Understanding Hydraulic Safety: Common Hazards and Solutions in Process Operations

In the world of process and manufacturing plants, safety is paramount. A variety of operational hazards can arise from equipment failures or human error, leading to serious consequences. Among these risks, hydraulic hammer and overpressure scenarios are particularly noteworthy. These issues often stem from pressure valves cycling too quickly, which can result in line ruptures or system overpressurization.

One significant cause of overpressure is operator inattention during the filling of ready storage tanks. If an operator forgets to close the line to a scrubber, the resulting overflow can create dangerous conditions. To mitigate this risk, it is essential to install features such as excess-flow valves at ready storage entrances and automatic shut-off mechanisms that activate if the liquid level reaches a critical percentage. These proactive strategies can help prevent accidents and maintain a safe operational environment.

Temperature fluctuations can also impact system pressure. While solar effects might increase the overall temperature within a hydraulic system, the risk of significant overpressure due to thermal expansion is usually minimal. As a result, existing safety measures are often deemed sufficient, allowing operators to focus on other potential hazards without overcomplicating their safety protocols.

Another operational concern arises when gas is introduced into the system, particularly when the liquid level in the reservoir is low. This situation can lead to pump cavitation, which disrupts flow to ready storage and creates inefficiencies in operations. Fortunately, procedural controls, such as carefully managing nitrogen purge systems, can help operators prevent this issue from occurring.

One often overlooked hazard is the potential for ice formation within ammonia systems caused by line contamination. If moisture enters the system, it can freeze and create dangerous ice plugs, ultimately leading to line overpressure. To counteract this risk, operators should ensure that all valve materials are compatible with ammonia and consider using filters to remove impurities before they can cause problems.

In conclusion, while process and manufacturing plants are equipped to handle a variety of hazards, it is crucial for operators to remain vigilant. By understanding the common risks associated with hydraulic systems and implementing appropriate safety measures, organizations can better protect their workers and infrastructure from potential incidents.