A hydraulic accumulator is nothing less than an "improvised explosion device" to an untrained worker

This post is about an accident that occurred at a lumber mill in Oregon. I suggest you read the newspaper article before reading my blog: https://www.oregonlive.com/washingtoncounty/index.ssf/2011/10/stimson_lumber_fined_5000_for.html

The regrettable accident at the Stimson Lumber Mill that claimed the life of a 60-year old worker, is yet another example of just how out of touch State and Federal safety agencies are when it comes to matters relating to hydraulic safety. From all accounts the victim was working on a hydraulic system that was equipped with one, or more, hydro-pneumatic accumulators (energy storage devices). Apparently, he and his colleagues, could not determine if the hydraulic system they were working on contained stored energy, which seems to be what caused the accident (I stand to be corrected). 

Let it be known that every hydraulic system operating in every mill in Oregon and Washington, including the one in which the victim worked, does not have the means to verify if hydraulic systems contains stored energy (after the power source has be isolated and locked out), and if they do, the systems are not equipped with the means for mechanics to safely remove it; even though the technology to do so is currently available. This leaves workers in ALL lumber mills in the US with only one option: defy OSHA'S controlled release of stored energy protocol and discharge the stored hydraulic energy to atmosphere, which leaves workers susceptible to severe injury or death.

It is safe to say that the hydraulic system Mr. Allen was working on was inherently unsafe by design (like the other 99% of the hydraulic systems operating in the US). 

Now let’s look at the situation regarding training. Companies have no legal requirement to teach their workers hydraulic safety, or even fundamental hydraulics for that matter, so why should they? Most companies cater only to safety matters mandated by OSHA. This leaves over 98% of the millworkers working in Oregon and Washington performing work on systems, which can injure, maim, burn, and kill them, with no hydraulic safety training. Moreover, only a small percentage of millworkers have receive proper training in fundamental hydraulics. No regulations, no due diligence on the part of employers, inherently unsafe hydraulic systems, and no hydraulic mandatory safety training for workers; the grounds could not be more fertile for more hydraulic related injuries and deaths

If the fact that Mr. Allen was killed because he could not determine if the hydraulic system he, and his colleagues, was working on contained stored energy, I sincerely hope that the subsequent lawsuit (if there was one) put the hydraulic system designer (s), and the machine manufacturer, on front and center stage, so they could explain to Mr. Allen's family why the system that he was working on killed him.

Needless to say, from all accounts, his company was allegedly at fault because of a disturbing statement made by the company's VP, Ms. Debra Muchow; “We'll never know from the employee's perspective if he was not trained properly or whether it was just a matter of a mistake at that time.” How disappointing! Apparently, the company has no idea what kind of training its employees have, if any at all. It is my distinct understanding that a supervisors’ primary responsibility is to insure that all workers that report to them are properly trained. Most saw mills depend on hydraulic power for almost all machine functions and operation. If the victim’s supervisor could not determine whether or not Mr. Allen was qualified to service, repair, and maintain hydraulic systems, how in the world did he/she get the job as a supervisor?  

The Oregon Occupational and Health Safety Administration’s response to the accident doesn’t surprise me at all. It’s the usual “victim was not properly trained” scenario. Moreover, there was no mention of the fact the hydraulic system was, in all probability, inherently unsafe by design. Regrettably, the Oregon Occupational and Health Safety Administration will probably do nothing to make it mandatory that ALL workers that perform work on and around hydraulic system receive proper training. They will also probably ignore the fact that over than 99% of the hydraulic systems in Oregon; besides those in sawmills and lumber mills, are not equipped with safety devices that would make it possible for workers to determine if a hydraulic system contains stored energy, or the means to safely remove it is it does.

Takeaway from this preventable tragedy:

Mechanics:

1. To prevent the Vice President of your company, and your supervisor, from being confused about your knowledge and training, arrange to have a joint meeting with your company’s human resources department, and your supervisor, and have them put on record your qualifications and training. Also, make them aware of any work you do that you are not trained or qualified to do.
2. OSHA’s lockout/tagout regulations clearly state: “Energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other sources in machines and equipment can be hazardous to workers. During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy could cause injury to employees.” 

Always bear in mind, lockout and tagout does not guarantee a hydraulic system is safe to work on. Most hydraulic systems have the inherent ability to store energy after shut-down. OSHA states “the release of stored energy must be controlled.” Unfortunately, this cannot be executed on over 99% of hydraulic systems operating in the USA. The only way for a mechanic to remove stored energy from a hydraulic system is to “crack” or loosen a connector. The other name for this procedure is “release the stored energy to atmosphere with absolutely no control whatsoever.” Ironically, although OSHA and machinery and equipment manufacturers ignore the proverbial "elephant in the room," they both agree that discharging high-pressure oil to atmosphere is extremely dangerous. OSHA says: “the unexpected start-up or release of stored energy could cause injury to employees. Machinery and equipment manufacturers go a step further with this warning: “discharging high-pressure oil to atmosphere can cause severe injury, death, or substantial properly damage.” Both organizations agree its hazardous, but ironically, neither of them do any thing about the fact that tens of thousands of American workers risk their lives everyday because they have no alternative but to defy the warnings and “crack” connectors.

1. The hydraulic industry is the only industry I am aware of that completely ignores OSHA’s lockout standard and gets away with it. In OSHA’s defense, it’s because the agency is as naive about hydraulic safety as the people that design hydraulic systems: with all due respect.  

Engineers:

1. If you are a hydraulic system designer, I beg of you to ignore the fact that making a hydraulic safe from the standpoint of the safe release of stored energy is not mandatory, and install safety devices in the system. The prudent design philosophy should be to design hydraulic systems on the basis that your children are going to work on them - with all due respect.
2. Design environmentally friendly hydraulic systems. Design-in products that make it possible for mechanics to purge air without contaminating the environment.

Safety personnel:

1. If your company does not currently provide hydraulic safety training for the people that work on and around hydraulic systems, make it your top priority to get them the training they desperately need as soon as possible. Bear in mind, most mechanics put themselves in harm's way only because they don't have the training in fundamental hydraulics they desperately need.
2. The fact that MSHA and OSHA ignore hydraulic safety doesn't mean hydraulic systems are inherently safe. On the contrary, hydraulic systems are arguably more hazardous than electrical systems. If your company is interested in on-line hydraulic safety training, please contact me. [email protected]
3. If your company designs hydraulic systems, or machines that have hydraulic systems, discuss with your engineers how they make it possible to verify if hydraulic systems , and how to remove it. 

Supervisors:

1. You "borrowed" a person from his or her family to work in your company. Your responsibility to the person, and his or her family, is to insure the person arrives home from work in the same, or better, health than when they arrived. NEVER let a person perform work on any machine/system he or she is not competent to work on.
2. A person that is trained in fundamental hydraulics MUST also receive training in hydraulic safety. 
3. Look for the best training for your workers, and don't abbreviate the training. Avoid using your suppliers for training. They may be qualified salespersons, but they are not necessarily educators. Your workers deserve the best training possible. Competent workers think safety and work safely, and they will also work more efficiently. It's a win-win situation for the worker, you, and the company's bottom line.

“Hydraulic safety doesn’t just happen it has to be vigorously pursed.”

Stimson Lumber fined $5,000 for fatal explosion in May

Dana Tims | [email protected] By Dana Tims | [email protected] 

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on October 04, 2011 at 3:00 PM, updated October 04, 2011 at 3:02 PM