Oil leaks in factories cause serious problems such as environmental pollution, a worsening working environment, and reduced productivity.
However, with the right knowledge and precautions, these risks can be significantly reduced.
In this article, we will explain the specific effects of oil leaks, emergency response methods when they occur, and how to identify the underlying cause and take countermeasures.
Oil leaks in factories and offices cause more serious problems than just dirt. They have a wide range of adverse effects, from the impact on the environment to the safety of workers and even on the economic activities of companies, so it is essential to accurately understand the risks and take appropriate measures.
Environmental contamination
Oil leaks can contaminate soil and water, potentially leading to serious environmental damages. In particular, if oil leaks into public waterways along with industrial wastewater or rainwater, they can cause river and ocean pollution, potentially damaging aquatic life and impacting fisheries.
In addition, oil that seeps into the soil can cause groundwater contamination and continue to have a negative impact on the environment for a long period of time.
Deteriorating working conditions and safety risks
Oil leaks significantly reduce the safety and the comfort of the work environment. Oil leaks onto the floor make it slippery and significantly increase the risk of falls. This not only leads to injuries to employees, but also to indirect losses such as production line shutdowns and compensation claims.
In addition, some types of oil are flammable or explosive, and oil leaks in places where open flames are strictly prohibited pose a risk of fire or explosion. Furthermore, there are concerns about the health hazards to employees, such as respiratory illnesses caused by inhaling oil vapors or mist, and dermatitis caused by direct skin contact.
When an oil leak occurs in a factory or business, prompt and appropriate initial response is extremely important, as it can prevent the damage from spreading, ensure the safety of human lives, and minimize environmental pollution and economic losses.
Emergency procedures for locating oil leaks
When an oil leak is confirmed, the first priority is to ensure safety and then quickly identify the leak location. Effective countermeasures cannot be taken if the source of the leak remains unclear.
Deciding and implementing an emergency shutdown
If there is a high possibility that the oil leak will spread over a wide area or if there is a risk of fire or explosion, consider an “emergency shutdown” to immediately stop operation of the affected equipment and cut off the power.
This will stop the oil supply and prevent further leakage, but it is important to carry out a risk assessment beforehand to ensure that shutting down the equipment does not create any other hazards
How to identify the leak location
To identify the location of a leak, follow the steps below.
1) Visual inspection: Perform a visual inspection to determine the source of the oil leak. Pay particular attention to areas that are particularly susceptible to stress, such as pipe joints, valves, pump seals, tank welds, and hose connections.
2) Check for abnormal sounds and odors: Check for unusual sounds (e.g., hissing) or a strong oily smell.
3) Check instruments: Check for abnormal readings on related instruments such as pressure gauges and oil level gauges. A sudden drop in pressure or oil level may indicate a leak.
4) Follow the trail: Trace the flow of the leaked oil and identify the point with the highest oil volume and the point where the oil trail ends
Preparing for safe oil leaks disposal
Once the leak location has been identified, the next step is to prepare for a safe initial response. Inadequate preparations can threaten the safety of workers and cause secondary accidents.
Preparing and wearing Personal Protective Equipment
Oil can cause irritation and make it slippery if it comes into contact with the skin, so wearing proper personal protective equipment (PPE) is essential.
Types of protective equipment | Main Role |
Safety glasses/goggles | Prevent oil from splashing and coming into contact with your eyes. |
Oil resistant gloves | Avoid direct contact of oil with the skin. |
Oil resistant safety shoes | Protects your feet from slips and falls caused by oil. |
Protective clothing/work clothes | Prevents oil from sticking to clothing and skin. |
Preparation of materials necessary for initial response
For the initial response to an oil leak, it is advisable to keep the following materials stocked in a fixed location at all times so that they can be prepared quickly.
・Oil absorbent materials:
oil mats, oil sheets, oil fences, absorbent tubes, etc. These efficiently absorb leaked oil and prevent it from spreading.
・Cloths and rags:
Used to wipe up small amounts of oil and for cleaning.
・Saucers and buckets:
These temporarily catch leaking oil and prevent it from spreading.
・Sandbags:
Used to block the oil outflow path and stop it from spreading.
・Sealed containers:
These are used to temporarily store absorbed oil and contaminated rags to prevent secondary contamination.
・Cleaning equipment:
Brushes, shovels, and other tools necessary for collecting and cleaning oil.
How to temporarily stop an oil leak
Once safety and preparations are complete, it’s time to stop the oil from spreading and temporarily treat the leak. Please keep in mind that this is only a temporary measure.
Stopping the spread of oil
The top priority is to prevent leaked oil from spreading over a wide area.
・Installing oil fences and sandbags:
These are installed to surround the oil leak path and prevent it from leaking outside the factory or into drains. In particular, flowing into drains directly leads to environmental pollution, so it is most important to block the entrance to the drain.
・Placing absorbent material:
Oil mats or absorbent sheets are laid around the leaking oil and in areas where the oil is likely to flow to absorb the oil.
・Installing a tray:
Place a tray or bucket directly below the leaking area to directly catch the oil.
Emergency measures for leaking areas
If the leak location can be identified and is safely accessible, try to temporarily stop the leak using the following methods.
・Applying absorbent material: If the leak is small, press the absorbent material directly against the leaking area to absorb it.
・Closing valves: If there is a valve that can stop the supply of oil to the leaking pipe or equipment, close it.
・Patching/clamping: Use special leak-stopping patches, clamps, tape, etc. to temporarily seal holes or cracks. This may require specialized knowledge and materials.
Recovery of leaked oil and preparation for disposal
In parallel with preventing the spread and taking emergency measures, proceed with the recovery of any oil that has already leaked.
・Wiping up with absorbent material: Carefully wipe up the leaked oil with absorbent mats or rags. Be careful where you step as the surface is slippery.
・Recovery with a pump: If a large amount of oil has accumulated, use a special pump to recover it.
・Storage in a sealed container: Be sure to place the recovered oil, used absorbent material, contaminated rags, etc. in a sealable container and move them to a designated temporary storage location. These must be disposed of properly as industrial waste.
After identifying the location of the oil leak, it is most important to determine the root cause of the leak. By identifying the cause, appropriate measures can be taken to prevent future problems.
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Main causes of oil leaks and their symptoms
There are many different causes of oil leaks, but here we will explain the most common causes and the symptoms that may appear. Use this information to take a closer look around the leaking area.
Main causes | Specific symptoms and signs | Checkpoint |
Deterioration | Hardening, cracking, and loss of elasticity of packings, O-rings, and gaskets. | Parts that have been in use for a long time. Oil deterioration (discoloration, strange odor). |
Damaged or broken parts | Cracks in piping and hydraulic hoses, pinholes in valves , pumps, cylinders, etc., and damage and wear to the body and connections of these components, widening of clearances. | External impact marks, |
Poor tightening/looseness | Looseness and falling off of pipe joints and bolts, oozing | Areas that can be tightened |
Other factors | Excessive pressure: Safety valve activation, piping expansion, rupture Poor design and construction: Inappropriate sealing material not used, forced piping connections Abnormal vibration: Fatigue damage to parts, loosening of fastening parts | Abnormal pressure gauge readings, |
Effective root cause identification procedures
Combining the following four approaches can help identify the cause of an oil leak more quickly and accurately.
1) Systematic visual inspection: A thorough observation is conducted to determine the location of the leak (joints, seals, etc.), check the oil’s color, viscosity, odor, and other conditions, and determine whether any other liquids are present in the surrounding area.
2) Operational status check and data analysis: If a leak occurs during operation, check instruments such as pressure gauges, thermometers, and oil level gauges, as well as past operating data, to determine whether pressure exceeded the specified level, temperatures were abnormally high, or excessive operating time or load was applied.
3) Use of specialized diagnostic tools: For small leaks or internal damage that are difficult to detect visually, specialized tools such as leak detection sprays and liquids (visualized with foam), ultraviolet (UV) lights (detected with fluorescent agents), thermal imaging cameras (indicating abnormalities through heat changes), and vibration diagnostic devices (detecting abnormal vibrations in rotating equipment) are effective.
4) Past records and information sharing: Past maintenance records, repair histories, regular inspection records, and abnormality reports are valuable sources of information. Checking for similar incidents and interviewing workers who handle the equipment on a daily basis, as well as collecting information on slight changes, strange noises, and abnormal behavior, can help identify the cause.
Once the cause of the oil leak has been identified, the next step is to implement specific countermeasures.
Replacement and repair of worn out parts
Most oil leaks are caused by deterioration or damage to equipment components. Once the cause has been identified, the most direct solution is to quickly replace or repair the affected parts.
Replacement of Packing and O-ring
The most frequent cause of oil leaks in hydraulic equipment and piping connections is deterioration of packings and O-rings. These are made of rubber or synthetic resin and are prone to hardening, wear, and cracking over time. If deterioration is found during regular inspections or if oil leaks are confirmed, replace them with new, compatible parts.
Replacement and repair of Hose and piping
Hydraulic hoses and metal piping can also be damaged by vibration, pressure fluctuations, external impacts, and aging, which can cause oil leaks. If a hose shows cracks or swelling, or if the piping is corroded or has holes, it should generally be replaced with a new one. Minor damage to metal piping can be repaired by welding, but this requires specialized skills and safety management.
Re-tightening of seals and bolts
Oil leaks from flange joints or equipment covers can be caused by deterioration of the sealant or loose tightening bolts. If the sealant is deteriorated, it can be replaced, and if the bolts are loose, it can be resolved by retightening them to the specified torque. However, care must be taken not to overtighten them as this can damage parts.
Regular maintenance plans for equipment
Planned and continuous maintenance is essential to prevent oil leaks and maintain stable operation of equipment. From the perspective of preventive maintenance, formulate and implement a maintenance plan that includes the following items.
Daily and periodic inspections
We visually inspect equipment on a daily basis to check for signs of oil leaks (oil stains, oil droplets, strange odors, etc.) In addition, we conduct more detailed inspections on a regular basis, such as weekly, monthly, and yearly.
Lubricant change and maintenance
Lubricant oil is extremely important for maintaining the performance of equipment. Deteriorated oil reduces its lubricating performance, accelerates wear of parts, and can cause oil leaks. Change lubricant oil at the appropriate time based on the manufacturer’s recommended replacement interval and the results of oil analysis.
Introducing predictive maintenance technology
In recent years, predictive maintenance using sensors and IoT technology has been attracting attention. By installing vibration sensors, temperature sensors, oil analysis sensors, etc. on equipment, signs of oil leaks and breakdowns can be detected early, enabling planned maintenance and part replacement. This reduces the risk of production stoppages due to sudden breakdowns.
This article explains the problems caused by oil leaks in factories or business, initial response measures, identifying the cause, and specific countermeasures. Oil leaks pose a wide range of risks, including environmental pollution, a worsening work environment, and reduced productivity. In order to prevent or minimize these problems, it is essential to take measures such as replacing worn parts, performing regular maintenance, and installing oil leak prevention products in addition to a prompt initial response.
By attaching our “OIL DETECTION TAPE”, oil leaks can be detected early. Detecting of oil leaks early allows for prompt initial response.