Hydraulic System Installation

Hydraulic systems use pressurised fluid to power cylinders, motors, and actuators in plant and process equipment.
Operating pressures in construction and industrial hydraulics typically range from 100 to 350 bar.
A pinhole leak in a hydraulic hose under pressure can inject fluid through skin causing fatal injury.
Hydraulic oil is hot during operation — contact with pressurised hot oil causes severe burns.
System installation involves pipe routing, hose connection, cylinder mounting, and reservoir filling.
All connections must be tightened to specification — under-torqued fittings leak and over-torqued fittings crack.
Pressure testing must follow a controlled procedure with exclusion zones around the test area.
Hydraulic fluid is harmful to the environment — spills must be contained and cleaned up immediately.
Stored energy in hydraulic accumulators must be discharged before any maintenance or disconnection.
The Pressure Systems Safety Regulations 2000 apply to hydraulic systems above specified pressure thresholds.

Injection injuries	Hydraulic fluid under pressure penetrates skin through pinhole leaks, causing tissue destruction requiring emergency surgery.
Burn hazard	Pressurised hydraulic oil at operating temperature causes severe thermal and chemical burns on contact.
Stored energy	Accumulators and trapped pressure in cylinders can release violently if the system is opened without depressurisation.

Do

Don't

Depressurise the system and discharge accumulators before disconnecting any component
Use a piece of card — never your hand — to check for pinhole leaks in hoses
Tighten all fittings to the specified torque values using calibrated tools
Establish exclusion zones around the system during pressure testing
Fill the reservoir with the correct hydraulic fluid grade specified by the designer
Route hoses and pipes clear of hot surfaces, sharp edges, and moving parts
Contain and clean up any hydraulic oil spills immediately using absorbent materials
Inspect hoses and fittings for damage, chafing, and correct routing before commissioning
Bleed air from the system gradually during initial filling to prevent cavitation
Brief the installation team on the injection injury hazard from pressurised leaks

DON'T run your hand along a pressurised hose to feel for leaks — use card only
DON'T open any hydraulic connection without confirming the system is fully depressurised
DON'T exceed the rated pressure of any component in the hydraulic circuit
DON'T use hoses, fittings, or seals that are not rated for the system pressure
DON'T route hoses where they can be crushed, abraded, or exposed to heat sources
DON'T mix hydraulic fluid types — incompatible fluids cause seal damage and failure
DON'T allow hydraulic oil to drain onto the ground or into watercourses
DON'T forget to discharge accumulators — they store energy even when pumps are off
DON'T overtighten fittings — cracked fittings fail under pressure with serious consequences
DON'T dismiss a small hydraulic oil leak — it may indicate an imminent hose failure

See also: MEICA Safety Awareness | Pressure Testing Safety

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