Delivering Fluid Sealing Solutions Since 1972

Working Safely with Hydraulic Cylinders

Hydraulic Cylinders Safety: Overview Guide

Hydraulic cylinders are essential in countless applications where immense force is required. They are primarily designed for the pulling, lifting, bending and holding of heavy loads. The ability to deliver precise, powerful movements makes them indispensable across industries such as construction, manufacturing, agriculture and automotive.

However, alongside this immense power comes significant risks. The forces that make hydraulic cylinders so effective also create the potential for serious hazards. The consequences when something goes wrong can be severe and dangerous. This is why, understanding and adhering to strict safety protocols is not only advisable, but also critical when working with these systems.

Cylinder Checks

Before operating any hydraulic cylinder, a thorough inspection for signs of damage or operational issues is essential. A cylinder that is compromised may not function properly, leading to system failure, significant safety hazards and potentially severe injury. Understanding the reasons why a cylinder may malfunction is key to crucial operation and best practices:

Reasons why a cylinder may not function properly and associated risks:

  • Failure to extend
    • – A coupler not fully tightened can prevent proper fluid flow and pressure build-up
    • – A worn or malfunctioning pump cannot generate the necessary pressure or flow
    • – Low oil level means the pump cannot draw enough fluid to extend the cylinder fully
    • – If the pump pressure relief valve is set too low, it will release pressure before the system reaches the required operating level
    • – The cylinder already being at full stroke is a common user-error
  • Partial extension
    • – This may be due to insufficient oil capacity in the system or an external obstruction blocking the cylinder movement
    • – A bent rod can also cause friction and misalignment, preventing full extension
  • Cylinder Leakage – often due to cylinder or seal damage, or a loose connector
  • Slow to Retract or No Retraction – this can be caused by a loose piston seal carrier or damaged piston seals, or a worn hydraulic pump unable to create sufficient return pressure

The Critical 80% Rule

A cornerstone of the safety operations of hydraulic systems is the 80% rule, which applies to both load and stroke ratings of the hydraulic cylinders. In practical applications, it’s rare that a load can be lifted or manipulated with absolute precision on its true centre of gravity. Even slight deviations introduce an “external side load force” that can exert significant stress on the cylinder, potentially leading to instability of the load. By limiting usage to a maximum of 80% of the cylinder’s rated load capacity, you create a vital safety buffer, drastically reducing the risk of the load shifting, tipping, or collapsing.

Ensuring a Stable Foundation

For a hydraulic cylinder to operate safely, it requires a firm, level and stable base. This means the cylinder must be placed on a flat surface capable of bearing the load, whilst ensuring the area beneath the cylinder is free from debris, loose material or unevenness that could compromise the stability. For this, a base plate is strongly recommended to to distribute the load over an even area.

Pressure Gauge

A pressure gauge is a vital and integral component of any hydraulic system. Its primary function is to provide real-time feedback, allowing you to meticulously monitor the force being applied on the cylinder within its reasonable margin of safety. This is crucial for preventing over-pressurisation, which can lead to catastrophic component failure, fluid leaks, and dangerous situations. Beyond its critical safety role, maintaining pressure within specified limits is also essential for the overall health and longevity of the hydraulic equipment, preventing stress and wear on internal components.

Sealing Components in Hydraulic Cylinders

Replacing and maintaining seals in hydraulic systems is essential for several critical reasons: they keep high-pressure fluid contained, preventing serious injuries such as fluid-injection burns and dangerous slip hazards from leaks. They ensure efficient operation by stopping power loss and keeping abrasive contaminants out of vital internal components and ultimately, saving money by preventing costly breakdowns, reducing downtime, extending the lifespan of expensive machinery, and minimising environmental impact from spills.

M Barnwell Services Hydraulic Seals

We offer Hydraulic and Pneumatic seals in Metric and Imperial sizes. They are available in a variety of materials, including Rubberised Fabric, PTFE (including Virgin, Carbon, Bronze, Glass filled), Polyurethane (AU), Nitrile (NBR), Hydrogenated Nitrile (HNBR). As well as, Viton® (FKM/FPM), Fluorosilicone (FVMQ), Ethylene propylene (EPDM), Silicone (VMQ), Nylon®, Nylatron®, Acetal, Peek, and Leather.

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E&OE. This information was gathered by our manufacturing partners.