Yes, high-pressure fluid can cause hydraulic injection injuries — a serious medical emergency where fluid is forced into the skin, causing internal damage.

Always wear personal protective equipment (PPE) and keep hands and body away from high-pressure areas.

Use cardboard or tissue around suspected areas — never your hands.

Ultrasonic leak detectors can detect high-frequency sounds emitted by escaping fluid.

Soap bubble solution can reveal small leaks under low-pressure conditions.

Always turn off system pressure before inspecting critical components.

Before servicing or disconnecting hydraulic components, operate control valves to relieve pressure in the system.

Bleed valves may also be used to safely release trapped fluid.

Ensure pressure gauges show zero before starting work.

Yes, hydraulic oil can be flammable, especially mineral-based oils. It’s crucial to store and handle oils carefully to prevent spills and avoid exposure to heat or open flames.

Excessive pressure, often due to system malfunctions or improper settings.

Aging hoses that lose their flexibility and strength.

Physical damage such as cuts, abrasions, or impacts.

Regular inspections and proper maintenance can help prevent hose failure.

Most hydraulic oils are amber or red, but color can vary based on the type of oil used, such as mineral or synthetic oils. Color is useful for identifying contamination and detecting oil degradation.

A safety protocol used to isolate energy sources to prevent accidental system activation during maintenance.

Lock equipment in the off position.

Tag the system to indicate it is being serviced.

Follow organizational safety procedures.

Hydraulic lock occurs when fluid is trapped under pressure in a confined space, preventing movement. This can happen in actuators or valves and can cause severe damage or system failure.

To avoid this, ensure pressure is relieved before disconnecting or servicing components.

Always use calibrated pressure gauges.

Gradually increase pressure to the required level, never exceeding system limits.

Perform tests in open, well-ventilated areas.

Monitor for leaks during the test.

Have emergency shut-off systems in place.

PPE such as gloves, goggles, and face shields protect against fluid sprays from high-pressure hoses, exposure to hot or toxic fluids, and physical injuries from moving parts and pressurised components.