One of our manufacturing clients addressed a critical fire safety exposure by installing a fire-activated automatic shutdown system for their high-pressure hydraulic equipment. Thanks to the recommendations of our Loss Control team, the facility significantly reduced their fire risk.
From Flammable Fluids to Ruptured Hose Lines: Hydraulic Equipment Increases Fire Risk
Background
During our initial loss control evaluation, our team gave a new manufacturing insured guidance concerning hydraulic systems. The company had many hydraulic systems operating under high pressure, presenting a significant exposure in the event of a fire.
At the time of the survey, hydraulic systems did not have an integrated automatic shutdown mechanism linked to fire detection systems, increasing the severity of a potential fire event.
Recommendation
Our loss control team issued a critical recommendation to install a fire-activated, automatic shutdown system for the hydraulic equipment.
We also recommended the company install fail-safe valves to stop fluid flow, coordinate the shutdown equipment with their facility's fire protection and alarm systems, and develop procedures for system-testing and maintenance.
Result
The manufacturer implemented our recommendations. The company installed heat detection sensors that linked directly to their hydraulic systems and integrated an automatic shutdown interlock that would immediately stop hydraulic pumps, activate system depressurization, and close supply valves to prevent fluid discharge.
The company also integrated the system with their facility-wide fire alarm panel, developed procedures for routine inspection and testing, and trained maintenance and production personnel on the new system.
As a result of these new loss control measures, the manufacturer has significantly reduced their risk in the event of a fire. Their hydraulic fluid is no longer a possible added fuel source, minimizing the risk of a hose rupture or high-pressure spray and improving their overall emergency response coordination and system reliability.
This success story serves as a best practice example of how combining fire detection with equipment control systems can effectively prevent escalation of hazardous conditions.
The Big Risk: Hydraulic Systems Operating Under High Pressure
Hydraulic fluid under pressure can intensify fire conditions due to:
- Atomization of fluid, increasing flammability
- Fuel contribution to fire spread
- Potential for hose rupture and uncontrolled spray
- Increased risk of secondary explosions or equipment damage
