BRITISH & METRIC FLUID CONVEYING PRODUCTS

Fewer Hydraulic Connections Means Fewer Problems

I have every issue of H&P right in my office, from the first issue, February 1948, to the most recent. We already have many of these old articles posted — some are purely for interest, but many still have relevance today. Leakage prevention certainly fits the bill, here. It describes how officials at an OEM in Detroit set out expose the detriments of leakage and reduce leakage in some of its hydraulic machine tools.

The author refers to “the war,” which, of course, was World War 2, and was still fresh in the minds of most Americans at the time. It was also a time when hydraulic controls dominated machine tools. Probably no one heard of computer numerical control (CNC), and if you mentioned a progammable logic controller, people would’ve assumed it used fluid logic, not electronics.

Read more: Fewer Hydraulic Connections Means Fewer Problems

Hydraulic Conductor Face Off: Hose vs Tube

What do lifting chains, bladder-type accumulators and hydraulic hoses all have in common? Well, they typically have only one mode of failure – and that’s catastrophic. One minute they’re working as they should and the next thing you know, they’ve gone to hell.

Oh sure, hoses can leak from around their ferrules and show obvious signs of abrasion, both of which are early warning signs that a change-out would be prudent. But even under these conditions, estimating their remaining service life is virtually impossible.

The Trouble With Hose

Beyond the fact that their service life is finite and difficult to estimate, other disadvantages of hydraulic hoses when compared to tube include:

  • They expand and stretch under pressure. This flexing requires extra volume and adds to machine cycle time.
  • They typically have a limited operating temperature range.
  • Their requirement for regular replacement makes them a source of contaminant ingression.
  • They are expensive.

Despite the above disadvantages, hoses are a necessary feature of most hydraulic systems. This is because the alternative conductor – tube, cannot be used where:

  • There is limited space (particularly in mobile hydraulics).
  • There is relative movement between machine components and superstructure.
  • Noise and vibration need to be suppressed.

However, hose is often substituted for tube when it’s not necessary. This is because a hose assembly can usually be fabricated much faster than a tube assembly. And the additional labor cost required to fabricate and install a tube, can make a hose appear to be the cheaper solution.

Read more: Hydraulic Conductor Face Off: Hose vs Tube

New Report Inspects Hydraulic Fittings Market Segmentation Application, Technology & Market Analysis Research Report To 2021

Hydraulic Fittings Market analysis is provided for global market including development trends by regions, competitive analysis of the Hydraulic Fittings market. Hydraulic Fittings Industry report focuses on the major drivers and restraints for the key players.

Hydraulic fittings are parts used to connect hoses, pipes, and tubes in hydraulic systems. Hydraulic equipment generally operates under high pressures and is often not a fixed system. Consequently, hydraulic fittings need to be strong, versatile, and reliable to operate safely and effectively in their respective applications. These fittings typically adhere to strict standards which dictate fitting construction, dimensions, and pressure ratings.

Hydraulic Fittings market analysis report speaks about the manufacturing process. The process is analysed thoroughly with respect four points Manufacturers, regional analysis, Segment by Type and Segment by Applications and the actual process of whole Hydraulic Fittings industry.

Read more: New Report Inspects Hydraulic Fittings Market Segmentation Application, Technology & Market Analysis Research Report To 2021

A Look at Hydraulic Hose Failures

We regularly look at what types of articles draw the most visitors on our websites. One of the biggies is maintenance. What’s interesting about maintenance of hydraulic systems is that even though many of the tools and instruments have changed dramatically during my 25+ years on H&P, many of the problems and their solutions are still the same.

Probably the most frequent cause of hydrauic system malfunctions continues to be contamination. But another is misapplication of products, especially hose. Hydraulic hose is really tough, and it seems to be almost indestructible when new. But after being subjected to the rigors of hydraulic pressure, flow, high temperatures, and wide swings in all these, hoses can suffer premature failure if not applied, routed, and installed properly.

If you’re faced with a hose that is leaking or, worse yet, started coming apart, how do you know what the cause is? Discovering what wnent wrong can be a big step in preventing future failures. Detailed fialure analysis should be left to experts, but sometimes seeing the results of misapplication or improper installationg will aid understanding of why manfacturers have developed their recommendations.

I found an article that does just this. It covers more than a dozen hose failures, explains what the problem is, what caused it, and how to prevent it in the future.

The key to preventing these premature failures, of course, is training. We have dozens of articles on our website describing proper application, routing, and installation of hydraulic hose.

Read more: A Look at Hydraulic Hose Failures

More-Bendable Hose Simplifies Routing, Saves Space

Whether your company manufactures new equipment or repairs existing equipment, hose routing can sometimes pose a real challenge. With today’s Tier-4 engines consuming more space within engine compartments, routing a hose from point A to point B can be tougher than ever. If you’re lucky, you’ll find a way to snake a hose around multiple obstacles. If luck isn’t on your side, you’ll have to remove and replace components to route a hose. Even outside the engine compartment, as equipment designs become more compact, placing components within a smaller envelope also presents greater challenges.

Fortunately, these challenges became a little easier with the introduction of E-Z Bend hose developed by Kurt Hydraulics, Minneapolis, Minn. E-Z Bend hose has half the bend radius of standard hose for easier routing. Providing greater flexibility and strength, E-Z Bend hose suits today’s compact applications that require hydraulic hose with tight bend radius using minimal installation force.

Targeted at high-pressure hydraulic oil lines in mobile and industrial hydraulic systems, E-Z Bend hose features four spiral layers of high-tensile-strength steel wire. Its inner tube is constructed of oil-resistant synthetic rubber. The hose’s working temperature range is –40 to 212°F, and it meets MSHA flame-resistance requirements.

E-Z bend comes in four standard sizes: ⅝, ¾, 1 and 1¼ in. Working pressures range from 5,000 to 6,000 psi, and minimum burst pressures extend from 20,000 to 24,000 psi (both depend on hose size).

The hose is intended to be used with Kurt’s W-style end fittings, which come in 562 different types. Designed for use with SAE 100 R12 non-skive and all-wire-braided hose, the end fittings feature RoHS-compliant corrosion-resistant plating and are compatible with most model crimpers.

Read more:More-Bendable Hose Simplifies Routing, Saves Space

Global bio-based hydraulic system oil industry in-depth investigation and analysis report for 2017 just published

This report studies Bio-based Hydraulic System Oil in Global market, especially in North America, Europe, China, Japan, Southeast Asia and India, with production, revenue, consumption, import and export in these regions, from 2011 to 2016, and forecast to 2020.

The CAGR of Bio-based Hydraulic System Oil industry is 3.2% for five years. Bio-based Hydraulic System Oil industry of the United States, Europe, Japan, and China accounts for 54% of the global consumer market share.

Meanwhile, as the market of Bio-based Hydraulic System Oil industry tends to be saturated in economic developed regions and the consumer market in the region of emerging economies such as China, India, Brazil, etc is on the rise, the demand for Bio-based Hydraulic System Oil industry will increase unceasingly.

Among them, the average output growth rate of Bio-based Hydraulic System Oil industry in China is 2.9%.

Besides, our analysts believe that it will increase rapidly with an average growth rate of 2.5% (5 years) in the next 5 years.

Read more: Global bio-based hydraulic system oil industry in-depth investigation and analysis report for 2017 just published

Smaller Hose Produces Long List of Benefits

For decades, SAE J517 has published guidelines for 100R1 through 100R12 series hydraulic hoses. These manufacturer-driven SAE standards have been based on design, construction, and pressure ratings to ensure that hydraulic hoses meet minimum construction requirements. They established minimum pressure ratings for various hose IDs (inside diameters) and were later revised to also include constant-pressure hoses—such as R13, R15, R17, and R19, where pressure rating remains constant within a group regardless of size.

More recently, however, hydraulic system designers began adopting ISO specifications. Many large OEMs switched to ISO standards in their design and manufacturing processes to ensure the sale and service of their equipment globally. Released in 2006, ISO Standard 18752 for hydraulic hose is relatively new to North American manufacturers.

ISO Standard 18752 takes a different approach, reflecting the design practices of users who typically design hydraulic systems based on performance and pressure requirements. Hydraulic hoses are classified in ISO 18752 according to their resistance to impulse pressure in four Grades: A, B, C, and D. Each Grade is then classified by the outside diameter (OD) of the hose into Standard Types (AS, BS, CS) or Compact Types (AC, BC, CC, DC).

Each grade level requires a specific number of impulse cycles the hose must meet at a specified temperature and impulse pressure. Parker’s new 787TC and 797TC series hoses—rated 35.0 MPa (5,000 psi) and 42.0 MPa (6,000 psi) constant pressure, respectively—not only meet the minimum 1 million cycles required in Grade D, Type DC, but have been successfully tested to 2 million impulse cycles at bend radii smaller than those required by ISO 18752.

Same ID, Smaller OD

The inside diameter of the 787TC and 797TC hoses is the same as common SAE spiral hoses. However, its OD is smaller, which makes the compact hose easier to fit into tight spaces and—perhaps more importantly—lets you bend it to a smaller bend radius with no decrease in pressure rating or life, and with less required bending force.

Key to the design success of the Compact Spiral hose is a proprietary Nitrile-based inner tube compound that is both stronger and thinner than what has been traditionally used in standard spiral hose. The overall strength properties of the new inner tube compound are such that it is possible to have the same ID, yet reduce the overall OD and size without sacrificing the pressure and sealing capabilities. In addition, the reduced tube wall thickness provided the opportunity to proportionally redesign the wire reinforcement, which led to an additional reduction in the hose OD.

Read more: Smaller Hose Produces Long List of Benefits

Subsea well intervention cutter ROV-operable

Webtool has developed a resettable emergency disconnect cutter for light and medium subsea well intervention.

This can be used either as part of a workover system or as a dedicated emergency disconnect package, and can be reset subsea by an ROV, avoiding the need to return the cutter to the surface vessel for this operation.

The device, the company claims, provides a simpler and quicker emergency disconnection than more complex multi-line stab-plate systems for mixed material bundles.

Within a well intervention emergency disconnect package, the bundles are securely positioned in the mouth of the cutter.

HFL Transfer Lines

Various fluid transfer lines and hydraulic flying leads (HFL), steel tension member, fiber rope, reinforced hoses, electrical conductors, cables and electrical flying leads (EFL), can all be cut in a single guillotine action taking just a few seconds, Webtool adds.

Should the need arise for an emergency disconnection subsea an ROV can reset the device by releasing the blade and re-charging the hydraulic system.

The ROV then places the new HFL and EFL/mixed material bundles in the jaw of the cutter which is set and ready to perform.

Webtool is also offering a solution that requires no external power source, and which automatically activates when the emergency disconnect package separates.

Read more: Subsea well intervention cutter ROV-operable

 

Could this alternative PTO system make slurry spreading safer?

Brothers Noel and Ger Hickey from Co. Waterford have created an alternative drive system for vacuum-type slurry tankers rather than the traditional PTO system.

The brothers’ new retro-fit drive system, called SafeShaft, replaces the tankers original mechanical drive (PTO) with a hydraulic drive system and mounting assembly.

The Hickey brothers were concerned that the mechanical PTO (Power Take Off) systems are notoriously dangerous if the protective guarding is damaged or missing.

Coming from a background working in the agricultural sector, Noel is an Agricultural Technician with CaseIH dealer Kill Agri Ltd in Co. Waterford and Ger has his own engineering business.

Combining their engineering and mechanical skills, the pair developed the SafeShaft drive system, which currently has a patent pending on its design.
An oil flow requirement of 40L per minute is needed for the new system, which means it can be powered by almost any tractor regardless of age or specification, according to the brothers.

“New tankers do offer a hydraulic system, but it is recommended that the oil flow is at 80L per minute.

“Our system is more efficient as it allows the operator the option to also use macerators or trailing shoes at the same time,” Noel said.

Results have yet to show if the new hydraulic system is more economic or whether it is more fuel efficient, but it is definitely no worse than traditional systems, he said.

Installing The SafeShaft System
In order to install the SafeShaft system, a 10mm thick baseplate is bolted between the existing vacuum pump and tanker chassis, which provides a mounting platform for the new hydraulic drive system and its components.

Key to the new system is the hydraulic motor, which provides the necessary rotational force required to replace the original mechanical PTO drive.

Read more: Could this alternative PTO system make slurry spreading safer?

 

Intensive Procedure Helps Ensure Hydraulic-Hose Cleanliness

A contaminant with a 60-micron diameter— the size of the smallest grain of pollen— can cause extensive damage to a hydraulic system. That is why the International Organization for Standardization only allows a mere 5-15 microns of dust in a hydraulic hose interior. IBT Industrial Solutions, manufacturer of customized hydraulic components and systems, follows a six-step process in order to match this standard.

  1. First, the hose is cut to meet a customer’s specifications.
  2. The IBT team then uses an Ultra-Clean hose cleaner that washes the inside of the hose three times to ensure less than 15 microns of contamination in the hose.
  3. A Goodyear PC650 system crimps the hose, recalibrating itself to the correct sizing and pressure for the specific product.
  4. IBT conducts a test to make sure that assemblies meet NAHAD/UL guidelines. All assemblies are tested with a 4:1 safety factor.
  5. Next, the ends of the hose are sealed and capped so that no contaminants can get in during shipping.
  6. Lastly, heat- and chemical-resistant self-vulcanizing labels , which display part number, system name, and test pressure, are applied to the hoses.

IBT is the only UL STAR-certified facility in its five-state region (Kansas, Missouri, Iowa, Oklahoma, and Arkansas). It exceeds all criteria for cleanliness and hose safety set by the National Association for Hose and Accessories Distribution (NAHAD), meeting guidelines for storage, temperature, hydraulic testing, cutting, and assembly methods. To ensure cleanliness of its products, the IBT facility undergoes UL inspections of equipment, processes, and workforce each year.

IBT also uses a Hose-Trakker software to track each hose produced in its facility. “At the customer’s request, we can follow any hose we produce, from cradle to grave,” said West. “When we cut the hose, we tag it and log it. Utilizing the Hose Trakker system, if your hose was assembled at IBT, we can now look up where it was made, the fittings used, the exact specifications, even when it was put into service—so that we can replicate it later.”

Read more: Intensive Procedure Helps Ensure Hydraulic-Hose Cleanliness

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