What is Hydraulic Hose?

Introduction

We discuss how chemicals and temperature ranges impact your choice of hose. We also discuss 5 main types of hydraulic hoses: SAE Standard, Standard High-Pressure, Low-Pressure, Steel Wire-Braided, and SS PFTE.

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Important Facts:

• Hydraulic hoses and hose assemblies are made of different materials to be used in different applications such as
  Elastomeric or rubber hoses are extremely flexible and recommended for low as well as high pressure applications.
  Fluoropolymer hose is considered suitable for transmission of harsh chemicals and better corrosion resistance as well as high temperature applications.
Thermoplastic hoses are considered suitable when the main concern is kink resistance.
Metal hoses are recommended for high temperature material transmission as well as ultra-high pressures. They are either flexible or hard.
• Hydraulic hoses usually consist of three parts including
  The inner tube is usually flexible and allows the smooth transfer of the liquid or fluid it carries.
  The reinforcement layer is a braided or spiral wire of fabric or metal. The braided wire is a crisscross pattern that allows flexibility and the spiral wires are parallel to each other wound around the hose.
The outer layer is weather or abrasion-resistant. It is designed to tolerate adverse environmental conditions. It is a cover for the hose.
• The hose is better than a tube because it provides better resistance to corrosion and heat. It is more flexible and can be easily fabricated. It is available in longer lengths, easy to install in small areas, and heat resistant.
• Hose durability is dependent on several characteristics such as temperature, environment, application, pressure, etc.
• The inner diameter of the hose is also called "Dash Size."
• The spiral hose is considered stronger and suitable for high-pressure applications as compared to a braided hose.
• Waste and dirt in a hydraulic system can damage the hose very quickly so in order to make it last longer oil and filter need to be changed regularly.

Types of Hydraulic Hoses

There are several standards that any type of hydraulic hose is required to meet in order to be considered suitable for high-pressure applications, and twisted hose assemblies. A standard hose is not considered suitable for hydraulic systems. Hydraulic hoses are used for high-pressure applications either on mobile or fixed machinery. They are used by oil & gas drilling companies, for mining or construction purposes, waste or recycling purposes, power generation, and repair and maintenance.

Hydraulic hoses are required to withstand an average internal pressure of psi and extremely high temperatures.

There are standards developed by SAE, the engineering organizations for manufacturing of the hoses in order to ensure efficient and effective operation, and human safety and security. There are standards that provide general requirements as to the dimensions and performance of hydraulic hoses that are to be used in mobile or fixed machinery.

The hose consists of three layers as mentioned above; the inner layer must be flexible and should be able to withstand the pressure and high temperature of the fluid. It is usually made of synthetic rubber or PTFE or thermoplastic material. The reinforcement layer is a fabric wired around to allow flexibility and resist high pressure in the hydraulic systems and the outermost layer is like a cover that protects the hose from external environmental damage and abrasion. It is also very important to consider hose fittings, their size, and whether the hydraulic fittings will be able to resist the pressure and temperature to which they are exposed.

The five most common types of hydraulic hoses that are used for different purposes are listed below:

1. SAE Standard Hose:

SAE 100R2 -S is a high-pressure hose that is used for petroleum or fluids having a water base. The reinforcement layer has two high tensile steel wire braids and the outer cover is abrasion, ozone, and weather resistant synthetic rubber, which is MSHA approved. The temperature ranges from -40F to +212F (+248F max.)

2. Standard High-Pressure Hose:

This type of hose is flexible and is commonly used for transmitting mineral oils as well as water-oil blends. They are highly in demand by construction, mining and oil refining industries, and agricultural purposes.

3. Low-Pressure Hose:

This type of hose is highly flexible and is used in lighter applications, for instance, return lines, lube lines, etc. The reinforcement layer usually consists of two synthetic textile braids and the outer cover is abrasion, ozone, and weather resistant synthetic rubber, which is MSHA approved. The temperature resistance ranges from -40F to +212F.

4. Steel Wire-Braided Hose:

It is available either in a single or double braided steel wire. It is durable and is suitable to be used in extremely high pressure or high-temperature applications. The double braided steel wire hose is also known as a hydraulic jack hose.

5. Stainless Steel PTFE Hose:

They are used by oil & gas drilling companies, for mining or construction purposes, for waste or recycling purposes, power generation, and repair and maintenance. The reinforcement layer is one braid of high tensile stainless steel braided wire and the tube is an extruded white PTFE. The temperature resistance ranges from -65F to +450F.

Several notable SAE standards are particularly important for hydraulic hoses:

SAE J517: This standard outlines the specifications for various types of hydraulic hoses, including the materials used, construction methods, and performance criteria. It categorizes hoses into different classes based on their intended use and pressure ratings. For example, SAE 100R1 and SAE 100R2 are standards for braided hydraulic hoses, while SAE 100R12 and SAE 100R13 pertain to spiral-wound hoses.

SAE J343: This standard details the testing procedures for hydraulic hoses to ensure they meet the required performance and safety criteria. The tests include burst pressure tests, impulse tests, and abrasion resistance tests, among others. These rigorous testing protocols help verify that the hoses can withstand the demanding conditions they will face in real-world applications.

SAE J: This standard provides guidelines for the design and use of thermoplastic hydraulic hoses, which are known for their excellent resistance to chemicals and environmental conditions. It specifies the materials, construction, and testing requirements for these hoses to ensure they meet high standards of performance and durability.

Adhering to SAE hydraulic hose standards is crucial for several reasons:

Safety: Hydraulic systems operate under high pressure, and a failure in a hose can lead to serious accidents and injuries. By following SAE standards, manufacturers ensure that their hoses can withstand the required pressure levels, minimizing the risk of failures and enhancing safety.

Performance: SAE standards ensure that hydraulic hoses perform reliably under various operating conditions. This includes maintaining flexibility at low temperatures, resisting degradation at high temperatures, and withstanding abrasion and wear. Consistent performance is vital for the smooth operation of hydraulic systems in critical applications.

Quality Assurance: By adhering to SAE standards, manufacturers can produce hoses that meet consistent quality benchmarks. This is particularly important for industries requiring high precision and reliability levels, such as aerospace and automotive.

Compatibility and Interchangeability: SAE standards provide a common framework that ensures hydraulic hoses are compatible with other components and systems. This standardization facilitates easier replacement and maintenance, reducing downtime and costs.

Braided hoses are commonly used in hydraulic systems due to their flexibility and durability. These hoses feature one or more layers of braided wire reinforcement, which provides the necessary strength to withstand high pressure while maintaining flexibility. The key characteristics of braided hoses include:

Construction: Typically, braided hoses consist of an inner tube made of oil-resistant synthetic rubber, one or two braided layers of high-tensile steel wire, and an outer cover made of synthetic rubber that is resistant to oil, weather, and abrasion.

Standards: Common SAE standards for braided hoses include:

SAE 100R1: This standard specifies a single layer of steel wire braid reinforcement. It is suitable for medium-pressure applications.

SAE 100R2: This standard specifies two layers of steel wire braid reinforcement, making it suitable for high-pressure applications.

Braided hoses are widely used in applications such as automotive hydraulic systems, industrial machinery, and agricultural equipment due to their ability to handle moderate to high pressure and their resistance to kinking and abrasion.

Spiral hoses are designed for high-pressure and high-impulse applications, where durability and reliability are paramount. These hoses feature multiple layers of spiral-wound wire reinforcement, providing exceptional strength and resistance to pressure spikes. The key characteristics of spiral hoses include:

Construction: Spiral hoses consist of an inner tube made of oil-resistant synthetic rubber, four or six layers of high-tensile steel wire spirally wound in alternating directions, and an outer cover made of synthetic rubber that is resistant to oil, weather, and abrasion.

Standards: Common SAE standards for spiral hoses include:

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SAE 100R12: This standard specifies four layers of spiral-wound wire reinforcement, suitable for very high-pressure applications.

SAE 100R13: This standard specifies six layers of spiral-wound wire reinforcement, providing even higher pressure capacity and durability.

Spiral hoses are ideal for demanding applications such as heavy construction equipment, mining machinery, and high-performance industrial systems, where consistent performance under extreme conditions is required.

Thermoplastic hoses are made from synthetic materials, offering excellent resistance to chemicals and environmental conditions. These hoses are lightweight, flexible, and suitable for a variety of specialized applications. The key characteristics of thermoplastic hoses include:

Construction: Thermoplastic hoses typically consist of an inner tube made of thermoplastic material, one or two braided layers of synthetic fiber reinforcement, and an outer cover made of thermoplastic material that is resistant to abrasion, chemicals, and weather.

Standards: Common SAE standards for thermoplastic hoses include:

SAE 100R7: This standard specifies a thermoplastic hose with a synthetic fiber braid reinforcement, suitable for medium-pressure applications.

SAE 100R8: This standard specifies a thermoplastic hose with a synthetic fiber braid reinforcement, suitable for high-pressure applications.

Thermoplastic hoses are used in applications where chemical resistance, low weight, and flexibility are critical, such as hydraulic systems in aerospace, medical equipment, and chemical processing industries.

Function: These layers provide the necessary strength to withstand internal pressures and prevent the hose from expanding or bursting.

Types: Reinforcement can be either braided or spiral-wound:

Braided Reinforcement: Involves one or more layers of braided wire (usually steel) or textile fibers, offering flexibility and moderate pressure resistance. Common in hoses specified by standards like SAE 100R1 and SAE 100R2.

Spiral Reinforcement: Consists of multiple layers of high-tensile steel wire wound in a spiral pattern, providing higher pressure resistance. Found in hoses like SAE 100R12 and SAE 100R13.

One of the most critical factors in selecting a hydraulic hose is its ability to handle the system’s maximum operating pressure. Using a hose that cannot withstand the required pressure can lead to failures, posing safety risks and causing system downtime. To determine the appropriate hose, consider the following:

Maximum Working Pressure: This is the highest pressure that the hose will be exposed to during operation. It should not exceed the hose’s rated maximum working pressure.

Burst Pressure: This is the pressure at which the hose is likely to fail. Ensure that the burst pressure is significantly higher than the maximum working pressure to provide a safety margin.

Pressure Spikes: Hydraulic systems often experience transient pressure spikes. Choose a hose that can handle these spikes without compromising performance.

The hose’s operating environment can significantly impact its performance and lifespan. It’s essential to consider environmental factors when selecting a hydraulic hose:

Temperature Range: Ensure the hose can operate within the expected temperature range. Both ambient and fluid temperatures should be considered.

Abrasion Resistance: In environments where the hose may be subjected to wear and tear, choose a hose with a durable outer cover that resists abrasion. This is particularly important in construction and industrial applications.

Chemical Exposure: If the hose will be exposed to chemicals, solvents, or other corrosive substances, select a hose with a cover that offers chemical resistance.

UV Resistance: For hoses used outdoors, UV resistance is crucial to prevent degradation from sunlight exposure.

Flexibility and Bend Radius: The hose should be flexible enough to accommodate the system’s movement without kinking or reducing flow. Consider the minimum bend radius specified by the hose’s SAE standard.

Apart from the primary factors mentioned above, there are other considerations to keep in mind when selecting a hydraulic hose:

Hose Size and Length: Ensure the hose has the appropriate diameter and length for the application. A hose that is too long or too short can cause issues with flow and pressure.

End Fittings: Choose compatible end fittings that match the hose’s size and material. Properly fitted ends ensure a secure connection and prevent leaks.

System Compatibility: Ensure the hose is compatible with other system components, including pumps, valves, and actuators.

Regulatory Compliance: Verify that the hose complies with industry standards and regulations relevant to your application. This includes SAE, ISO, and other applicable standards.

SAE hydraulic hose standards are essential for ensuring the safety, reliability, and performance of hydraulic systems across various industries. By adhering to these standards, manufacturers and users can maintain high-quality, durable hoses that meet rigorous performance criteria. Ensuring proper selection, installation, and maintenance of hydraulic hoses according to SAE guidelines is crucial for minimizing risks and maximizing system efficiency. Staying informed about the latest industry standards and technological advancements will help you maintain the integrity and effectiveness of your hydraulic systems, providing long-term reliability and safety.

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