What Is FluidSafe™ Additive?

FluidSafe™ hydraulic fluid additive is a revolutionary product (U.S. and foreign patents pending) that was developed within the mining industry to improve worker safety and reduce operating costs. It is specially designed to aid in the detection and surgical removal of hydraulic fluid in the event of accidental high-pressure fluid injection under the skin.

How can FluidSafe help protect your workforce, reduce operating costs and minimize equipment downtime at your mining site?

  1. FluidSafe allows for the quick detection of high-pressure fluid injection injuries on site. This allows triage of cases not requiring surgery, thus preventing the expense and trauma of unnecessary surgeries. When used correctly, FluidSafe also helps pinpoint the exact location of hydraulic fluid under the skin, assisting in limiting soft tissue dissection required during surgery.
  2. FluidSafe enhances the management of fluid power systems by aiding in the early detection of hydraulic leaks. When used in combination with a SafetyBlu™ blue light inspection kit or blue lens filter specially designed to fit over a variety of mining lamps, FluidSafe can quickly and easily detect leaks that are hard to find under normal circumstances. Users have reported savings in hydraulic fluid consumption of 5% to 7%, vastly surpassing the cost of FluidSafe.

Who uses FluidSafe?

High-pressure fluid injection is a major medical emergency on the worksite. When a confirmed case of accidental fluid injection occurs, all work operations must stop to remove the injured worker and investigate the incident ― costing upwards of $50,000 per hour in lost labor and production!

Studies have shown that the quick and accurate detection and treatment of a fluid injection injury by trained first aid personnel can greatly reduce the injured worker’s pain and suffering, disfigurement and recovery time, as well as improve worksite safety.

In one case study, there were 16 instances at three mining sites where, with the use of FluidSafe additive, paramedics were able to determine that fluid splashed on mine workers did not actually penetrate the skin. In all instances, the miners were able to quickly return to work and production losses were minimized.

In January 2012, at a mine in Australia that uses FluidSafe, a worker suffered a penetrating injection injury. With the aid of FluidSafe and an associated blue light inspection kit, surgeons were able to clearly see the boundaries of the penetration within the subcutaneous tissue and minimize damaged tissue removal. The lessened pain and disfigurement allowed the worker to return to the job sooner.

Peabody Energy Australia reported a dramatic decline in the number of hydraulic fluid release incidents following the introduction of FluidSafe in all of their fluid power systems in late 2010. In the three years prior to FluidSafe’s implementation, Peabody suffered 155 fluid release incidents. After implementation, they had only 39 incidents in a similar period. In each of those incidents, the use of blue light inspection kits allowed the quick determination of fluid penetration. Only one incident in 2012 turned out to require surgery, and the costs of unnecessary surgical procedures were avoided.

Injuries

High-pressure fluid injection is a major medical emergency on the worksite. When a confirmed case of accidental fluid injection occurs, all work operations must stop to remove the injured worker and investigate the incident ― costing upwards of $50,000 per hour in lost labor and production!

Studies have shown that the quick and accurate detection and treatment of a fluid injection injury by trained first aid personnel can greatly reduce the injured worker’s pain and suffering, disfigurement and recovery time, as well as improve worksite safety.

In one case study, there were 16 instances at three mining sites where, with the use of FluidSafe additive, paramedics were able to determine that fluid splashed on mine workers did not actually penetrate the skin. In all instances, the miners were able to quickly return to work and production losses were minimized.

In January 2012, at a mine in Australia that uses FluidSafe, a worker suffered a penetrating injection injury. With the aid of FluidSafe and an associated blue light inspection kit, surgeons were able to clearly see the boundaries of the penetration within the subcutaneous tissue and minimize damaged tissue removal. The lessened pain and disfigurement allowed the worker to return to the job sooner.

Peabody Energy Australia reported a dramatic decline in the number of hydraulic fluid release incidents following the introduction of FluidSafe in all of their fluid power systems in late 2010. In the three years prior to FluidSafe’s implementation, Peabody suffered 155 fluid release incidents. After implementation, they had only 39 incidents in a similar period. In each of those incidents, the use of blue light inspection kits allowed the quick determination of fluid penetration. Only one incident in 2012 turned out to require surgery, and the costs of unnecessary surgical procedures were avoided.

OIL-BASED HYDRAULIC SYSTEMS

PRODUCT
NUMBER
CONTAINER SIZE SUGGESTED
DILUTION RATIO
FSOG-250 250 ml (8.5 oz) bottle 0.62 L (21 oz) of additive per 1,000 L (264.17 gal) of oil-based hydraulic fluid
FSOG-500 500 ml (17.0 oz) bottle
FSOG-1L 1 liter (33.8 oz) bottle
FSOG-1G 3.8 liters (1 gallon) container
FSOG-5G 18.9 liters (5 gallons) container
FSOG-55G 208.2 liters (55 gallons) drum
FSOG-1T 1,000 liters (264.2 gallons) tote

WATER-BASED HYDRAULIC SYSTEMS

PRODUCT
NUMBER
CONTAINER SIZE
FSWG-250 250 ml (8.5 oz) bottle Addition to oil-in-water emulsions (to be diluted)

When adding FluidSafe WB to a concentrated oil-inwater emulsion before dilution, the correct amount of FluidSafe WB needed will depend on the final percentage of emulsion that will be in the equipment once it has been diluted with water. To calculate the correct ratio of FluidSafe WB to add into an emulsion concentrate before dilution, divide 0.3 by the final concentration of emulsion when it is mixed with water. In the formula below, “E” represents the final percentage concentration of emulsion in the application solution:

(%FluidSafe WB) = (0.3/E) %

For example, if an emulsion concentrate is to be used at a 2% ratio in water, replace “E” with “2” and calculate the ratio, in this case (%FluidSafe WB) = (0.3/2) %, a 0.15% concentration. If adding to 1,000 liters of concentrate at this ratio, then 1.5 liters (0.15%) of FSWB would be required.

Additon to filled systems (with diluted emulsion or water)

The correct treatment ratio for fluid in working equipment is 0.0042% (0.042 liters FluidSafe WB per 1000 liters of working fluid).

Resources

Fluid power safety and hydraulic injection injuries are often underweighted within safety management systems. The resources (links) below draw from a variety of sources to help you better understand the consequences of injection injuries and to provide information about effective fluid power safety systems from world leaders.