Safety in the workplace is paramount. Few people would disagree with this statement, especially working professionals in the maintenance and lubrication fields, who are primarily well-trained in this area.

When it comes to handling and transferring chemicals and lubricants, the safety dress code for personnel must be specific and very clear. The need for the correct personal protective equipment (PPE) is absolute.

Typical PPE will, at a minimum, include protective footwear, coveralls, gloves, and eyewear designed to protect against skin and eye contact exposure to oils, greases, and chemicals for anyone handling, transferring, or cleaning up spills.

Here’s A Tip: As each plant or workplace supports using a unique inventory of lubrication fluids and chemicals, determining the correct PPE requires maintenance to list all lubricants and chemicals on site.

This list is then used to gather an up-to-date set of Safety Data Sheets (SDSs) for each lubricating fluid and chemical used in the plant/workplace from the lubricating fluid supplier(s). Once this has been done, these documents can be referenced to build a specific PPE-requirement table listing for each fluid, based on what’s spelled out in “Section 8: Exposure Control/Personal Protection” of its SDS.

Based on this table, a standardized corporate or departmental set of PPE for lubricating fluid handling and transfer requirements can be developed. Note: Fluids that require additional non-standard PPE (e.g., use of a respirator for lubricants, chemicals, and solvents identified as potentially hazardous to lungs) are best identified and listed as an additional PPE requirement on the work order.

At this point, the PPE lists and SDS library have become an asset, which, like any other asset, must be maintained to remain current and effective.

Keep in mind that lubricating fluids are heavy. With a standard 55-gal. drum weighing close to 500 lbs., proper training on the correct use of lifting devices, slings, and ergonomic devices is essential.

In addition, to protect against accidentally dropped or tipped lubricating fluid containers, all boots and shoes should be grade-one safety certified with steel toes and puncture-proof, oil-resistant soles.

Thus far, this article has focused on the common hazards associated with storing, handling, and transferring lubricating fluids into machine reservoirs.

However, once those fluids are in a pressurized lubrication-delivery system, such as an automatic grease or oil lubrication system, hydraulic system, or a simple manual pressurized grease gun, a whole new set of potential hazards confront the maintainer, lubrication technician, or machine operator. Referred to as “high-pressure injection hazards,” they can be lethal.

Lube-Application Safety Specifics

Most people are unaware that simple electric/compressed air grease guns available from local hardware and big-box stores can deliver lubricants at nozzle pressures up to and greater than 5000 psi. Nor do they realize that an innocuous hand grease gun can develop pressures up to 15,000 psi.

A 2020 study titled, Management of High-Pressure Injection Injury of the Hand in the Emergency Department, by S.O. Sanford and T.J. Mills (see link below) noted that “High-pressure-injection injuries occur when a high-pressure injection device, such as a paint or grease gun, injects materials into the operator [skin].

This injury most commonly occurs in the dominant hand and index finger.” As the researchers further explained, “The injection typically occurs to the fingertip when the operator is trying to wipe clear a blocked nozzle, or to the palm when the operator is attempting to steady the gun with a free hand during the testing or operation of the [grease gun] equipment.”

Similar injuries can occur when performing condition and leak checks on other pressurized hoses and lines (especially flexible-line material). Alas, it’s not uncommon to see maintainers and machine operators in TPM (Total Productive Maintenance) environments running their hands over high-pressure flexible lines to feel for leaks or soft spots that, if found, can easily inject fluid into a curious hand. Leak checks are best performed using a piece of stiff card, NEVER your arm, hand, or fingers.

Proper grease-gun training instructs the operator never to place his or her finger directly over the flexible delivery tube or nozzle tip when activating the trigger.

When cleaning the nozzle tip, always take the non-dominant hand off the trigger or pump lever. Unfortunately, many companies fail to provide adequate grease gun training to maintainers and machine operators.

Injection through the skin can occur at less than 1,000 psi. The higher the pressure, though, the more damage that can occur to the structure of the hand or finger. (If you ever received an inoculation in your arm using a medical pressurized jet injector, you may recall that the “pressure” felt pretty low, as such devices operated between 1,000 and 2,000 psi. Imagine, however, what pressures of 5,000 psi to 15,000 psi could feel like or do to a body part.)

It could be easy to ignore a pressure-injection injury and, ultimately, begin second-guessing if it did or did not occur. Don’t. According to the cited Sanford and Mills study, “A high-pressure injection injury should be considered a surgical emergency.”

To learn why, refer to the 2018 YouTube safety video titled Hydraulic Injection from Northwest Linemen College. It visually demonstrates how, if it’s not quickly addressed medically, a seemingly small injection site, with a slight area of redness, can turn into a devastating injury within mere hours.

The Sanford and Mills study found the overall incidence of amputation stemming from pressure-injection hazards was 48%. Solvents caused the greatest damage, followed by grease injection. In 25% of all cases, amputation occurred.

Similarly, in an earlier medical study performed at New York Methodist Hospital, J.T. Snarski, and R.H. Birkhan found that high-pressure grease guns/systems were responsible for 57% of all injection injuries, seconded by hydraulic-fluid injuries. Furthermore, the researchers found that the overall incidence of medical amputation resulting from such injuries was 48% and closer to 100% when injection pressure was greater than 7,000 psi.

Even if affected limbs can be saved, the long-term outcomes for the injured individuals are not always good. For example, the Sanford and Mills study found that among those who underwent successful surgical debridement, 50% ended up with a reduced range of motion; injuries adversely affected daily living activities; grip strength was reduced by 35% in 75% of cases; and all patients continued to suffer from some level of neuropathic pain.

Knowing What to Do

If you suspect a high-pressure injury has occurred, you (or the person in question) must seek professional medical treatment immediately. Studies show that the quicker these injuries are recognized and professionally treated, the higher the chance of limiting damage and saving an affected limb.

The Sanford and Mills study listed the following details that physicians require to determine the severity (and treatment) of pressure-injection injuries:

• Type and viscosity of the injected material (a copy of the fluid-type SDS is essential here).
• Time interval between injury and treatment (log when the injury occurred).
• Amount of material injected and velocity of injectant.
• Pressure of the appliance (or system).
• Anatomy and distensibility (swelling amount) of the site of injection.

If possible, use a smartphone, tablet, or other device to photograph or record a video of the injury as soon after the incident as possible. Also, photograph or record a video of the injection device.

In its safety video, Northwest Lineman College recommends the following first-response plan for pressure-injection-type injuries:

• Treat Immediately (seek medical attention).
• Don’t let the victim drive.
• Don’t leave the victim alone.
• No food or drink.
• Immobilize and elevate the wound.

If you feel that you (or others) have ingested lubrication fluid, have skin or eye irritations through exposure, or believe you (or someone else) may have suffered a pressure-injection injury, seek medical advice immediately. Since time is of the essence in these situations, it is always better to be safe than sorry.

First published in The RAM Review.

For professionals who work with machinery, it is vital to grasp the potential risks of fluid injection injuries. Although these incidents are rare, they are a significant concern, especially for personnel who are engaged in performing lubrication tasks. Let’s simplify the facts to understand why these injuries matter and how we can prioritize safety.

A few years ago, the International Fluid Power Society held a webinar on preventing and managing fluid injection injuries. The webinar highlighted some concerning facts from a study conducted by emergency department doctors at New York Methodist Hospital, revealing some serious statistics.

In North America, approximately 600 fluid injection incidents occur every year. This number may seem low, but it raises some concerns about maintenance staff working in the industrial sector.

Many doctors may underestimate these injuries because they’re rare, creating a problem since time is crucial in addressing them. On average, people wait about 8 to 9 hours before seeking medical help, assuming the injury isn’t severe. Unfortunately, waiting too long can worsen the situation and may even lead to amputation of limbs.

How Do Fluid-Injection Injuries Happen?

A question arises: Where do these injuries come from?

Most of these injuries occur from high-pressure grease guns and associated systems, making up 57% of cases.

Paint, hydraulic oil, and similar fluids follow at 18%, with diesel fuel injectors contributing 14%. Professionals who perform lubrication activities must understand the reasons behind these incidents to ensure their safety while working with machines.

Have a look at some of the worrying facts:

• The likelihood of amputation (losing a body part) after a fluid injection injury is, on average, 48%.
• If the pressure exceeds 7000 PSI, this risk approaches 100%. This highlights the need to ensure the utmost care, especially when dealing with high-pressure greasing systems.
• Another highly concerning factor is the duration it takes to seek medical assistance. If more than 10 hours pass, the likelihood of amputation can increase up to 100%. It is, therefore, crucial to act promptly to minimize the damage.

Injuries caused by fluid injections are often severe and usually need surgical intervention to fix the wound and avoid further damage caused by the fluid. Professionals working on high-pressure hydraulic machines and grease systems should spread this vital information and ensure everyone within their team knows how to stay safe.

How to Prevent High-Pressure Fluid Injection Injuries

Now, let us discuss how we can prevent these workplace-related injuries. First, be aware of the working hazards, be careful, take all the necessary precautions, let others know about the risks, and follow all the safety rules.

Understanding the dangers and taking simple precautions can help create a safe environment for lubrication tasks. Safety should always be the priority at the workplace.

Some basic steps must be implemented to ensure our workplaces are safe.

Always wear the appropriate PPEs, including hand gloves and protective eyewear, while performing the lubrication tasks.

While working with hydraulic systems, it’s important to be cautious and never underestimate the potential risks. If any signs of a fluid injection injury are noticed, like swelling or redness, seek medical consultation immediately without any delay. Waiting can worsen the injury, which should be avoided through immediate action.

Professionals who use high-pressure grease guns for the greasing task must be aware of the maximum pressure that grease guns can generate in case of overpressure.

Extra care must be taken when dealing with high-pressure grease guns and systems. It is also essential to be aware of the potential risks, including the chemical properties of the fluids being handled, and take the proper steps to avoid getting hurt.

It is important to let others know about safety regarding fluid handling. Consider having toolbox talks and safety awareness campaigns about fluid handling.

If everyone within the company knows and cares about safety, the chances of getting hurt by fluid injections are significantly reduced.

In conclusion, safety is everyone’s responsibility, especially when working with hydraulic machines. Understanding the associated risks, taking simple preventive measures, and spreading awareness can create a safer work environment for everyone within the organization. Let’s make safety a habit and ensure we go home safe and sound at the end of the day.

I recall starting my career in the mines in the late 1980s when Health and Safety was beginning to become a huge priority. I remember the sign at the entrance with the target and actual hours worked without incident.

Since then, whatever the industry, every site visit I’ve undertaken is usually only possible following a site induction, and having worked off-shore extensively over the last twenty years, I have regularly had to update my Basic Off-shore Survival Induction and Evacuation Training (BOSIET) along with the Helicopter Underwater Evacuation Training (HUET).

Safety is so integral in any business now that systems such as “Stop the Job” and similar systems requiring employees to complete two Observation cards per week are commonplace, especially in the oil and gas sector.

Safety comes first, followed by the environment and then profits, and no one will ever lose their job because of stopping work where safety is at risk.

Over the years, though, safety has become the norm, from simply slipping on a seat belt to automatically reaching for the safety glasses when I’m tinkering in the garage. It’s become second nature to the extent that I recall once stepping out of the office on a site and, within a few paces, feeling something wasn’t right: I’d forgotten my hard hat on the peg.

The culture of safety has become ingrained, with few willing to risk the shortcut of not preparing for a job. There is no excuse for not taking the necessary precautions when working.

Signage is a constant reminder, colleagues are a constant reminder, legislation is the final word; safety must always be complied with, no matter how low the risk.

There’s a sign I often see on the mirrors in the washrooms on sites; “Who’s responsible for your safety?”. What if there was another that said, “Who’s responsible for reliability on this site?”

Sadly, reliability does not enjoy the same legislation as Health and Safety or the environment. Therefore, it is too easy for senior management to overlook reliability and spend the money only where legislation requires, that is, safety and the environment.

Yet, reliability is a fundamental aspect of improving health and safety and reducing environmental impact. However, for this article, I will focus on safety and how reliability and lubrication best practices can help.

Fundamentally, planned work is always safer than reactive work.

Reactive work is typically:

1. “At risk” work requiring permits for:
   1. Hot work
   2. Working at height
   3. Confined spaces entry
2. More involved and undertaken less frequently than planned work with little time to assess the risks properly.
3. Accompanied by management pressure to restart the system as soon as possible with the attendant risk of shortcuts being taken and even encouraged.

Planned work is proactive and typically:

1. Undertaken routinely so the risks are understood.
2. More straightforward work involving inspections and minor adjustments to the system.
3. Time is allocated accordingly to complete the job safely.

Data from the Mine Safety and Health Administration (MSHA), an agency of the U.S. Department of Labor, showed that 43% of injuries and 24% of fatal accidents in mining occur during conveyor maintenance or inspection.

The conveyor-related fatal accidents typically include replacing idlers, clearing blockages, and cleaning up with a shovel or hose. However, an aspect of conveyors is that the work is often at height.

Consequently, any lubrication-related reliability issues will increase the risk of injury or fatality.

Notably, Ron Moore, managing partner of The RM Group, Inc., wrote an article, “A Reliable Plant is a Safe Plant is a Cost-Effective Plant,” published by Life Cycle Engineering and available on their website. Please look for this paper on the internet and read it.

However, in the concluding summary, Ron Moore wrote:

Finally, anyone who has been through a safety initiative understands that to improve safety, you must go through a series of specific steps to drive the improvement process. These are listed below.

• Top-down leadership – clear, consistent expectations
• Bottom-up ownership and employee engagement
• Education and training
• Action plans and measures
• Visual communication of expectations
• Standards and procedures
• Benchmarking and aggressive goals
• Audits and assessments
• Root cause focus
• Rewards (& willingness to challenge non-compliance)
• Resources for supporting improvement
• Continuous improvement expectations and process
• A culture – a way of life

All the companies I’ve worked with have policies and strategies similar to those related to safety. Few companies have these policies as it relates to reliability. Moreover, if the CEOs of these companies truly believe that safety is a top priority, they must have similar policies for reliability. The truth is they do not. They must, or else their commitment to safety is weak.

As I look at this list in the summary above, I see all the parallels with introducing a lubrication best practices program. Each of the above-bulleted points is what we need to implement a world-class lubrication management system successfully. The final sentence, “They must, or else their commitment to safety is weak.” speaks volumes.

So, what aspects of implementing a lubrication best-practices strategy and its implementation help address and improve safety? In fact, should not reliability engineers be putting safety as the main driver for justifying changes over the cost benefits? Let’s look at a few areas that I see as potential safety enhancers.

Desiccant Breathers

The key aim of a desiccant breather is to minimize both moisture and fine particulate ingress. However, they can also reduce oil vapors exiting the machine.

This has several safety benefits:

1. Minimizes poor air quality for personnel working in the area.
2. minimizes oil vapors settling on walkways and creating a slip hazard.
3. Indicates high humidity in the system, creating an early warning of problems and possibly avoiding catastrophic failure.

Quick-Connects

This one is my favorite, having observed funnels and open jugs left next to machines on so many occasions. The use of quick-connectors for attaching a hose to pump the oil into or out of a machine will not only eliminate the risk of contamination associated with pouring oil through a funnel but, from a safety perspective, it will:

1. Minimize the risk of spillage and necessary clean-up.
2. Minimize the risk of back injury associated with lifting large containers to pour oil through a funnel.

Moreover, it follows the fundamental principle of implementing reliability: “Make the right thing to do the easy thing to do” and encourages best-practice adoption.

Sealable Oil Containers

While these have now been available for over twenty-five years, I still find these containers left wide open. In the image below, these containers were allowing rainwater into the containers simply because the spouts were not being closed, creating a reliability issue and a potential injury because of water-induced wear and failure on the asset.

However, the simplicity of the design means that with the spout closed, spillages are avoided when the container is dropped or knocked over. I always prefer using the hand-pump version and quick-connectors on the hose and machine mentioned above to eliminate the risk of spillages and the possibility of the spout being left open.

Easily Accessible Inspection Devices

Too often, I find that oil-level sight gauges are inaccessible or awkward to reach. Apart from the obvious issue of potential catastrophic failures resulting from not inspecting levels properly and missing other warning signs, the very nature of awkwardly placed inspection units puts personnel at risk because of having to lean over equipment, for example.

Ensuring the 3D inspection units and bearing oil sight glasses are easy to see without reaching and not in dark places will help reduce risks.

Storage

This is a whole area for safety that must be addressed concerning safe storage.

Up-to-date Safety Data Sheets SDS are important as printed copies in the oil store, along with the appropriate provision of PPE (Personnel Protective Equipment) and fire-fighting aids.

However, correct lifting equipment is essential. About twenty years ago or more, I noted a lot of sites transitioning away from larger containers, such as 208L drums, to the smaller 25L pails.

While lifting a 25L pail is safer, back injury is a potential issue without the proper training on correct lifting. Add to this that the cost per liter of a smaller container increases, so there is a tendency to buy larger drums and IBCs (Intermediate Bulk Containers) to reduce the purchase price.

Still, the proper rigging and the correct provision of the bunding for the standing of these is critical.

Hence, using storage tank systems to dispense smaller containers is becoming increasingly popular. While the initial cost is high, the long-term benefit is providing filtered oil from correctly color-coded tanks and dispensing points. This means smaller containers can be used while still enjoying the cost savings of the larger drums.

Providing a dedicated storage unit for satellite lubrication activities at points around the plant makes a lot of sense, especially as these are portable and can be moved should the need arise. However, the units offer a best-practice set-up with rapid implementation.

Safety with Greasing

As a good friend, Haris Trobradović often states in his lectures, we call it a grease gun because it can kill. Not just machines but people, too. I always recommend that the flexible hose on a grease gun should be replaced annually.

This incident was reported in December 2013 at Liebherr Australia Pty Ltd. The operator was attempting to remove a hand-operated grease gun from a grease nipple after pumping several times to try to clear a blocked grease nipple or Zerk.

While gripping the hose and maneuvering it to release the nozzle, the hose ruptured, injecting grease into the operator’s little finger. It should be noted gloves were not being used at the time.

Medical attention was sought, resulting in a lengthy operation and removal of a vein in the forearm, which was replaced with an artificial vein.

In conclusion, I hope the above discussion has provided an alternative view on reliability. When seeking to implement the improvements, it is not just about the system’s reliability but the safety of those who maintain and operate the systems.

Never underestimate the safety implications when justifying the upgrades, nor should one underestimate the potential hazards for something as simple as a lubrication tool, even though so many see lubrication as a simplistic discipline for unskilled workers.