Todays Advanced Hose and Hydraulic Systems

7/29/2019 Todays Advanced Hose and Hydraulic Systems

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As its tools and technologies advance, modern uid power systems

are under greater pressure than ever beore to perorm saely and

precisely. Stronger perormance leads to greater productivity and profts

across a wide range o industries rom oilfeld and mining to mobile

equipment and marine. This multi-chapter Gates Fluid Power eBook

explores challenges in the feld and highlights innovative approaches

to testing, saety measures, and diagnostics and monitoring.

In this chapter, we present solutions to these common

hydraulic hose assembly issues: mismatched

components, poor perormance, the environmenta

impact o ailed systems and corrosion.

MISMATCHED COMPONENTS

Every hydraulic system includes a series o hoses and

couplings that transport uid under pressure rom a pump

to an actuating mechanism, which in turn converts the uid

into motion or orce. That makes the hose and couplings a

critical sub-system o the larger hydraulic circuit.

Suppliers oer countless types and styles o hydraulic hoses,

couplings and fttings. Because o industry-wide pressures

to contain costs and solve challenges quickly, engineers

oten match hose rom one manuacturer with couplingsrom another. Mixing components, as opposed to taking a

systems approach, can have consequences ranging rom

minor leaks to major saety hazards. With the high pressures

and temperatures o todays compact hydraulic systems,

employing systems with mismatched components leads to

unanticipated downtime and maintenance costs.

Taking a SystemsApproach

When selecting an OE hydraulic hose and coupling system

or fabricating an aftermarket assembly, ones rst step

should be matching hoses and couplings from the same

manufacturer.

QUICK TIP

The Society o Automotive Engineers (SAE)

recommends against using couplings rom one

manuacturer with hoses rom another manuacturerinterchangeably. SAE documents are available

through its customer service line 724-776-4970.

Although most American-made hydraulic hoses and many

imported hoses are built to conform to SAE specications

SAE allows a wide range of materials to be used. Different

materials result in a variety of hose styles, and each

manufacturer designs its hose and coupling components to

t distinct tolerances.

CHAPTER 1

Innovative

Solutions or

Hydraulic System

Challenges

TODAY'S ADVANCED

HOSE AND HYDRAULIC SYSTEMS

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Hoses from various manufacturers may have similar

dimensions and constructions but different rubber

compounds and reinforcement materials, for example.

In addition, couplings are individually designed and

tested to handle the hose manufacturers unique product.

The proliferation of thread ends from around the world in

recent years has dramatically increased the possibility of

mismatching threads and seats on various couplings.

The following sections include recommended approaches to

selecting hose and couplings.

Hose Selection

To take into account the hose performance characteristics and

the demands of a particular application, a simple and easy

method is used to properly select hydraulic hose: STAMPED.

Size

The inside diameter of the hose must be adequate to keep

pressure loss to a minimum and avoid damage to the hose due

to heat generation by excessive turbulence. Velocity of hydraulic

uid in suction lines should always fall within a specic range

recommended to ensure efcient pump operation. To determine

the replacement hose size, read the layline printing on the side

of the original hose. If the original hose layline is painted over

or worn off, the original hose must be cut and inside diameter

measured for size.

QUICK TIP

Beore cutting an original hose assembly,

measure the overall assembly length and coupling

orientation. This measurement will be required to

build the replacement assembly or match the hose

I.D. to the port size.

Temperature

When selecting a replacement assembly, two areas of

temperature must be considered. These are uid temperature

and ambient temperature. The hose selected must be capable

of withstanding the minimum and maximum temperatures of

the system.

Application

Determine where or how the replacement hose or assembly

is to be used. Consider every factor, including the type of

equipment, working and surge pressures, uid and ambient

temperatures, uid compatibility, environmental conditions

routing requirements, minimum bend radius, expected service

life and beyond. Most often, only a duplicate of the origina

hose will have to be made, provided the original hose assembly

gave acceptable service life.

Material to Be Conveyed

Some applications require specialized oils or chemicals to be

conveyed through the system. Hose selection must ensure

compatibility of the hose tube, cover, couplings and O-rings

with the uid used. Additional caution must be exercised in

hose selection for gaseous applications where permeation

can occur.

Permeation is seepage through the hose resulting in loss of

uid. This may occur when hose is used with uids such as

liquid and gas fuels, refrigerants, helium, fuel oil or natura

gas. Consider whether there are potential hazardous effects

of permeation through the hose, such as explosions, res and

toxicity. Refer to applicable standards for specic applications

STAMPED

S = Size

T = Temperature

A = Application

M = Material to be conveyed

P = Pressure

E = Ends or couplings

D = Delivery (volume)

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such as fuels and refrigerants. If gas permeates through the

tube, consider pin-perforated covers to prevent gas build-up

under the cover. Also consider the compatibility of the system

uid not only with the tube but also with the braid, cover,

ttings and other components since permeation may expose

the entire hose assembly to the system uid.

Pressure

In the hose selection process it is essential to know thesystem pressure, including pressure spikes. Published working

pressures of the hose must be equal to or greater than the

system pressure. Pressure spikes greater than the published

working pressure shorten hose life.

QUICK TIP

Burst pressures are reerence pressures

intended or destructive testing purposes and

design saety actors only. Typically, or dynamic

hydraulic applications, the minimum burst pressure

rating is our times that o the maximum working

pressure rating.

Ends or Couplings

Identifying the proper end connectors, the hose barb end and

the port-connecting end for a hose assembly is critical. Find

additional information in the Coupling Selection section of

this chapter.

Delivery

The amount of uid that must pass through a hose determines

the size of hose needed. Under-sizing a hose leads to increased

pressure loss, while over-sizing the hose adds unnecessary cost,

weight and bulk.

Coupling Selection

The amount and types o machinery being imported into the

United States is growing dramatically as the marketplace

becomes more global. The primary difference between a

conventional SAE coupling and a foreign coupling is the thread

conguration and seat angle.

It is important to be aware of these differences and be able to

correctly identify all the different types of couplings.

International thread ends can be metric, measured in

millimeters, but also include British Standard Pipe (BSP

threads, which are measured in inches. Knowing the countryof origin for a piece of equipment provides a clue as to what

type of thread end is used. Deutsche Industrial Norme (DIN)

ttings indicate a German or Swedish manufacturer, while BSP

is found on British equipment. Japanese Komatsu machinery

uses Komatsu ttings with metric threads, while other Japanese

equipment most likely uses Japanese Industrial Standard (JIS)

BSP threads, or in some cases, BSP straight or tapered threads

Three determinations are required for correct identication o

these couplings:

Seat: Inverted (BSPP & DIN), regular (JIS & Komatsu)or at (ange, at-face)

Seat Angle: 30 (JIS, BSP, DIN and Komatsu) or

12 (DIN)

Threads: Metric (DIN or Komatsu), BSP (BSPP,

BSPT or JIS), or tapered (BSPT or JIS tapered)

The coupling or hose interface must be compatible with the

hose that is selected. Follow the hose manufacturers coupling

recommendations only. The proper mating thread end must

be selected so that leak-free sealing can be made to mating

components.

ASSEMBLYPERFORMANCE ISSUES

Just as components from different manufacturers cause

hydraulic system issues and lead to failure, hose assembly

performance suffers when parts are not properly installed. Al

systems must be compliant with SAE or ISO (Internationa

Organization for Standardization) requirements, so most

engineers choose hoses based on the published specications

Often they assume that assemblies will be built correctly and

perform as intended. Of course, that does not account fo

human error, and over-crimping or under-crimping certainly

affects performance.

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QUICK TIP

Always check the crimp diameter to ensure that it

is within the published limits. Record your actual

crimper setting to achieve the specifed crimp

diameter or uture use.

Confrming Proper Components

During the assembly process, crimp specifcations are oten

unknown, but other basics (like hose length) are clear. One

solution or ensuring that proper components are selected, and

that a system will perorm as expected, has been instituted

by leading manuacturers, including Gates Corporation. The

manuacturers help OEs document and veriy parts supplied

by third parties. How? Every fth component in a parts kit is

certifed by an independent laboratory or by internal quality

control personnel.

If the extra component does not meet system requirements, it

is likely that other items in the kit will not. If time and again the

part is correct the right length, the right cleanliness, etc. it

is likely that the assemblies are being built properly. This is

an especially useful process when applications are custom and

there is greater room for error.

QUICK TIP

When replacing hose that has no visual indicators

or specs, reer to the system manual or guidance as

to the correct hose type. And always remember the

three Fs: Fit, Form and Function.

Basic Crimp Procedures

Always reerence the operators manual or

instructions specifc to individual crimpers. Also

remember to wear saety glasses and to keep hands

and clothing away rom moving parts.

1. Reer to a crimp data chart or skive data,

die selection, fnished crimp diameter and

approximate crimp setting.

2. Load the selected dies into the crimper. When

using a die set or the frst time, apply a thin

coat o lubricant to the contact surace and

cone but not to the bore o the die. This layer

o lubricant must be thinly re-applied when

contact suraces become shiny. Locate dies in

the crimp position.

3. Adjust the machine to the proper crimp setting.

4. Adjust the depth stop i necessary.

5. Insert the assembly, and locate it with the die

fngers.

6. Install a die cone i needed.

7. Activate the crimp mechanism.

8. Remove the assembly rom the dies, and

measure the crimp diameter.

MegaSys Products

MegaSyshoses rom

Gates Corporation eature

an exclusive layline

treatment that helps

users identiy crimping

specifcations, match

hoses with the right

couplings and identiy

hoses in stock and in

service. The distinctive design and pressure-

related, color-coding system is just one beneft

o the constant pressure spiral-wire and wire-

braid hoses.

Other benefts o MegaSys include:

Bends up to one-third SAE bend radius

specifcations

Saves overall hose assembly length

Facilitates easier plumbing and routing in

tight applications

Eases installation with higher exibility

Lowers inventory requirements

Reduces costs by as much as 64 percent

To learn more about the hoses and their innovative

coupling counterparts MegaCrimp and

GlobalSpiral visit the Gates Hydraulics Site.

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ENVIRONMENTAL IMPACT

One challenge or those working with hydraulics is system

ailure. An even greater problem can be the environmental

impact that results. Where the ailure occurs, the size o

the spill, the type o uid leaked and the involvement o the

industrys governing bodies are some o the key actors that play

into the costly cleanup needed to remedy the situation.

Hydraulic system ailure is common especially when systemshave not been built with the right components, properly

assembled or correctly installed. In act, it is not rare that any

given eet experiences two or more spills per year. In addition,

everyday drippage is a common problem with environmental

implications.

Source: Totten, George E. (2000). Handbook o Hydraulic Fluid Technology.

New York: Marcel Dekker, Inc. Pg. 514.

The costs and legal repercussions o environmental damage can

be signifcant. Complete all certifcations and testing oered by

equipment manuacturers and organizations in your industry,

such as the Mining Saety and Health Administration (MSHA)

or the Society o Automotive Engineers (SAE), to help prevent

ailures that could have disastrous eects on the environment.

Environment-Friendly Hoses

Todays most environment-riendly hydraulic hoses were

designed to transer uid that degrades more easily than most

While restrictions around such uid are still tight and leaks o

such uid can still be costly, the hoses are one way in which

the uid power industry is working toward cleaner, greener

solutions.

The biodegradable uid is an especially useul solution oenvironmentally sensitive applications where there is signifcant

risk associated with an oil spill rom a ruptured line, such as

arm tractors and marine dredging.

QUICK TIP

The biodegradable oils are available as ISO 32,

ISO 46, and ISO 68 specifcation oils. Also reerence

American Society or Testing and Materials (ASTM)

standards ASTM-D-6006 (Guide or Assessing

Biodegradability o Hydraulic Fluids)

and ASTM-D-6046 (Standard Classifcation o

Hydraulic Fluids or Environmental Impact).

EnviroFluid Hose

Biodegradable uids can seep through ordinary

hose tubes, causing cover blisters and sweat

and resulting in premature and expensive hose

failures. EnviroFluid spiral-wire hose from

Gates is specially designed or biodegradable

hydraulic uids and other aggressive oils like

synthetic esters, polyglycols and vegetable oils.

Its nitrile tube handles biodegradable uids

at operating temperatures up to 250F without

perormance loss, and it oers signifcantly lower

permeation than neoprene tubes when used with

petroleum-based oils.

Learn more about EnviroFluid Hose.

Even low leakage rates rom hydraulic systems

can lead to gallons o oil lost over time.

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CORROSION

Corrosion is a common challenge in hydraulic applications,

which makes coupling selection particularly critical. Part o the

process in choosing the right coupling or any given application

is ensuring that is has the proper plating. Oten, environmental

actors must be considered, as equipment operating near

the ocean, or example, contends with salt corrosion. For

equipment operating inland, on the other hand, traditional

plating oten works. Standard plating options will not sufce

when agricultural chemicals or ertilizers are moving through

the system. Because there are such varied uses o hydraulic

systems, manuacturers have created plating technologies or

virtually every situation.

QUICK TIP

I you see red rust on your coupling, it is time

to replace it. When it rusts, metal loses strength

and becomes unreliable.

To determine the right coupling or your application, reerence

the chemical resistance tables that manuacturers include in

their catalogs.

As the need to replace couplings arises, purchasing them rom

a reputable source is the best deense against poor perormance

or ailure.

CONCLUSION

While the hydraulic system challenges outlined in this chapter

are not new, leading manuacturing companies are constantly

innovating solutions to respond. Sometimes the solutions are in

the orm o new products, developed and tested to oer greate

eatures or unprecedented capabilities. Other solutions are less

tangible and come in the orm o new practices in the feld

application engineering support or training that minimizes the

eects o ordinary human error. Gates Corporation is at the

oreront o such advancements, and uture chapters o this

eBook will explore changes in testing, saety measures, and

diagnostics and monitoring.

Additional Resources

Find inormation on Gates Fluid Power hydraulic hose

couplings, crimpers and accessories at www.gatesprograms

com/hydraulics. For resources on sae hydraulics practices

and preventive maintenance, visit www.gatesprograms.com

saehydraulics. Gates also oers a special hydraulic preventive

maintenance training program called Sae Hydraulics

designed to help maintenance managers, repair technicians

and machine operators identiy component weaknesses beore

ailure. For inormation, contact [email protected].

Rating Scale

1 Excellent resistance

2 Good resistance

X Not recommended

Testing recommended

TuCoat Plating

Introduced in 2001, TuCoat plating sets the

standard or corrosion resistance. Tested under SAE

J516 and ASTMB117 salt-spray conditions, the

plating provided more than 400 hours o protection

against the ormation o red rust or 500+ percent

improvement over the 72-hour SAE standard.

Due to environmental concerns, Gates has

eliminated hexavalent chrome rom the TuCoat

manuacturing process. This green approach to

manuacturing has not aected coupling corrosion

resistance or changed torque recommendations.

Learn more about TuCoat Plating.

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As its tools and technologies advance, modern uid power systems

are under greater pressure than ever beore to perorm saely and

precisely. Stronger perormance leads to greater productivity and

profts across a wide range o industries rom oilfeld and

mining to mobile equipment and marine. This multi-chapter Gates

Fluid Power eBook explores challenges in the feld and highlights

innovative approaches to testing, saety measures, and diagnostics and

monitoring.

In this chapter, we examine product testing as an important

component o driving innovation in the uid power feld.

NEW PRODUCTS & EXISTINGEQUIPMENT

Todays testing equipment and acilities or industrialhose assemblies and product prototypes are incredibly

sophisticated. Engineers, chemists and technicians reeze,

heat, abrade, impulse cycle, age and otherwise simulate

real-world conditions or thorough testing o both existing

assemblies and new concepts. They evaluate compounds,

metals and designs to learn what works and what needs

improvement and create microenvironments to expose

materials to everything rom dry air to ozone.

Testing is most successul when product application (PA)engineers rom uid power system manuacturers collaborate

closely with OEMs to solve their specifc challenges. Changes

are immediately put into eect, rather than requiring a

back-and-orth process where systems have to be

re-engineered and problems repeatedly corrected.

Gates Corporation has made major headway in creating pro-cesses or efcient product and equipment testing. On site

or at the companys Customer Solutions Center (CSC), Gates

PA engineers eectively work side-by-side with OEMs, thei

development teams and their engineers on novel and existing

platorms. Components are positioned within platorms to

improve hose routing and reduce hose, coupling and adapte

cost, and custom solutions are delivered to customers.

CHAPTER 2

Successful Product

Testing Through

New Technologies &

Collaboration

TODAY'S ADVANCED


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Materials Test Lab: A fully environmentally controlled space, ideal for developing and testing new

materials, compounds and reinforcements and ensuring compliance with stringent industry standards

Finished Hose Test Lab: Where engineers put completed assemblies through a series of strenuous

physical tests and environmental extremes

Prototype Equipment Bay: Provides customers with a secured workplace for sensitive R&D projects

Sample Build & Metrology Lab: Where engineers make assemblies for testing across a broad range of

Gates crimpers and have access to sophisticated measurement equipment for analysis and microscopic

examination

Impulse Test Lab: An advanced lab that puts hoses and connectors through their paces

Watch a videoto learn more about the CSC.

Gates CustomerSolutions Center

The CSC is a state-of-the-art facility leading the uid

power industry in customer-focused product research,

development, testing and training.

Staffed by approximately 45 of the top engineers, scientists

and technicians in uid power technology, the CSC is

headquarters for understanding challenges and meeting

uid power needs on a global basis. The center features

these testing areas:

New Product Testing

In developing new products, important properties o the

product materials are tested in a controlled environment and

detailed plans are put in place to ensure that fnal products

will meet or exceed industry requirements.

Agencies That Set

Manufacturing Standards

Many governing bodies set manufacturing standards

for a variety of applications around the world. They

include:

ABS American Bureau of Shipping

AS Australian Standard

DIN Deutsch/German Industrial Norm

DNV Det Norske Veritas for North Sea Floating Ve

EN European Norm/Standard

GL Germanischer Lloyd

IJS Industrial Jack Specications

RCCC Regular Common Carrier Conference for

Truck and Bus

SAE Society of Automotive Engineers

United States Government Agencies

DOT/FMVSS Department of Transportation/Fe

Motor Vehicle Safety Standards

MSHA Mine Safety and Health Administration

USCG U.S. Coast Guard

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Even with the most careul testing processes, outcomes are

not always easy to predict. When Gates began designing its

LieGuard line-o-sight sleeving system, the frst true

protection in line-o-sight hydraulic applications,

unexpected obstacles arose. When the aluminum collars

are crimped on the assembly, it has to be done in a way

that allows uid to escape the sleeving. During testing, the

desired eect could not be consistently produced using

standard feldtooling, so a new tool that would retroft existing machines

was designed.

In addition, since LieGuard

sleeving was designed to

protect operators in cases o

ailure, feld testing outside

o ft was not an option.

During product testing Gates

had to be able to subject the

sleeving to specifc types o ailure in a burst chamber. This

allowed Gates to saely create pinhole leaks o specifc sizes

and generate bursts. Capturing video o the ailures allowed

the testing team to review and analyze how the sleeve and

clamps reacted in each instance.

QUICK TIP:

Many hose products go through multiple testing

iterations beore meeting requirements. Even once

requirements are met, couplings can blow o or

leak during impulse testing, especially when high

temperatures are involved. In some cases, ull

testing requires months o eort.

The Prototype Testing Process

Over the years, the testing process or new products has

been refned. Everyone involved with the assembly assesses

it, including application engineers, materials engineers,

hose engineers, coupling engineers and even marketing

representatives.

Generally, the process follows these steps:

1. Test procedure written

2.Procedure submitted to lab

3.Lab technicians prepare samples

4.Initial tests conducted

5. Engineering Change Notifcation (ECN) submitted

6.Changes made

7.Further tests conducted

8.Requirements met

9.Team sign o

The Engineering Change Notice (ECN), also reerred to as

an Engineering Change Order (ECO), is documentation o

design changes made throughout the prototyping and

lie-cycle phases o a product. This documentation contains

the justifcation or changes made to a component or

system once the initial design is complete. It also orces

changes to be approved by the relevant authorities.

For Gates, working directly with customers has made the

greatest dierence in creating prototypes that not only

meet but exceed requirements. The companys customized

process, rom design and development to testing, efciently

generates innovative solutions.

What to Include in an ECN

According to David G. Ullman in his 2009 book

Mechanical Design Process, an ECN must contain

following information:

Identication of what needs to be changed. This sh

include the part number and name of the compo

and reference to drawings showing the componen

detail or assembly.

Reason(s) for the change.

Description of the change. This includes a dra

of the component before and after the change.

drawings must clearly show the detail(s) affected

the change.

List of documents (and in industry, the departme

affected by the change. The most important pa

making a change is ensuring all pertinent groups

notied and all documents updated.

Approval of the change. As with the detail

assembly drawings, the changes must be approve

management.

Instruction about when to introduce the change

immediately (scrapping current inventory), during

next production run or at some other milestone.

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VEVA

Gates Value Engineering/Value Analysis is a method used to achieve necessary product and/or service functionalityat minimum cost with an increase in overall value. Rather than just replacing hose and couplings with cheape

versions, engineers nd ways to increase throughput and reduce labor costs. Warranty claims provide valuabl

insight into possible areas of improvement, and systems are retooled to eliminate leak points. At times, component

can be entirely eliminated an option that is often better than downgrading them.

Improving Existing Equipment

When improving existing equipment, a preliminary meeting and onsite evaluation must take place in order to

determine the projects parameters. For Gates, once this step is complete, the machine is shipped to the CSC or

prototyping and VEVA Value Engineering/Value Analysis.

At the CSC new technologies are applied to units under analysis, and hose and coupling engineers are readily

available to assess and fnd solutions or problem areas. Once a platorm has been plumbed, Gates proposes changes to t

customer who chooses which recommendations to pursue. Ultimately, the machine is sent back to the acility or proving

grounds or testing.

CONCLUSION

Advanced testing processes and technologies are required to create innovative uid power products and improve the value

o existing equipment. Gates is leading the industry by combining the most sophisticated tools available with hands-on

expertise rom knowledgeable engineers and technicians. Only through close collaboration with OEMs are the most

productive, cost-saving solutions created.

Additional ResourcesFind inormation on Gates Fluid Power hydraulic hose, couplings, crimpers and accessories at www.gatesprograms.com/

hydraulics and resources related to E2E industrial hose products at www.gatesprograms.com/hosesystems . Questions?

Contact [email protected].

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Increased equipment productivity

Better utilized in-shop maintenance(less emergency work)

Improved control of spare part inventory and

reduce parts usage

Decreased equipment downtime

Reduced safety hazards

Increased equipment service life

Less environmental nes and clean-up costs

due to leaks

As its tools and technologies advance, modern uid power

systems are under greater pressure than ever beore to perorm

saely and precisely. Stronger perormance leads to greater

productivity and profts across a wide range o industries

rom oilfeld and mining to mobile equipment and marine. This

multi-chapter Gates Fluid Power eBook explores challenges in

the feld and highlights innovative approaches to testing, saety

measures, and diagnostics and monitoring.

In this chapter, we explore best practices or hydraulic and

industrial hose system saety.

SAFETY & FLUID POWERPREVENTIVE MAINTENANCE

Small hose problems can turn into catastrophes whenindustrial and hydraulic hose systems are not properly

maintained. And as demands on uid power applications

increase, risk rises.

Implementing a preventive maintenance program helps

identify component weaknesses before system failure.

Start by selecting the proper hoses and ttings. Take time

to ensure that theyre properly assembled, routed and

installed. Then schedule periodic inspections and

troubleshoot any issues that arise. Make sure that thoseworking on and around the equipment are properly trained

to handle any safety issues they may face.

Armed with the knowledge that comes from performing

preventive maintenance, companies can take action to

replace or repair hose systems, reducing the instances of

workplace injuries while protecting the environment and

their equipment.

CHAPTER 3

Maintaining a Sae

Working Environment

TODAY'S ADVANCED


PreventiveMaintenanceBenefts

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Saety Factors or Hydraulic Hose Systems

Maintaining a safe working environment is a necessity when

working with hydraulic systems. Employees who operate

or work near these systems should know the risks and

potential for danger and thoroughly understand how the

equipment works. There are several key factors to be aware

of, including pressure, temperature, ammability,mechanical and electricity.

Pressure:Operating pressures of hydraulic systems can

be up to 10,000 psi. With this much hose pressure, even

the tiniest of pinhole leaks can cause a serious medical

crisis. And if the assembly is not properly installed, the

couplings could come off and hit an operator or cause the

hose to spray dangerous uids. In other instances, the

tting could come apart and the loose hose could whip

around, endangering those in the vicinity.

Temperature:Most hydraulic systems typically operate

at 150 to 180F, while others may go as high as 300F.

Hoses, liquids, ttings, adapters and other metal parts can

be extremely hot and, if touched, can burn skin.

Flammability: Most hydraulic uids that are not

comprised primarily of water are ammable when they

come into contact with sources of ignition, such as sparks,

open ames, extremely high temperatures, and hot

manifolds. Leaking pressurized hydraulic uids can develop

a ne spray or mist that can explode when ignited, causing

serious injury, even death.

Mechanical: Hydraulic equipment parts move or rotate

at high speed with signicant force. When a hose fails,

objects supported by uid pressure can fall, causing serious

damage.

Electricity: Electricity can create the spark that causes

a re, explosion or even electrocution. During normal

equipment operation, workers may be exposed to electrical

hazards such as high-voltage power lines and underground

power sources. Most hydraulic hose is wire-reinforced,

making it conductive to electricity. Even non-wire

reinforced hose may be conductive through the rubber

compound itself or moisture that penetrates a pin-pricked

hose cover.

Understanding the safety factors for hydraulic hose systems

and taking proper precautions to create a secure

working environment will help reduce accidents, injuries

and production loss.

QUICK TIP:

Take responsibility for personal safety. Always wear safety

glasses, keep appendages away from moving parts, do not

wear loose-tting clothing and make sure equipment is

securely mounted and connected.

Hydraulic Hose Saety Tips

When working with hydraulic hose systems make s

to take caution in dangerous circumstances.

Do not touch or go near a pressurized hydraulic ho

assembly. I uid punctures the skin, even i no pa

is elt, a serious emergency exists. Obtain medical

assistance immediately.

I whipping hose is a potential hazard, make sure

restrain or guard the hose using clamps or protect

shielding.

Precautions should be taken to eliminate all ignitisources rom contact with escaping uids, sprays

mists resulting rom hydraulic ailures.

When using mobile equipment, always chock the

to prevent rolling.

Make sure to turn hydraulic equipment o beore

working on it. I you are perorming maintenance o

plant equipment, lock the control box and tag it w

a warning sign stating DOWN FOR MAINTENANCDO NOT TURN ON POWER. Or, i the equipment

mobile, take the key and/or disconnect the battery

cannot be started.

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Hydraulic Saety Solutions:

A Systems Approach

Selecting the right hoses and couplings for hydraulic

equipment is a key part of preventing safety hazards.

Suppliers offer hundreds of different types and styles of

hydraulic hoses, and thousands of different couplings

and ttings, but not all are ideal matches. Both Gates

Corporation and the Society of Automotive Engineers (SAE)

recommend against using couplings and hoses from different

manufacturers.

Although most American-made hydraulic hoses, and many

imported hoses, are built to conform to SAE specications,

SAE allows a wide range of materials to be used. Hoses

from various manufacturers may have similar dimensions

and constructions, but different rubber compounds and

reinforcement materials, while couplings are individually

designed and tested to handle the hose manufacturersunique products. Also, the proliferation of thread ends from

around the world in recent years has dramatically increased

the possibility of mismatching threads and seats on various

couplings. Just one improperly matched coupling could

cause a hose leak or the ends to blow off.

Taking a systems approach to hose selection ensures that

the hydraulic assembly is tested together with matching

components and is less likely to fail, reducing injuries.

Saety Factors or Industrial Hose Systems

Industrial hose applications are demanding. They operate athigher working pressures and temperatures than hydraulic

applications and transfer hazardous materials, such as

corrosive chemicals, LP gas, petroleum products and steam.

However, much like hydraulic hose systems, If they arent

designed, installed and maintained properly, they can be a

huge safety risk, causing leaks, bursts, whipping hose, re,

high force movement, explosions and electrocutions.

LieGuard Line-o-SightSleeving System

Gates has engineered the frst sleeving system

specifcally designed to protect operators, equipm

and the environment rom the hazards o catastrop

hydraulic hose ailure.

How it Works

The LieGuardsleeve is slipped onto the hose an

clamped at each end. I a hose burst or pinhole le

occurs, escaping pressures and uids are containe

by the sleeve material and then exit the system via

openings at each end, creating a noticeable pool

o leaking uid, alerting operators to the need or

replacement.

The LieGuard sleeve was rigorously tested both in

the lab and in the feld to veriy its perormance a

capabilities at typical uid pressure and temperat

levels. It meets a variety o industry standards,including ISO 3457, which requires operator prote

within a three-oot line-o-sight o any hose convey

uid above 725 psi at 120F (49C), and MSHAs

ame-resistance requirements.

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Industrial Saety Solutions:

A Systems Approach

As with hydraulic hose systems, if an industrial hose

is improperly matched with ttings from a differentmanufacturer, it can pose a safety risk. Taking the time to

properly match all the components, or taking a systems

approach, is important for a safe working environment

Selecting the right hose will ensure proper performance for

the material being transferred. It will also minimize the risk

of property damage or bodily injury due to leaks, bursts or

ends blowing off. Use STAMPED to remember hose selection

characteristics.

Keep in mind that taking a systems approach involves more

than a quick glance at a hose manufacturers chemical

resistance tables; it takes careful study and analysis.

Hose compounds with identical names are more complex

than they might appear. For example, a tube made from

the EPDM elastomer may differ from another EPDM tube

because of differing ingredients such as accelerators, age

resistors, vulcanization agents, carbon black or processing

aids. Due diligence in hose selection can create a safer

working environment and prevent costly accidents.

Choosing the Right Hose

An improperly matched hose can be a saety

nightmare. To fnd the proper hose or an applicat

use theSTAMPEDacronym to remember importa

characteristics.

Size

I.D. (inside diameter)

O.D. (outside diameter)

Length

Flow rate requirements (GPM for liquids;CFM or gases)

Temperature

Ambient temperature

Internal temperatures

Temperature impact on material being conveyApplication

Where the hose will be used

How the hose will be used

How often the hose will be used

Environmental conditions

Special hose construction needs

Conductivity requirements

Critical applications (ammable uids,compressed gas, steam, etc.)

Government or industrial standard requireme

Material Being Conveyed

Chemical name(s) and state(s)

Food, pharmaceuticals, cosmetics

Dry or powder

Liquid

Pressure

Working pressure

Maximum surge pressure

Vacuum

End Requirements

Type of end connections/couplings

Delivery

How many items and when they need tobe supplied

Special packaging or branding requirements

Industrial Hose ApplicationsTypical industrial hose applications, as identifed

by the National Association o Hose & Assembly

Distributors (NAHAD) include the ollowing:

Air Hose

Asphalt ChemicalPlastic Lined

ChemicalRubber Lined

Food HandlingRegulated

Food HandlingNon-Regulated

Lay Flat

Material HandlingBulk Transfer

Material HandlingCement

Petroleum

Push On Sandblast

Steam

Water/Multi-Purpose

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Dont forget to carefully consider ttings as well. Some factors to consider in selecting the proper hose couplings include:

Hose size

Compatibility with the material being conveyed

Installation design and attachment options

Corrosion resistance

Thread type (hose end and thread end)

CONCLUSION

Injuries incurred while working with hydraulic and industrial applications are avoidable. For a safe working environment, star

by taking a systems approach to selecting your components and follow up with regular preventive maintenance to ensure tha

the proper precautions are taken to decrease injury and loss of life.


Find information on Gates Fluid Power safety at www.gatesprograms.com/safehydraulics and resources related to E2E

industrial hose products at www.gatesprograms.com/hosesystems . Questions? Contact [email protected].

Other Industrial HoseSelection Factors

Abrasion

Electrical conductivity

Environment

Flammability

Flow rate

Fluid velocity

Movement (type, distance, frequency)

Ozone

Permeation (vapor conveying hose)

Pressure drop

Routing

Salt water

Static electricity

Ultraviolet light

Vibration (frequency rate Hz,

amplitude G load)

Some additional industrial hose selection considerations rom NAHAD are:

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Gates Engineering & Services (E&S) oers Gates

Hose Management, a risk-based management

program or hose assemblies. It is based around

the UK Oshore Operators Association (UKOOA)

Quantifying productivity requirements, safety

risks, and environmental risks.

Understanding customer FHA program and

usage.

Evaluating client practices and recommendingsteps for improving FHA, QA and HSE.

Performing necessary installations and services

on-site.

Developing integrity-based inspection,

maintenance and recertication strategy.

Providing hose monitoring and diagnostics

powered by Gates Sentry Services for reliable

operation and continuous improvement.

For more information about Gates Hose Management Services, call 1-972-664-9287.

As its tools and technologies advance, modern uid powersystems are under greater pressure than ever beore to perorm

saely and precisely. Stronger perormance leads to greater pro-

ductivity and profts across a wide range o industries rom

oilfeld and mining to mobile equipment and marine. This

multi-chapter Gates Fluid Power eBook explores challenges in

the feld and highlights innovative approaches to testing, saety

measures, and diagnostics and monitoring.

In this chapter, we examine the evolution o hose lie monitoring

and diagnostic solutions.

HOSE MANAGEMENTSOLUTIONS

When uid power equipment ails, it is costly in terms o

time, money and production loss. All types o equipment

in the feld, rom drilling rigs to wind turbines, rely on hose

systems to operate efciently. Monitoring the condition and

perormance o hose systems and properly predicting hose

lie can mean the dierence between routine maintenance

time and catastrophic downtime.

CHAPTER 4Advancements in Hose

Monitoring, Diagnostics

& Identifcation Practices

TODAY'S ADVANCED


Gates Hose ManagementServices

Flexible Hose Assembly Standard (FHA) and

is designed to reduce risk in all aspects o

operations by:

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Temperature, Pressure & Hose Lie

Hydraulic hose lie is impacted by a number o conditions,

but most instances o ailure arise rom issues ound inside

the hose: extreme temperatures and signifcant changes in

hose pressure.

Exposure to internal or external temperatures that exceed a

hoses specifcations can cause its synthetic rubber

compounds to harden, reducing exibility and making it

more susceptible to cracking. Similarly, when a hose

operates at low ambient temperatures (-40 and lower),

it may become less exible, brittle and crack.

Pressure also aects hose integrity. While a drop in

pressure rom the time the uid enters a hydraulic hose

assembly to the time it leaves is to be expected, it may be

necessary to control it or optimum system perormance.

For most dynamic hydraulic applications, the minimum

burst pressure is our times the maximum working pressure

rating. The working pressure o any hose used should be

greater than or equal to the maximum system pressure.

This generally increases cycle lie. In act, Gates testing

has ound that using a hose at 50% below its rated working

pressure will approximately quadruple the cycle lie.

QUICK TIP:

The minimum impulse cycle lie ound in SAE J517 can be

used as an indicator o expected hose cycle lie. However,

remember that dierent hose types, and in some cases

hose sizes, have dierent expected cycle lives.

Some hose manuacturers have products

that ar exceed SAE minimums.

While its necessary to ascertain the external condition o a

hose with a visual inspection, to get a clear picture o the

state o the hose, internal actors such as temperature and

pressure need to be closely monitored as well.

Traditional Hose Monitoring& Identifcation Practices

For years, mobile equipment operators and eet

managers have relied on basic identifcation and monitoring

processes. Hoses have stainless steel tags afxed to them

that are logged or identifcation and operators keep records

o which hoses have been replaced and when. Hoses and

connectors are visually inspected at regular intervals to

check or signs o cracking, abrasion, wear, leaks, corrosion

or other indicators that indicate ailure is imminent.

While visual inspections have been the most common way

to inspect the hose assembly, operators have the option o

paying or costly uid chemical analyses and flter

inspections to try to establish internal hose conditions.

Unless there are warning signs, there is no clear indication

that a hose will ail simply due to age. Typically, hoses arereplaced in accordance with manuacturers suggested lie

and operational experience.

Traditional hose monitoring methods rely heavily on visual

examinations and require a lot o maintenance time.

Factors on the inside o the hose play a large part in the

overall hose lie, and relying solely on the external

conditions o the hose misses that key component. An

operator may replace a hose that has valuable service lie

let too soon based on the manuacturers recommenda-tions. Or he may not realize that pressure spikes and

temperature within the hose have degraded the hose quality

so much that ailure (and possibly injury or costly cleanup)

is imminent.

New Technology or Hose Monitoring,Diagnostics & Identifcation

Todays technology enables companies to streamline their

hose management processes. Identifcation, monitoringand diagnostics are no exception. While stainless steel

tags and manual logs have long been standard, new radio

requency identifcation (RFID) and tagging have

revolutionized monitoring practices.

Instead o identiying hoses using stainless steel tags,

high-tech RFID tags can be afxed to all hose assemblies

in the feld. Each tag, when scanned by a hand-held RFID

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reader, provides data including hose type, size, length, end

fttings, location, orientation, test certifcations, assembly

notes, bill o materials (BOM) and other important data.

The inormation can be read or updated on-site and

synchronized with a PC database. I a hose needs to be

serviced or replaced, personnel can easily scan the tag to

obtain its inormation and determine the correct assembly.

Taking the process rom manual to digital, RFID tagging isefcient, saving time and money.

While visual hose inspections are still necessary, installing

sensors on dierent parts o each hose in a system allows

operators to monitor pressure pulsations and temperatures

or each hose. This inormation is sent to an electronic

control unit (ECU), which can be programmed to calculate

a hoses remaining service lie and warn users o

out-o-spec conditions. The data can help personneldetermine when to order replacement parts and anticipate

downtime, reducing the likelihood o unexpected

catastrophic hose ailure and helping control costs.o

RFID 101

Radio Frequency Identication (RFID) is a technology

that uses radio waves to transmit inormation rom

electronic tags to a reader in order to identify or

track objects. An RFID system consists of a tag that

includes a chip and antenna, and a reader. The RFID

reader transmits radio waves to the tag at a specic

frequency. Upon receiving them, the tag sends back

inormation to the reader. The reader then translates

the waves into digital inormation and pulls relevant

data from the computer database. RFID tagging is

used on several objects, rom pets microchips to

library books. Even casinos use the technology.

They place RFID tags on high-value chips in order

to identify counterfeit chips and instances of card

counting, and to track betting habits.

Gates Sentry Services

Gates Sentry Services, a comprehensive prevent

maintenance solution, allows feet managers and

equipment operators to estimate remaining hose l

and accurately identify hoses that need to be repla

Sentry Services consists of Sentry IQ and Sentry

ID:

Sentry IDoers real-time monitoring and diagnost

inormation about the current operating condition

perormance o hose assembles. It provides warnin

based on a pre-established set of reporting param

Service warning for any of the monitored hoses

Warning of over-temperature or over-pressure

conditions

Warning of any system faults such as failed sen

cabling or ECU

Sentry IDis an RFID tagging system that identies

tracks specic hose assemblies worldwide.

High-frequency Sentry ID tags provide easy eld a

to any hose data deemed important. This includes

but is not limited to, hose type, length, location, s

bill of materials (BOM), assembly notes, maintena

records, photographs and installation instructions.

For more information about Gates Sentry Services,

www.gatesprograms.com/sentryservices .

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CONCLUSION

Visually inspecting external hose components is an important part o preventive maintenance. However, to truly understand

hose condition and predict remaining service lie, it is necessary to use available technology to monitor temperature and

pressure changes inside the hose. Recent advances in RFID technology help streamline the maintenance process, preventin

catastrophic hose ailure, reducing downtime and saving money.


Find inormation on Gates Fluid Power hydraulic hose, couplings, crimpers and accessories at

www.gatesprograms.com/hydraulics . and resources related to E2E industrial hose products at

www.gatesprograms.com/hosesystems . For inormation about Sentry Services, visit

www.gatesprograms.com/sentryservices . Questions? Contact [email protected].

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