User Guide Hose - David Harries and Co.
Contents
1. 24 Velocity of flow through pipes y GPMx0 3208 A V Velocity in feet per second A Inside opening area in in Entrained air At room temperature standard hydraulic oil contains 8 9 air by volume Heat generation BTU hr 1 5 x GPM x PSI PSI Pressure loss which does not produce work Head pressure Oil creates a pressure due to its weight at 0 4 PSI per foot of depth Pressure drop through pipes _ _VxF 18300D P Pressure drop per foot V Viscosity in SSU D Inner diameter in F Flow in GPM 25 Notes PIXX BELTS amp HOSES CORPORATE OFFICE amp WORKS PIX TRANSMISSIONS LIMITED J 7 M I D C Hingna Road Nagpur 440 016 Maharashtra India Ph 91 7104 237729 236501 4 Fax 91 7014 236505 6 E mail info O pixtrans com Web Site www pixtrans com PD BELTS amp HOSES PIX EUROPE LIMITED 11 Foxtail Road Ransomes Europark Ipswich Ip3 9RT Suffolk England Ph 44 1473 719677 Fax 44 1473 719688 E mail info O pixeuro com Web Site www pixeuro com PD AMERICA BELTS amp HOSES PIX SOUTH AMERICA LIMITED Rua Emilio Goeldi 639 Agua Branca 05065 110 Sao Paulo SP Brasil Ph 55 11 3611 9000 Fax 55 11 3611 3661 E mail info O pixsam com Web Site www pixsam com dd PIX GERMANY GmbH Nikolaus Otto Str 2 Borchen 33178 Germany Ph 49 5251 878 6003 Fax 49 5251 878 6009 E mail pix g2. acid salt water heat or extreme cold Violation of the minimum bend radius Improper installation of the hose causing the twisting of hose primarily and causing the burst at such bends 17 Troubleshooting Types of failure Bursting of hose at about 6 to 8 inches away from End Fitting Blisters on the cover of hose Fitting blew off at the end of the hose Swelling and deterioration of the hose Bursting of the hose with cover being badly deteriorated and cracking of rubber Hose is badly flattened out in the burst area Hose is not burst but leaking profusely Elongation of the hose Causes Improper crimping of the End Fittings allowing the moisture to be trapped between inner and outer liner causing corrosion of the braiding wires Pin holes in the hose tube allowing the high pressure oil to seep in between the gaps Improper crimping or wrong End Fitting improper stack allowance while installing Incompatibility of the hose with the working substance Old Hose Sharp bend Erosion has taken place Insufficient support to the hose 18 Product range High Pressure Hydraulic Hose Specification Type of Hose Nominal Hose I D Followed DIN 20022 1ST RIA IA 5 16 3 8 1 2 5 8 3 4 1 1 1 4 1 1 2 amp 2 EN 853 2ST R2A IA 5 16 3 8 1 2 5 8 3 4 1 1 1 4 1 1 2 amp 2 SAE J 517 1SN RTAT 1 4 5 16 3 8 1 2 5 8 3
3. 12 20 3 4 19 0 16 25 1 25 4 20 32 1 1 4 31 8 24 40 1 1 2 38 1 32 50 2 50 8 23 Formulae amp factors Formulae amp Conversion Factors for Fluid Power Use Quantity Customary SI Unit Conversion Conversion U S Unit FromU S toSI From Sito U S units units Area Squareinch SquareMetre in x6 451x m x1550 003 in m 10 m in Force Pound Newton Ib x4 4482 N x2 2481x Ib N N 10 lb Frequency Cycles Second Hertz 1 cps 1 Hz 1 Hz cps cps Hz Length Inch Metre in x2 540x m x39 370 in m 10 m in Mass Pound Kilogram lbm x4 5359x Kg x2 2046 Ibm Kg 10 Kg lb m Power Electric Hosepower Watt HP x7 460x W x1 3405x HP W 10 W 10 HP Pressure Pounds sq in Newton sq mtr psi x6 8948x N m x1 4504x psi N m 10 N m 10 psi psi Pascal psi x6 8948x pa x1 4504x Pa 10 Pa 10 psi psi BAR psi x6 8948x Bar x1 4504x Bar 10 Bar 10 psi Bar N m Bar x100 000 N m x1 00x N m 10 Bar Temperature Degrees Fahrenheit Degrees F 32 1 8 ext 8 32 F Celsius C C F Torque Pound inch Newton Metre Ib in x1 1298 N m x8 8507 Ib in N m x10 N m Ib in Volume US Gallon Cubic Metre Gal x3 7854x m x2 641 TX Gal M 10 m 10 Gal Litre Gal x3 7854 1 x2 6417x I I 10 Gal Work Foot Pound Joule ft lb x 1 3558 J x7 3756x Ft Ib J J 10 ft Ib
4. 4 1 1 1 4 1 1 2 amp 2 2SN R2AT 1 4 5 16 3 8 1 2 5 8 3 4 1 1 1 4 1 1 2 amp 2 BRITISH COAL Two wire 1 4 3 8 1122 SD 1 1 4 Ee amp EE BOARD SPEC braid hose BCS 174 High Pressure Compact Hose Specification Type of Hose Nominal Hose I D Followed EN 857 1SC 1 4 5 16 3 8 1 2 5 8 3 4 amp 1 2SC 1 4 5 16 3 8 1 2 5 8 3 4 amp 1 Hot Water Standard Compact Hose Type of Hose Nominal Hose I D Single Double 1 te 5 1 6 3 8 amp 12 Wire braided Hot Water Availablein Black amp Blue colour Krishi Agriculture Hose Type ofHose Nominal Hose I D Followed Single Wire braided 1 2 19 Product range Rock Drill Hose Specification TypeofHose Nominal Hose l D Followed 1S 446 1987 Wire braided 1 2 5 8 3 4 1 1 1 4 1 1 2 amp 2 Type 3 LPG Hose Specification Type of Hose Nominal Hose I D Followed 1S 9573 1998 Wire braided 5 16 3 8 amp 1 2 Type 4 Note 5 16 hose in Orange colour Others available in Black colour Gasoline Hose Type of Hose Nominal Hose I D Wire braided 5 8 3 4 amp 1 CNG Hose Wire braided Specification Type of Hose Nominal Hose I D Followed SAE J30 R6 Wire braided 5 16 20 Product range Steam Hose Specification Type of Hose Nominal Hose l D Followed 1A 12518 IA A Wa 2 amp 2 BS 5342 1985
5. IS 10655 Type 2 amp Type 3 2A 1 2 5 9 374 1 11 42 11 2282 1B 12 518 34 1 14 4 11282 BS 5342 1985 2B 1 2 5 8 3 4 1 1 1 4 1 1 2 amp 2 X el XP High Pressure Hose Exceeds EN 853 2SN Type of Hose Nominal Hose I D Double wire 3 8 12 8 3l 8 qu braided means sizes on request X el XT High Temperature Hose 40 to 150 c Type of Hose Nominal Hosel D One or Two wire 1 4 5 16 3 8 1 2 5 8 3 4 1 1 4 1 1 2 amp 2 braided 21 Bend radius 86 ol 29 LE 9 ve 0 OS 298 NA 06 BA 09 LS 9E Vt 0 Ist 298 NA GES ZI OSL SUL L6 6S Ls GV 6 oN s98 8 vc AOF GGI 8l v6 64 Ln ES GY 6 NSG NIO 8 vd L 6L SS SUL v6 64 Lo US gv 6 NS NIC UPON NOW AO Sio Sik Sebe ERBE v6 V6 SA pz E E LS LG Sy gy 6 6 1S6 St NIG NIG suoneooads ose BSc 005 00 ER SSL gar al g6 g6 08 08 07 EEA 09 09 GY SN Ov Ov lV d Lvld 00L 00L avs eis SAHONI NI SNIGV AN3 NNWININ MEZ 0 06 S 9 0 cL 6 08 OL 09 gv Ov You 001 EME 095 MIE Gol Ocl GO 08 07 0S Eu 07 Vid 001 AVS 6 GH BH vie 8 S ol 8 91 s vll Seuou ul 310g jeuwoN 22 azIS Hose conversion factor HOSE CONVERSION FACTOR Dash DN Nominal Bore Inch mm 04 06 1 4 6 40 05 08 5 16 7 90 06 10 3 8 9 50 08 12 1 2 12 10 16 5 8 15 9
6. USER UO HOSE Bazargaon Plant Profile Certifications Work environment End fitting selection criteria Hose selection criteria Inspection Protecting the hose Installation Types of failure Trouble shooting Product range Bend radius Hose conversion factor Formulae amp factors Notes 01 02 03 03 04 05 06 07 15 16 17 18 19 21 22 23 24 25 Profile PIX TRANSMISSIONS LIMITED is engaged in the manufacturing of wide range of world class quality V Belts and Hoses to suit various power drive needs Its comprehensive manufacturing setup at Nagpur and Bazargaon conforms to the stringent ISO 9001 2000 amp TS 16949 standards and is designed to include all sophisticated manufacturing and testing facilities under one roof The wide range of Hoses manufactured by PIX have found their acceptance in various industries eg Mining Earthmoving Moulding Logging Agriculture Drilling Petroleum Waste Refuse Crane Railroad Manufacturing Construction Pulp and Plywood Mills Infrastructure Advantage State of art Braiding Machines Highly advanced amp sophisticated Impulse Testing Machine Testing facilities for Proof Pressure Burst Pressure Changing Length Flame Resistance State of art Ozone Chamber Hose Assemblies and End Fittings PIX has got a full fledged manufacturing facility for producing wide range of high quality End Fittings and Hose Assemblies The f
7. acility includes CNC machinery for manufacturing of End Fittings Crimping machine Cutting machine Skiving machine Proof Pressure Testing Machine for assemblies e Hose assembly cleaning facility Metal Crack Detection Machine for incoming raw material Certifications Bualily Policy Ix 272 E IA NISI 2 hzb ROAD dl de dia de dik B AU ari CAF KR Eric nz ru dex re ar EGIN Tic xf HE diek TH 7 Parr IR ISen ZAS lom BAGA IBExU Institut fur Sicherheitstechnik GmbH Directive 94 9 EC Test Report No IB 03 4 934 pll 2GD c IIB X US Department of Labor Mines Safety amp Health Administration MSHA Marking No MSHA IC 226 Work environment The most effective and the best way to maintain the safer work environment can be achieved by knowing your equipment properly The chart below list down the factors one need to look in the equipment Work Environment Pressure Flammability Electricity Pin hole Ignition sources Leak Burst Temperatures Mechanical Coupling motion Blow off Fluid Temp Whipping Hose Ambient Temp End Fitting Selection Criteria End Fitting Selection Thread end Vibration Pressure compatibility Fluid Use of Corrosion compatibility adaptors resistance Temperature ion criteria Hose select Hose selection criteria The following factors are to be considered to ensure that the best hose is selected for the desired ap
8. ecting the Hose It is imperative that for an efficient running of the system the hoses have to be duly protected from surrounding factors which can cause potential damage to the hose leading to the failure of the equipment The following simple techniques can help in protecting the hose Bundling Only similar construction hoses need to be bundled together Never bundle high and low pressure hoses together Mechanical movement of the hose should be considered when bundling the hoses together Hoses in same bundle should bend in the same plane only Sleeving Sleeving is generally done to protect the hose from abrasion for use in bundling and to prevent the operator from injury in case of hose failure Spring Guards opring guards are generally used to protect the hose from abrasion and to provide stability when bundled together Installation Bend Restrictors Bend restrictors are generally PVC pipes and are installed near the coupling ends to reduce the bending stresses in the hose Hose Installation Procedure 1 Clean the surrounding area where the connections are to be made so that no dirt or grime enters the open ends of hose and of the equipment Install adaptors into ports if they are used Lay the hose assembly into routing position to verify the length and correct routing Screw one end of the hose fitting onto the port If the hose assembly uses an angled fitting then the angled end
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10. must be fitted first to ascertain proper orientation Screw the other end of the hose fitting without twisting the hose Properly torque both ends Run the hydraulic system to circulate oil under low pressure and reinspect for leaks Installation Installation Proper hose installation is essential for satisfactory performance If hose length is excessive then the appearance of the installation will be unsatisfactory and unnecessary cost of equipment will be involved If the hose assemblies are too short to permit adequate flexing and changes in length due to expansion or contraction then hose service life will be reduced The following diagrams show proper hose installa tions which provide maximum performance and cost savings Consider these examples in determining length of a specific assembly Proper Installation Procedure Wrong a hrs E ple Right When the hose installation is straight allow enough slack in hose line to provide for length changes which will occur when pressure is applied Prevent twisting and distortion by bending hose in same plane as the motion of the boss to which hose is connected Right Route hose directly by using 45 or 90 adaptors and fittings Avoid excessive hose length to improve appearance Right When radius is below the required minimum use a
11. n Often clamps are required to support long hose runs or to keep hose away from moving parts Use clamps of the correct size Too large clamp allows hose to move inside the clamp and causes abrasion 14 Wrong Right To avoid hose collapse and flow restriction keep the hose bend radius as large as possible Refer the hose specification tables for minimum bend radius 15 Types of failure e Hose Fraying Bulging near End Fitting Cover wear off due to abrasion 16 Troubleshooting Types of failure Hose tube is hard and cracked Hoses cracked internally and externally even though it is flexible at room temperature Bursting of the hose and random breaking of braiding wires along the length Bursting of hose at more than one place Hose has burst examination reveals that the wire has rusted and the cover has been cut Hose has burst on the outside bend and appears to be elliptical in the bent section Hose appears to be flattened out Has burst in this area and appears to be twisted Causes High temperature causing the rubber to over cure Reaction of Oxygen with aerated oil Cavitation occurring inside the tube Operating temperature below 40 c High frequency pressure impulse conditions Pressure has exceeded the minimum burst pressure Cover basically protects the hose elements that damage the cover may be abrasion cutting
12. n angle adaptor to avoid sharp bends Wrong Right Use proper angle adaptors to avoid sharp twists or bend in the hose 10 Avoid twisting of hose lines or bends in two planes by clamping hose at the change of plane Wrong Adequate hose length is necessary to distribute movement on flexing applications and to avoid abrasion 11 No pressure High pressure To allow for length changes when hose is pressur ised do not clamp high at bends so that curves will absorb changes Do not clamp high and low pressure lines together High ambient temperatures shorten hose life Make sure that the hose is kept away from hot parts If it is not possible insulate the hose 12 When installing hose make sure it is not twisted Pressure applied to a twisted hose can result in hose failure or loosening of connections Wrong Right Reduce number of pipes or thread joints by using proper hydraulic adaptors instead of pipe fittings 13 Installation Wrong Right Elbows and adaptors should be used to relieve strain on the assembly and to provide neater installations to facilitate inspection and maintenance at an ease O O D Wrong Right Run hose in the installation so that it avoids rubbing and abrasio
13. plication doJp eJnssaJg ed Buijdno 9 9S0H 40 AI Algwasse jo y Bua7 pinj Jo eJnjeJeduue L p ny jo ed uono soDueuo eoJe Mo eJnssaJg Bu pu3 jo d L SI 99IAJOS uoisesqy snipeJ pu q UIN UONONNSUOI 9SOH speo jeoiueuoe N sjueuieJinbe Bunnoy SUOI Ipuoo JejueuluoJI u3 Ayiquedwos DII eJnsseJd a ng eJnsseJd BubJoM ed A juawdinby uoneoi ddy pa aAU09 aq 0 pin J dwa jueiquiv qua pin 4 eJnjeJeduJos 9SOH ezis 9SOH 119 142 UOI29 8S 9SOH Inspection Inspection Procedure To achieve the best from your equipment it is imperative that a maintenance schedule be set up and ascertain that the periodic inspections are carried out to prevent the substantial losses which may incur at later stages Normally it is considered a safer practice to inspect the equipment every three months However the frequency of inspection will be by large governed by the following factors Criticality of the equipment Pressure range Temperature range Hazard value of working media Type of usage Procedure 1 Turn the power off 2 Place the components in neutral position 3 Remove inspection panels and examine hose and fittings for damages and leaks Repair or replace as needed Inspect the associated hydraulic components Re install the inspection panels Turn the power on Look out for the proper working of equipment CONDOS Protecting the hose Prot
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