Workplace safety focuses on identifying, preventing, and eliminating hazards that cause accidents or negatively impact worker health. The Occupational Safety and Health Administration (OSHA), part of the United States Department of Labor, sets safety standards that organizations must satisfy. Adhering to these standards is crucial for maintaining a safe working environment.
Anyone who operates equipment is responsible for adhering to the safety precautions and operating procedures detailed in the equipment owner’s manual and the company’s safety policies. Proper training ensures operators are proficient in these safety practices. Improper equipment operation and maintenance can create hazardous conditions, resulting in death, injury, and equipment damage. Before using your water jet equipment, ensure you have received comprehensive training and have read and understood your product manuals. Highlight any safety information contained in them.
While there are many financial and reputational benefits to following robust safety protocols and complying with regulations, the best reason is that the safety and wellbeing of your employees should be your number one obligation.
⚠️ Warning: This blog is only intended to provide an overview of safety tips when operating a water jet. Consult your owner’s manual and your company’s safety manual prior to operating or performing service on your water jet system.
A complete water jet cutting system many components, each with unique safety protocols. This blog will focus on water jet motion systems and outline important safety practices intended to protect your operators from injury.
The motion system is the water jet cutting tool component that receives an ultra-high-pressure water stream delivered through high-pressure water lines from a remote pump. This high-pressure water is converted to a highly focused “jet” at the cutting head for precise cutting and machining of the stock material.
Don’t be fooled by the word “water.” In the context of a water jet, it refers to the output generated by a 60,000 psi (4,100 bar) ultra-high pressure pump capable of producing water velocities up to 2,000 mph (3,300 kph). Water jet cutters can easily slice through materials like titanium, stainless steel, and aluminum – all of which can be several inches thick. As you can imagine, this kind of power can be extremely dangerous if the proper safety protocols are not always followed before, during, and after operation.
Your OEM should provide a factory technician to set up the motion system and connect the ancillary components. As the purchaser, you will usually be responsible for contracting riggers to place the equipment as well as engaging certified electricians to connect high voltage electrical wiring. You’ll also be responsible for providing maintenance resources to provide inlet water and compressed air.
Key motion system installation criteria include:
Your OEM factory technician will ensure all components are installed correctly and working as part of the installation. The complete system will be fully tested to ensure it has been installed correctly and delivers the performance as expected. Initial training on safety and operations should be provided at that time as well.
For maximum safety, all operators must receive comprehensive training before powering up the motion system. Best safety practices prohibit the operation of the motion system until all necessary training has been completed successfully or the operation is under the direct supervision of a competent, trained individual.
Key preparation steps before turning on the water jet tool include:
Wearing appropriate personal protective equipment (PPE) is non-negotiable when operating a water jet cutter – no gear means no operation allowed. The high-pressure water stream can produce powerful ricochets upon contacting stock, hold-down fixtures, or slats. These ricochets may contain water, abrasives, or stock debris that can injure eyes, cut skin, or be inhaled.
The motion system moves before, during, and after the cutting process. Awareness of moving parts is critical to avoid contact and potential injury. Only fully trained operators should perform water jet cutting by themselves. Less experienced operators should be adequately supervised until they are proficient in all aspects of the cutting tool's operation.
It is also essential to thoroughly understand the stock material’s properties and how it reacts to the cutting process. Operators must understand the proper material fixturing or hold-down methods, required pump pressures, and whether they will perform water-only or abrasive cutting.
Check your PPE for proper fit and function and ensure everyone in the area is similarly protected. Do not remove any piece of your PPE while the water jet is operating.
To ensure a complete inspection is performed prior to shift start, create a waterjet inspection checklist. Have the individual performing the inspection confirm each step has been performed by initialing each step, dating the form and signing.
The dry run feature executes the part’s cutting program’s axis movement with the cutting heads turned off. Typically set to run the program as fast as is practical, it helps validate the programmed tool path and allows for adjustments to feed rates, dwell times, and other program parameters to optimize cut execution. It also verifies that the cutting head never contacts the workpiece and stays within the cutting boundaries.
Adhering to the routine maintenance schedule your water jet’s manufacturer recommends is essential for ensuring all components function correctly. Critical maintenance practices include:
Component cleanliness is a primary factor in proper machine performance. Contamination from hydraulic fluid, water, abrasives, etc., can lead to significant equipment failures. Use a damp cloth to remove grit and dirt accumulations on the cross beam, side beams, and z-axis assembly. Frequently rinse the cloth in clean water to avoid recontamination. Ensure thorough cleaning of the equipment after each use.
Tool movement relies on servomotors, ball screws, ball nuts, and linear bearings in the cross beam, side beams, and z-axis assembly. As specified in your water jet owner's manual, these components require regular cleaning, inspection, and lubrication. Use only manufacturer-recommended lubricants and avoid applying lubricants unless they match the type and grade already in use.
Visual inspection before operation goes a long way to ensuring your water jet operates correctly and as expected. Here are the steps recommended for this safety procedure:
Service procedures should only be performed by individuals experienced in servicing water jet systems and familiar with all operational aspects of the motion system, remote pumps, high-pressure lines, and any installed accessories or options.
When servicing the motion system, always lock out and tag the electrical switch, following OSHA guidelines, to prevent the machine from being turned on during maintenance unless power is required for a maintenance or service procedure.
⚠️ Warning: Never bypass safety features such as the emergency stop switch. Eliminating safety features can result in personal injury to the operator and financial liability to the company.
Shutting off the water jet may not remove all pressure. Opening a fitting with residual pressure can produce a cutting, penetrating spray that can result in injury. To reduce high-pressure hazards, verify all pressure is relieved before disconnecting any ultra-high-pressure water line by bleeding off residual pressure and confirming all pressure gauges read zero before starting service. Ensure all connections are adequately tightened after performing service or maintenance.
Never modify your equipment without consulting the original equipment manufacturer (OEM). Modifications may void warranties, cause unpredictable equipment behavior, and result in personal injury or death, exposing the company to liability. If assistance is needed to diagnose an issue or resolve any uncertainty about performing a repair, contact the OEM service department before starting any service.
Adherence to safety protocols is essential for maintaining a safe working environment. If you do not have a copy of your water jet systems’ operating manual including outlining the safety protocol and operating procedures, please request one immediately from your OEM. If you’re using a Jet Edge system, please request one from our technical support page. For assistance with specific issues, contact our technical service team —they are always available to help.
Jet Edge provides 24/7/365 live telephone support and is there for you if you need help and free factory training for those operating Jet Edge equipment. Additionally, a library of routine maintenance training videos is available so you can take advantage of real time training at your convenience.
Click on the image below to view our full library:
Jet Edge offers a comprehensive library of maintenance training videos, case studies, best practice blogs and a whole lot more in our resource center.
If you would like to learn more about Jet Edge Water jet Systems, visit us online at jetedgewaterjets.com. If you are ready to speak with your regional expert, just let us know on our contact us page, or call us toll-free at 1-800-JET-EDGE (538-3343), internationally at +1-763-497-8700.
Since 1984, Jet Edge has been designing and manufacturing Ultra-High-Pressure Water jet technology that doesn't back down. Our systems are used around the world in a broad range of industries from the world's leading airlines, to automotive, aerospace and industrial manufacturers, and machine job shops.
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