear or damage during routine checks.

How often should hydraulic hoses be inspected?

For optimal performance, try to inspect hydraulic hoses every three to six months, adjusting the frequency based on usage and environmental factors (more often than every three months doesn't hurt, either). This will help you catch any potential issues early on and extend the lifespan of your hydraulic system.