Hydraulic & Offshore Supplies Hose Manufacturing Data YOUR GATEWAY TO GLOBAL SUPPLY HOSE ASSEMBLIES PRESSURE TESTING WALFORM EQUIPMENT PACKAGES FLANGES PIPE & TUBE
HOSE MANUFACTURING DATA STORAGE Detailed recommendations for storage of product are contained in BS 5244, 1986 (1991). Tables 1, 2 and 3 of this document are produced with the kind permission of BSI. Hose & Hose Assemblies Stored as Separate Items Before fitting, all hose assemblies should be subjected to visual examination for evidence of deterioration. The recommendation in Tables 1 and 2 apply to stored hoses and assemblies, depending on their age. TABLE 1 TEST RECOMMENDATIONS FOR RUBBER HOSES AGE RECOMMENDATIONS Up to 3 years Use without further testing 3 to 5 years Use after representative samples subjected to a proof pressure test 5 to 8 years Use after representative samples subjected to proof, impulse and burst pressure tests, and cold bend and electrical tests Over 8 years Scrap TABLE 2 TEST RECOMMENDATIONS FOR RUBBER HOSES ASSEMBLIES AGE RECOMMENDATIONS Up to 3 years Use without further testing 3 to 5 years Use only after subjecting each assembly to a pressure test of 1.5 x design working pressure and representative samples to a burst pressure test 5 to 8 years As for 3 to 5 years plus impulse pressure test and cold bend and electrical tests on representative samples Over 8 years Scrap
TABLE 3 TEST RECOMMENDATIONS FOR STORED EQUIPMENT AGE RECOMMENDATIONS Up to 3 years Use without further testing 3 to 5 years Use only after subjecting each assembly to a pressure test of 1.5 x design working pressure and representative samples to a burst pressure test Over 5 years Scrap NOTE 1: NOTE 2: It is important that hose assemblies fitted to stored equipment should be filled with the operating fluid with which they will be used on that equipment. It is highly recommended that hose assemblies fitted to stored equipment in conditions of extreme temperature, humidity or ozone concentration (strong sunlight) should be tested after 1 year according to the criteria stipulated for 3 to 5 year old assemblies. TABLE 4 TEST RECOMMENDATIONS FOR THERMOPLASTIC HOSE AGE RECOMMENDATIONS Up to 5 years Use without further testing 5 to 8 years Use after representative samples subjected to proof pressure test 8 to 12 years Use after representative samples subjected to proof, impulse and burst pressure tests, and cold bend and electrical tests Over 12 years Scrap TABLE 5 TEST RECOMMENDATIONS FOR THERMOPLASTIC HOSE ASSEMBLIES AGE RECOMMENDATIONS Up to 5 years Use without further testing 5 to 8 years Use only after subjecting each assembly to a pressure test of 1.5 x design working pressure and representative samples to a burst pressure test 8 to 12 years As for 3 to 5 years plus impulse pressure test and cold bend and electrical tests on representative samples. Over 12 years Scrap
ROUTING In general, routing should be such that bends lower that minimum bend radius or tensile loading of the hose assemblies must be avoided. The minimum bend radius is measured to the inside of the bent hose and the length of the assembly should be such that there is a 25mm long straight portion of the hose at the inlet to each end fitting. Where abrasion of the product is likely, consideration should be given to extra protection. This can be provided in the form of steel or plastic spring guarding over the external surface of the hose preventing exposure to damage. To this end, specific attention must be paid to the movement of the hose when operating between components of a hydraulic system which move relative to each other. It is advisable to ensure that hose is routed such that there is no bending of the hose within 25mm of the end fitting to which it is attached and that where possible, assemblies are not manufactured with swept elbows at either end. When deciding the routing of hose assemblies specific attention should also be paid to clipping and/or clamping hoses at appropriate points. INSTALLATION Before attempting to connect a hose assembly it is essential to ensure that the joining surfaces are completely free from foreign matter and from burrs, flash or fins. Damage to these surfaces, especially where metal to metal cone connections are concerned, may result in leakage. Also, hose assemblies should have been cleaned internally to avoid any contamination entering the system which may be residue of the hose assembly manufacture. PROBLEM Hose bursts on outside of bend and is out of shape. Coupling blows off end when under pressure. Hose liner swells or deteriorates, blocking fluid flow or leaking Wire reinforcement is rusty at site of hose burst. POSSIBLE CAUSE & MISAPPLICATION Hose bent too tight in routing. Reinforcement opened up too much on outside bend. Incorrect coupling used. Couplings not crimped to correct swage dimension. Coupling not fully inserted. Hose not correct skived. Hose too short, twisted or bent too tight. Hose liner is not compatible with fluid. Temperature may be a factor. Hose cover broken by cutting, abrasion, extreme temperatures, chemical attack, improper cover skiving, internal gas caused by blisters. SOLUTION Increase hose length, also may be able to use different end fittings, i.e. swept 90 instead of straight. Check hose coupling compatibility, check swage information. Does routing cause excessive stress on assembly. Before making assembly, identify fluids and temperature in use. Check compatibility. Use hose guard, nylon sleeve, anti abrasive cover hose. Check temperature & fluid compatibility. Cover may require perforating. NOTE: IN SOME INSTANCES, FAILURE MAY BE CAUSED BY PREVIOUS REPAIRS.
FACTORS AFFECTING SERVICE LIFE Main Causes * Excessive Pressure * Abuse * End of Working Contributory Factors * Installation * Below recommended minimum bend radius * Twisting * Pulling * Temperature extremes * Vibration * Chemical attack * High velocity oil erosion (hose tube) * Ageing (ozone) * Incorrect angle orientation
DO S AND DON TS TO PROLONG HOSE LIFE DO Always use Hydraulic & Offshore Supplies fittings together with Hydraulic & Offshore Supplies approved hose. DON T Ever mix and match hose and couplings from different sources. Make hose assemblies from Hydraulic & Offshore Supplies matched components to ensure compatibility and performance. DON T Cut out a piece from an existing assembly to remove the bad bit and put a new coupling on. If a hose has failed it is likely that the reinforcement has passed its working life. First aid repairs are potentially lethal and invalidate any manufacturer s guarantee. DON T Alter the pressure relief valve in your hydraulic system without considering whether the increased pressure will exceed the recommended max working pressures of your hose assemblies. If it will, replace the hoses with more suitable assemblies.
GUIDELINES FOR THE USE OF HYDRAULIC FLUID POWER HOSE & HOSE ASSEMBLIES
ANGLE ORIENTATIONS 0 315 45 270 90 Refer to the following picture to define the correct fitting orientation. 235 180 135 Furthest End Keep straight the further end and rotate clockwise the closest end of the requested angle.
STANDARD 316 STAINLESS STANDARD 316 STAINLESS 316 STAINLESS 316 STAINLESS 316 STAINLESS STANDARD STANDARD 316 STAINLESS STANDARD STANDARD STANDARD 316 STAINLESS STANDARD STANDARD 316 STAINLESS STANDARD STANDARD 316 STAINLESS STANDARD STANDARD 316 STAINLESS STANDARD 316 STAINLESS STANDARD 316 STAINLESS CHART OF RECOMMENDED SWAGING DIAMETERS Dimensions: mm - Average tolerance +0.00/-0.2 Doc No. 01/11 Issue 13 15/09/2010 Legend Standard Insert Long Tail Multispiral Insert Interlock Fitting 316 Stainless Steel Product EN 853 1ST SAE 100R1A TFD0001 EN 853 2ST SAE 100R2A TFD0002 EN 853 1SN - DIN 20022 1SN - TFD0011 & TFA0011I EN 853 2SN - DIN 20022 2SN - TFD0021 & TFA0021I EN 857 1SC TFE001K EN 857 2SC TFE002K SAE 100 R16 SAE 100 R17 2SC ANTI-ABRASIVE TFEPO2KI HIPAC 3 BRAID THE003K VAMAC TF-VAMAC Insert Ferrule 3/16'' 03 1/4'' 04 5/16'' 05 3/8'' 06 1/2'' 08 5/8'' 10 3/4'' 12 1'' 16 1.1/4'' 20 1.1/2'' 24 2'' 32 STANDARD STANDARD SKIVE SKIVE SKIVE SKIVE NO SKIVE NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE NO SKIVE PRE-CRIMP NO SKIVE SKIVE SKIVE NO SKIVE NO SKIVE 0001 X001C 0002 X0022 001C 0022 0011 G X001C X0022 0022 0021 G X0022 001C G X001C 001C 0022 G X0022 0022 G X0022 001C G X001C 001C G X0022 0002 X0022 0022 X0022 14.9 20 17.2 23 19.2 23 21.1 24 28.3 27.0 32.3 31.0 16.4 21 16.8 20.4 22.0 23.3 24.5 27.1 27.0 29.5 16.6 21.0 17.8 22.0 20.5 22.0 21.7 24.0 25.1 28.7 27.0 33.0 31.0 17.7 21.5 19.2 21.5 21.5 21.5 24.8 23.5 28.0 28.0 32.8 31.0 14.5 15.8 18.2 19.8 23.5 27.0 15.2 16.5 18.7 20.8 24.3 26.5 31.1 16.5 18.5 20.5 24.0 27.5 31.0 16.6 20.8 24.0 28.0 30.7 17.8 21.6 25.1 28.3 32.2 16.5 19.9 21.7 25.1 27.7 31.7 21.5 28.0 32.5 18.4 20.3 22.3 25.8 29.4 33.4 15.3 16.7 19.1 22.6 26.4 29.0 15.5 20.0 23.0 17.7 23.5 27.4 30.0 18.1 19.6 23.2 27.1 16.7 18.7 20.8 24.3 27.0 17.0 18.8 20.5 24.5 27.5 31.5 17.8 21.6 25.2 28.2 32.4 17.0 19.2 21.0 24.7 27.5 31.3 17.3 18.8 21.0 25.3 28.2 31.6 13.5 15.2 17.1 18.7 22.8 29.9 16.0 21.0 24.8 28.5 32.6 18.1 19.6 23.2 27.1 17.0 18.8 20.5 24.5 27.5 31.5 17.8 21.6 25.2 28.2 32.4 21.6 24.8 39.9 37.0 39.0 39.0 40.5 37.0 39.4 35.0 38.5 38.3 37.5 39.0 39.9 39.3 40.2 41.0 40.5 36.8 38.4 38.5 39.0 39.5 39.4 39.6 40.3 39.2 42.0 38.5 39.5 39.4 47.4 42.0 53.0 44.0 49.0 39.5 53.4 46.5 50.8 43.0 57.2 45.0 52.7 40.5 56.5 48.0 65.9 68.2 69.5 70.6 60.0 62.0 61.0 57.0 48.0 55.5 68.5 47.5 53.6 68.7 49.7 54.5 70.4 51.7 54.9 70.0 51.0 58.0 71.0 50.4 57.9 70.8 53.2 57.1 72.3 48.0 Product EN 856 4SP - DIN 20023 4SP TFD04SP EN 856 4SH - DIN 20023 4SH TFD04SH EN 856 R13 - SAE 100 R13 TFS0013 EN 856 R15 - SAE 100 R15 TFS0015 SAE 100 R14 TF-PTFE 1SN JETWASH HOSE TFN0011 & TFB0011 2SN JETWASH HOSE TFN0021 & TFB0021 Insert Ferrule 3/16'' 03 1/4'' 04 5/16'' 05 3/8'' 06 1/2'' 08 5/8'' 10 3/4'' 12 1'' 16 1.1/4'' 20 1.1/2'' 24 2'' 32 STANDARD STANDARD STANDARD MULTISPIRAL316 STAINLESS STANDARD MULTISPIRAL INTER-LOCK 316 STAINLESS STANDARD STANDARD MULTISPIRAL INTER-LOCK INTER-LOCK 316 STAINLESS 316 STAINLESS STANDARD STANDARD INTER-LOCK INTER-LOCK 316 STAINLESS 316 STAINLESS STANDARD 316 STAINLESS 316 STAINLESS STANDARD 316 STAINLESS STANDARD 316 STAINLESS NO SKIVE NO SKIVE SKIVE SKIVE SKIVE NO SKIVE SKIVE SKIVE SKIVE SKIVE NO SKIVE NO SKIVE SKIVE SKIVE SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE SKIVE SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE SKIVE NO SKIVE SKIVE NO SKIVE BMC1 BMC2 0009 0019 X0022 BMC1 004H 0019 004N X004N BMC1 BMC2 0013S 004N 0013 X004N X0013 BMC1 BMC2 004N 0013 X004N X0013 SMOOTH CONVOLUTED 2 BRAID SMOOTH CONVOLUTED 0001 X001C 0002 X0022 46.0 57.3 10.3 10.3 18.4 18.4 18.4 23.5 PTFE-04 PTFE-04-C XPTFE-04 XPTFE-04-C 17.2 16.4 17.8 17.7 22.0 30.0 21.5 34.0 12.0 13.15 12.0 13.15 23 21 22.0 21.5 19.2 16.8 20.5 19.2 23 22.0 21.5 23.2 23.4 22.4 27.0 PTFE-06 PTFE-06-C PTFE-06-D XPTFE-06 XPTFE-06-C 21.1 20.4 21.7 21.5 25.5 31.0 21.5 37.0 16.0 15.20 16.47 16.0 15.20 24 22.0 24.0 21.5 26.5 27.0 25.7 32.0 PTFE-08 PTFE-08-C XPTFE-08 XPTFE-08-C 23.3 25.1 24.8 28.0 34.0 23.5 36.0 18.9 19.40 18.9 19.40 24.5 23.5 30.0 29.8 29.4 PTFE-10 PTFE-10-C XPTFE-10 XPTFE-10-C 31.0 38.0 28.0 22.8 23.10 22.8 23.10 34.3 34.9 33.8 34.6 34.1 33.0 34.1 34.1 PTFE-12 PTFE-12-C XPTFE-12 XPTFE-12-C 33.0 39.0 31.0 39.0 52/15 52/15 52/15 52/15 26.2 26.35 26.2 26.35 42.3 42.7 40.2 42.2 41.5 41.5 41.5 42.6 42.5 42.6 PTFE-16 PTFE-16-C XPTFE-16 XPTFE-16-C 48.0 56.0 35.0 46.4 56.0 64/17 64/17 46.3 64/17 64/17 64/17 64/17 33.2 32.5 33.2 32.5 51.2 52.4 48.5 50.5 50.5 53.8 54.2 53.8 54.2 PTFE-20-C XPTFE-20-C 54.0 40.5 54.0 74/22 74/22 74/22 74/22 55.2 74/22 74/22 44.3 44.3 59.6 56.5 57.9 57.0 57.0 60.5 60.3 60.1 60.3 PTFE-24-C XPTFE-24-C 62.0 48.0 62.0 81/22.5 81/22.5 81/22.5 74/22.5 81/22.5 74/22.5 50.0 50.0 73.0 70.5 72.0 72.0 77.9 77.9 PTFE-32-C XPTFE-32-C 64.0 64.0 85/30 85/30 85/30 85/30 61.6 61.6 PTFE-03 XPTFE-03 Product Ferrule 3/16'' 03 1/4'' 5/16'' 05 3/8'' 1/2'' 5/8'' 3/4'' 1.1/4'' 20 1.1/2'' 24 2'' Insert 04 08 10 12 1'' 16 STANDARD STANDARD STANDARD 316 STAINLESS STANDARD 316 STAINLESS STANDARD 316 STAINLESS STANDARD 316 STAINLESS STANDARD STANDARD STANDARD PRE-CRIMP STANDARD 316 STAINLESS STANDARD STANDARD PRE-CRIMP 316 STAINLESS 316 STAINLESS 316 STAINLESS 316 STAINLESS 316 STAINLESS NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE NO SKIVE 0003 0003 0021 X001C 0007 X0007 0007 X0007 0007 X0007 0007 0022 0011PS G G X0022 42100 0022 G X0022 0009 0019 1AW-06 X0022 0022 X0022 001C X0022 0007 X0007 11.8 14.1 06 21.1 18.4 18.3 18.6 18.3 18.6 18.8 21.0 32 SAE 100 R3 TF-0003 14.6 17.0 18.4 25.7 29.7 33.2 40.5 46.2 34.5 41.4 SAE 100 R4 TFS0004 49.8 58.0 68.2 41.1 SAE 100 R6 TF-0006 13.0 14.7 17.1 23.1 26.3 30.2 22.3 29.0 36.0 36.5 SAE 100 R7 TF-0007 12.0 13.8 16.3 22.8 25.6 12.0 13.8 22.3 29.0 29.0 SAE 100 R8 TF-0008 11.8 14.1 22.8 25.6 29.0 0007-03-IM 13.5 14.1 16.3 16.4 17.7 22.0 25.9 28.4 26.9 1 WIRE BRAID TF-MT1-15.0 17.5 17.5 36.8 36.5 36.8 36.6 38.4 37.5 WIRE BRAIDED THERMOPLASTIC COVER HOSE ALSO SUITABLE FOR SOLVENTS AND PAINTSPRAY 17.0 17.0 18.5 24.3 26.7 2 WIRE BRAID TF-MT2-31.1 39.0 18.5 20.5 700 BAR THERMOPLASTIC HOSE 17.7 17.7 23.6 18.2 ORANGE THERMOPLASTIC SEWER HOSE TF-1PS 24.8 32.2 MULTIPURPOSE HOSE TF-TU25 17.1 19.0 21.0 28.0 31.6 39.6 38.6 AIR HOSE TF-AIR 14.7 18.4 23.1 26.3 30.2 36.0