The Marine Safety Forum (MSF) draws lessons learned from an incident where a crew member suffered a hand injury after a high-pressure grease gun hose burst.
The incident
During routine greasing of a tensioner unit using an electrically powered battery grease gun, the hose burst and grease punctured the Injured Person’s (IP) hand. The crew member was wearing full PPE and performing the task in accordance with safety procedures. As the crew member attempted to remove the greasing hose from the greasing point, the hose burst on his right hand. The high-pressured grease passed through the damaged hose, causing a penetration through his glove and resulting in a small open wound on his skin.
The IP immediately attempted to remove as much grease as possible from the wound and proceeded directly to the onboard medic for evaluation and treatment. After consultation between the medic and captain and review of the COSHH Assessment / MSDS, it was decided to sail back to port for medical attention at a local hospital.
Immediate cause
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The failure of the greasing gun hose under pressure caused the unexpected release of grease.
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The pressure release valve did not function as expected, causing grease to be injected at high pressure.
Underlying cause
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Possible human error in handling the greasing equipment due to lack of experience, insufficient training, and lack of awareness of the hazards involved. When the IP needed to swap the grease hose from one grease nipple to another, he found it difficult to remove the hose.
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The IP was unaware of the high pressure in the grease gun system and began exerting force to remove the grease hose. The hose (most likely) collapsed under the pressure, resulting in grease injection through his glove and skin into his right hand.
Lessons Learned
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High-pressure grease guns have the potential to cause serious injury or even death if not properly used and maintained. Grease in this type of equipment is under pressure up to an operating pressure of 69 MPa (10,000 psi).
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The velocity of grease forced through a pinhole break in a hydraulic hose can exceed 250 meters per second (600ft/s), which is close to the muzzle velocity of a rifle and can drive fluids through protective clothing, including gloves.
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Skin penetration can occur at pressures as low as 100 psi.
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Personnel were not aware of the dangers of high-pressure injected injuries.
Actions
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Specific JSA / RA to be in place for using grease guns and compliance with the equipment manufacturer’s manual. Anyone using grease guns should inspect the integrity and security of grease nipples and hoses prior to starting the task.
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Ensure correct gloves are used with grease guns (part of JSA).
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Raise awareness of the dangers of using grease guns throughout the company and at a wider industry level.
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Investigate suitable alternatives to the grease guns in use.
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Discuss the incident with the OEM to inform them about the hose failure.
