General information for hoses and hose assemblies - TESS AS

GENERAL INFORMATION FOR HOSES AND HOSE ASSEMBLIESGeneral information for hoses and hose assembliesTESS provides complete hose units according

to established procedures and approved quality system.

To maintain safety regarding the installation and use of hoses, it is appropirate to make an assessment. Incorrect use will not only affect the life time of the hose, it can also have serious consequences for safety at the work site. There are no shortcuts. Use materials (hoses and fittings) that are recommended.

For example, an air hose incorrectly used in a steam system will fail after a few minutes of use and a dangerous situation will occur.

When selecting hose, you must consider several factors. Especially important are:

Working pressureHydraulic hoses are used with safety factor of 1:4. This means that burst pressure is 4 times working pressure. Safety factor will vary depending on medium and installation requirements. We always recommend that hoses are pres-sure tested before use.

VacuumVacuum, continuously or periodically, requires a different type of hose than used for pressure. Vacuum rate (usually in % or meter suction height) must be established.

MaterialThe lining of hose (material inside) must withstand the medium transported. Different mediums may require different material qualities. Chemical resistance charts should be used to assess the recommanded lining material.

It is important to note that these charts only accounts for chemical resistance. Conditions as diffusion, temperature, abrasion etc. must be additionally evaluated.

The cover of the hose (material outside) must withstand the influence from the enviroment. If the cover is exposed to spills of oil or chemicals, these may affect the material. Hoses installed outdoor, should be able to resist the influence of the weather.

Furthermore, hoses submerged in the medium (such as vacuum/suction hose) also need to resist the medium outside. To clarity the resistance of the outer material chemical resistance charts may be helpful.

Service timeHoses used up to and over the maximum permitted load will have a significantly shorter service time than a correspond-ing installation with moderate utilization.

Generally said, the more you exploit the hose capacity ralating to pressure, temperature, bending and flexing, the shorter the service time.

• Service time is a relative term with regards to hoses and is impossible to calculate.• Hoses will be exposed to wear and tear and will need to be replaced regularly. In general we recommend installing hoses so they can be easily replaced.• Always check hoses at any maintenance shut down• Look for cracks, blisters, tears, leaks, and stiffness.

Rules and regulationsThe government is continuously working for standardiza-tion of hoses. Make sure the hoses you are using meet the requirements of the authorities. Previously approved hoses are not necessarily approved today.

Each hose installation, must also be considered as the owners responsibility of the equipment for the safety of use. It is therefore important that the owner and user is familiar with available safety and protective equipment for use on and in connection with hoses.

TESS performs condition monitoring of hose installations and has developed THM (TESS Hose Management) to prevent hose failure. The system could help the customer to avoid dangerous situations and downtime on equipment/ machines. This and other services related to safe hose installations are performed by TESS Approved hose workshop that covers all of Norway.

Key information to select the correct hose assembly:1. Total length including couplings: ...………………………………………………………………………………………………..

2. Diameter inside: .....……………………………………...... Max. outside: .....………………………………………………….

3. What shall be transported in the hose: ..…………………………………………………………………………………….……..

4. Working pressure: .……………………………………....... Test-pressure: …………………. Burst pressure: .……....……

5a. Temp. in medium: .…………………………………........... Temp in the environment: ………………………………….…...

5b. Any extreme-temp: ...…………………………………...... Duration: ………………………………………………………….

6a. Hose couplings one end: ..…..………………………….... Material: .………………………………………………...………..

6b. Hose couplings other end: .....…………………………..... Material: .……………………………………...…………………..

7. Any external strains, vibrations, wear, etc.: .......................……………………………………………………………………....

8. No. of units: ...………………………………………........... Wanted delivery time: …...........………………………………...

9. Documentation required: .….……………………………………………………………………………………………….............

HOSE ASSEMBLY ROUTINGBelow some useful examples of correct routings in order to design reliable solu-tions and increase the hose life dura-tion. Please refer to the examples supplied by the SAE J1273 specification and ISO/TR 17165-2. Reference to SAE J1273 par. 5 for further details on hose selection and routing.

Under pressure, a hose may change in length. Always provide some slack in the hose to allow for this shortening or elongation. It’s not recommended to have excessive slack (fig. 1).

If a hose is installed with a twist, operat-ing pressures tend to force it towards the straight position. The internal stress due to the twistcan cause reinforce-ment separation and the hose could burst at the point of maxi-mum strain or near the fitting (fig. 2).

On bended con-figurations, provide sufficient hose so that it does not have a bend radius less than its recom-mended minimum bend radius, in addi-tion the hose is not pulled.Too tight a bend may kink the hose and restrict or stop thefluid flow. In many cases the proper use of adapters and hose fittings (elbows 45°, 90°, etc) can

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r min

abrasion

r < r min

abrasion

r < r min

min. dist.

r min

d

r min 1,5 d

Hose assembly routing

NOwrong use

YEScorrect use

NOwrong use

YEScorrect use

For detailed information concerningthe recommended practices for HydraulicHose assemblies, please refer to SAEJ1273.This document should be used as a guideto be considered when selecting, routing,fabricating, installing, replacing, maintainingand storing hose for hydraulic systems.

High temperature parts

fig. 1

fig. 2

fig. 3

fig. 4

fig. 5

fig. 6

fig. 7

003_hoseselection 29-06-2005 11:23 Pagina 48

eliminate tight bends or kinks (fig. 3).

Avoid contact with objects that can cause abrasion or dam-age. On moving applications, pay particular attention when specifying hose length to avoid tensile stress or abrasion (fig. 4).

In applications where there is considerable vibration or flex-ing, allow additional hose length. The metal hose fittings, are not flexible, and proper installation protects metal parts fromundue stress, and avoids kinks in the hose (fig. 5).

When hose lines pass near an heat source, they should beinsulated by a heat resistant sleeve or shield, firesleeve or ametal protection. In addition, the use of proper clamps keephoses in the right position and reduce risks of abrasions. Forinstallations where abrasion to hose cover cannot be pre-vented with the use of clamps or brackets, a steel or plastic protective spring or an abrasion resistant sleeve should be installed over the hose (fig. 6).

Prevent hose bending in more than one plane: fix the as-sembly into separate segments, by clamping hose at change of plane (fig. 7).

The following list of troubleshooting is a useful guideline torecognise the hose field problems and identify faults, causesand correct solutions. It is also a useful training session withprevention targets, based on the field experience.Even if not exhaustive, this list highlights the main problems of common use, installation, maintenance of hose assem-blies, fittings, adapters, etc.

When selecting a component for a new application, theknowledge of potential failure modes is a suitable guideline to drive the selection of hose and fittings and to develop theproper assembly solution considering the functional param-eters of the application/equipment.

When replacing a failed hydraulic hose assembly it is impor-tant to understand what caused the failure.This is to ensure that the replacement assembly is “fit for purpose” and that premature failure can be avoided.

Failure of assemblies can be avoided by implementing regu-lar inspection and monitoring deterioration. Hydraulic hose

assemblies can then be replaced before a failure occurs.Failure of hose assemblies can cause danger to personnel,possible machine damage, a fire hazard and environmentalpollution.

We will now take a look at the faults that can be identified asa reason for failure or increase the risk of failure, the causes of these effects and remedies to prevent future failure result-ing in extended hose assembly service life.We can categorise failure faults, as follows: • visible faults on the external hose & connectors: - hose has burst – critical failure! - hose cover shows signs if deterioration - fluid spray from hose cover (pin hole) – critical failure! - connectors become detached – critical failure! - leakage from connectors - weapage at the rear of the ferrule • non-visible faults from within the hose & connectors: - internal tube material fault - internal tube deterioration.

HOSE ASSEMBLY TROUBLESHOOTING GUIDE

CautionBefore attempting to replace or inspect a hydraulic hose assembly on an application first ensure that the machine is turned off and all moving parts are secured and lowered to the ground. Ensure that the assembly is depressurised before attempt-ing to un-install. The assembly and internal fluid may be hot, therefore, allow to cool down before handling. Wear personal protection equipment. Never place a hand or other body part near a high pressure fluid jet. A through risk assessment should be carried out prior to working on machinery and sites.

Hose has burstThe reason for this occurrence may have been one of thefollowing: • The peak pressure of the hydraulic system is too high for the hose type utilised this is generally due to poor knowledge of the application or of an application function but also to component faults (fig.1).

• The hose has been bent past its minimum bend radius, damaging the wires, weakening the assembly and resulting in a pressure burst failure at the centre of the hose bend.

• The hose cover has been abraded by external causes, the reinforcement is corroded in the location of the burst: external protections for the hose can be necessary or special cover materials are recommended (fig. 2).

• A hose burst close to the connector may be due to conical stress caused by wire fatigue. This can be the result of starting the bend too close to the connector (fig. 3) or a very flexible hose that has been allowed to whip, creating the “elephant ear effect” (fig. 4). A hose end restrictor can be used. The hose assembly has been damaged causing an instant failure or a failure due to a damage induced weakening of the hose assembly (fig. 5).

• High-frequency, intense pressure spikes fatigued bold reinforcement: it is advisable to check the severity of pressure spikes. The selection of robust hose types (e.g. with wire spiral architecture instead of wire braided reinforcement). Replace hose assembly with properly crimped assembly.

• Pressure exceeded strength of the hose and/or the hose bold is twisted during attachment to ports and movement opened gaps in reinforcement. In this case

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Hose has burstThe reason for this occurrence may have been one of thefollowing:• The peak pressure of the hydraulic system is too high for

the hose type utilised this is generally due to poor know-ledge of the application or of an application function butalso to component faults (fig.1).

• The hose has been bent past its minimum bend radius,damaging the wires, weakening the assembly and resultingin a pressure burst failure at the centre of the hose bend.

• The hose cover has been abraded by external causes, thereinforcement is corroded in the location of the burst:external protections for the hose can be necessary or specialcover materials are recommended (fig. 2).

• A hose burst close to the connector may be due to coni-cal stress caused by wire fatigue. This can be the result ofstarting the bend too close to the connector (fig. 3) or a veryflexible hose that has been allowed to whip, creating the“elephant ear effect” (fig. 4). A hose bend restrictor can beused. The hose assembly has been damaged causing aninstant failure or a failure due to a damage induced weaken-ing of the hose assembly (fig. 5).

• High-frequency, intense pressure spikes fatigued boldreinforcement: it is advisable to check the severity of pressurespikes. The selection of robust hose types (e.g. with wirespiral architecture instead of wire braided reinforcement).Replace hose assembly with properly crimped assembly.

• Pressure exceeded strength of the hose and/or the hosebold is twisted during attachment to ports and movementopened gaps in reinforcement. In this case it is necessary tocheck pressure rating output of the system, eventually use ahose with a higher pressure rating, and improve the routing,maybe with swivel couplings, studying the flexing configura-tions so that the hose remains always in the same plane (it is notrecommended to bend the hose in more than one plane).

Hose cover shows signs of deteriorationHose cover deterioration will involve a reinforcement decaydue to corrosion, etc. and could eventually lead to a criticalassembly failure. The cause of deterioration may be one of thefollowing:

• Hose cover abrasion, as a result of hose assemblies rub-bing against each other or as a result of contact with sharpedges or rough machine components, will expose the hosereinforcement allowing wire corrosion to take place. Severeabrasion may have damaged the reinforcement, weakeningthe hose. With synthetic fibre reinforced hose types the abra-sion weakens the hose’s ability to withstand the internal pres-sure. All instances will eventually lead to a critical hose failure(fig. 6-7).

fig. 1

fig. 2

fig. 3

fig. 4

fig. 5

006_maintenance 29-06-2005 11:56 Pagina 107

Fig. 1

Fig. 2

Fig. 3

it is necessary to check pressure rating output of the system, eventually use a hose with a higher pressure rating, and improve the routing, maybe with swivel couplings, studying the flexing configurations so that the hose remains in the same plane (it is not recommended to bend the hose in more than one plane).

Hose cover shows signs of deteriorationHose cover deterioration will involve a reinforcement decaydue to corrosion, etc. and could eventually lead to a criticalassembly failure. The cause of deterioration may be one of the following: • Hose cover abrasion, as a result of hose assemblies rubbing against each other or as a result of contact with sharp edges or rough machine components, will ex pose the hose reinforcement allowing wire corrosion to take place. Severe abrasion may have damaged the reinforcement, weakening the hose. With synthetic fibre reinforced hose types the abrasion weakens the hose’s ability to withstand the internal pressure. All instances will eventually lead to a critical hose failure (fig. 6-7).

• Cracks may be observed on the hose cover. This may be due to natural ageing or as a result of accelerated ageing due to ozone attack or use of the assembly at extreme range of temperature (fig. 8).

• A hardening of the hose cover may be the result of an incorrectly specified hose type for the application system temperatures, internal or external. Excess temperature may have been generated by high friction of the fluid inside the system (e.g. closed circuits) or by external heat sources (e.g. engine compartment).

• A soft hose cover may be a result of an incorrectly cured rubber by the manufacturer or the effects of an incompatible fluid coming into constant contact with the cover. • A cracked and peeled hose cover may indicate an extreme abrasion contact, maybe in combination with a flexing of the hose close to the connector, during application causing fatigue. Another symptom can be fluid weeping from the same area of the hose cover (fig. 9).

• Blisters observed on the hose cover may be a con sequence of fluid leakage from inside the hose assembly or fluid being driven through the hose cover. This may be due to a manufacturing fault or the effects of an incompatible fluid (fig. 10).

• The aging and the effects of environmental conditions such as heat, cold, ozone and sunlight, cause loss of performance properties and failure. The production date of the hose has to be checked: hoses older than 5 to 7 years are due for replacement to meet the application conditions.

Hose cover is cracked radially but the cover material is not hard or brittleThe hose has been exposed to extreme cold temperatures that caused radial cracks of the cover during the flexing movements. It is necessary to select a hose with character-istics that meet these conditions or to insulate the assembly with a suitable protection.

Cracks in hose liner and cover result in leakage while tube and cover are still soft and flexible at room temperature: this is the evidence that flexing of hose during periods of extreme

107

Hose has burstThe reason for this occurrence may have been one of thefollowing:• The peak pressure of the hydraulic system is too high for

the hose type utilised this is generally due to poor know-ledge of the application or of an application function butalso to component faults (fig.1).

• The hose has been bent past its minimum bend radius,damaging the wires, weakening the assembly and resultingin a pressure burst failure at the centre of the hose bend.

• The hose cover has been abraded by external causes, thereinforcement is corroded in the location of the burst:external protections for the hose can be necessary or specialcover materials are recommended (fig. 2).

• A hose burst close to the connector may be due to coni-cal stress caused by wire fatigue. This can be the result ofstarting the bend too close to the connector (fig. 3) or a veryflexible hose that has been allowed to whip, creating the“elephant ear effect” (fig. 4). A hose bend restrictor can beused. The hose assembly has been damaged causing aninstant failure or a failure due to a damage induced weaken-ing of the hose assembly (fig. 5).

• High-frequency, intense pressure spikes fatigued boldreinforcement: it is advisable to check the severity of pressurespikes. The selection of robust hose types (e.g. with wirespiral architecture instead of wire braided reinforcement).Replace hose assembly with properly crimped assembly.

• Pressure exceeded strength of the hose and/or the hosebold is twisted during attachment to ports and movementopened gaps in reinforcement. In this case it is necessary tocheck pressure rating output of the system, eventually use ahose with a higher pressure rating, and improve the routing,maybe with swivel couplings, studying the flexing configura-tions so that the hose remains always in the same plane (it is notrecommended to bend the hose in more than one plane).

Hose cover shows signs of deteriorationHose cover deterioration will involve a reinforcement decaydue to corrosion, etc. and could eventually lead to a criticalassembly failure. The cause of deterioration may be one of thefollowing:

• Hose cover abrasion, as a result of hose assemblies rub-bing against each other or as a result of contact with sharpedges or rough machine components, will expose the hosereinforcement allowing wire corrosion to take place. Severeabrasion may have damaged the reinforcement, weakeningthe hose. With synthetic fibre reinforced hose types the abra-sion weakens the hose’s ability to withstand the internal pres-sure. All instances will eventually lead to a critical hose failure(fig. 6-7).

fig. 1

fig. 2

fig. 3

fig. 4

fig. 5


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• Cracks may be observed on the hose cover. This may bedue to natural ageing or as a result of accelerated ageingdue to ozone attack or use of the assembly at extreme rangeof temperature (fig. 8).

• A hardening of the hose cover may be the result of anincorrectly specified hose type for the application systemtemperatures, internal or external. Excess temperature mayhave been generated by high friction of the fluid inside thesystem (e.g. closed circuits) or by external heat sources (e.g.engine compartment).

• A soft hose cover may be a result of an incorrectly cured rub-ber by the manufacturer or the effects of an incompatible fluidcoming into constant contact with the cover.

• A cracked and peeled hose cover may indicate an extremeabrasion contact, maybe in combination with a flexing ofthe hose close to the connector, during application causingfatigue. Another symptom can be fluid weeping from thesame area of the hose cover (fig. 9).

• Blisters observed on the hose cover may be a conse-quence of fluid leakage from inside the hose assembly orfluid being driven through the hose cover.This may be due to a manufacturing fault or the effects of anincompatible fluid (fig. 10).

• The aging and the effects of environmental conditions suchas heat, cold, ozone and sunlight, cause loss of performanceproperties and failure. The production date of the hose hasto be checked: hoses older than 5 to 7 years are due forreplacement to meet the application conditions.

Hose cover is cracked radially but the cover material is nothard or brittleThe hose has been exposed to extreme cold temperatures thatcaused radial cracks of the cover during the flexing move-ments. It is necessary to select a hose with characteristics thatmeet these conditions or to insulate the assembly with a suit-able protection.

Cracks in hose liner and cover result in leakage while tube andcover are still soft and flexible at room temperature: this is theevidence that flexing of hose during periods of extreme coldwhen liner and cover were brittle caused the failure.In this case it is important to check the minimum internal andexternal temperatures, in particular at the time of equipmentstart-up. Use a hose that remains flexible below the applica-tions lowest operating temperature.

fig. 6

fig. 7

fig. 8

fig. 9

fig. 10


Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

cold when liner and cover were brittle caused the failure.In this case it is important to check the minimum internal andexternal temperatures, in particular at the time of equipmentstart-up. Use a hose that remains flexible below the applica-tions lowest operating temperature.

Fluid spray from hose coverDanger! Do not attempt to put your hands near the spray. This could result in serious injury!Fluid venting from the hose cover may be the result of wirereinforcement breakage due to hose damage or maybe as aconsequence of a hose tube manufacturing fault (fig. 11).It may also be the result of a hose tube failure due to the useof incompatible fluid, extreme temperatures or hose-tubefatigue.Incorrect assembly operation could be another cause of thistype of failure.

Connector has become detached (blow-off)The possible causes of such a severe failure can be: • Connector and hose are mix-matched between two different manufacturers, therefore there is not the correct level of connector retention on the hose (fig. 12).

• The internal pressure, may be over the rated one, lateral stretch, axial twist or a combination of all the stress/strain resulted in a critical assembly failure.

• Connector has been incorrectly installed onto the hose and/or not swaged/crimped according to the manufacturer procedures (fig. 13).

• A connector may be damaged due to incompatible inserts and ferrules being used resulting in a material fracture.

• A ferrule may crack resulting in a hose assembly failure. This may be due to incorrect swaging assembly equipment or to a material fault (fig. 14).

Leakage is observed from connectorsConnector leakage can be linked to the following causes: • The connector may have become loose due to incorrect tightening or as a result of machinery vibration. The fluid may be seen leaking from the end of the connector or behind the nut (fig. 15).

• The sealing surface of the connector and/or the mating surface may be incorrectly manufactured, old and/or corroded or damaged (fig. 16).

• Where an O-Ring is specified, it may have been damaged or aged after a long period in service or simply was fallen out of the insert or mating surface allowing leakage (fig. 17).

• The connector nut, thread or clamp bolt thread may have been damaged misaligning the components while tightening.

Leakage between the insert and the top of the ferrule(hose-fitting area) • This may be the result of incorrectly matched or assembled hose and connectors, hose deterioration due to extreme temperatures, too high working pressure for the selected hose type (presence of uncontrolled pressure peaks), vibrations, hose stretch or twist (severe routing with reduced bend radius near the fittings or twist), chemical incompatibility with the service fluid (fig. 18-19).

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• Cracks may be observed on the hose cover. This may bedue to natural ageing or as a result of accelerated ageingdue to ozone attack or use of the assembly at extreme rangeof temperature (fig. 8).

• A hardening of the hose cover may be the result of anincorrectly specified hose type for the application systemtemperatures, internal or external. Excess temperature mayhave been generated by high friction of the fluid inside thesystem (e.g. closed circuits) or by external heat sources (e.g.engine compartment).

• A soft hose cover may be a result of an incorrectly cured rub-ber by the manufacturer or the effects of an incompatible fluidcoming into constant contact with the cover.

• A cracked and peeled hose cover may indicate an extremeabrasion contact, maybe in combination with a flexing ofthe hose close to the connector, during application causingfatigue. Another symptom can be fluid weeping from thesame area of the hose cover (fig. 9).

• Blisters observed on the hose cover may be a conse-quence of fluid leakage from inside the hose assembly orfluid being driven through the hose cover.This may be due to a manufacturing fault or the effects of anincompatible fluid (fig. 10).

• The aging and the effects of environmental conditions suchas heat, cold, ozone and sunlight, cause loss of performanceproperties and failure. The production date of the hose hasto be checked: hoses older than 5 to 7 years are due forreplacement to meet the application conditions.

Hose cover is cracked radially but the cover material is nothard or brittleThe hose has been exposed to extreme cold temperatures thatcaused radial cracks of the cover during the flexing move-ments. It is necessary to select a hose with characteristics thatmeet these conditions or to insulate the assembly with a suit-able protection.

Cracks in hose liner and cover result in leakage while tube andcover are still soft and flexible at room temperature: this is theevidence that flexing of hose during periods of extreme coldwhen liner and cover were brittle caused the failure.In this case it is important to check the minimum internal andexternal temperatures, in particular at the time of equipmentstart-up. Use a hose that remains flexible below the applica-tions lowest operating temperature.

fig. 6

fig. 7

fig. 8

fig. 9

fig. 10


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Fluid spray from hose coverDanger! Do not attempt to put your hands near the spray. Thiscould result in serious injury!Fluid venting from the hose cover may be the result of wirereinforcement breakage due to hose damage or maybe as aconsequence of a hose tube manufacturing fault (fig. 11).It may also be the result of a hose tube failure due to the useof incompatible fluid, extreme temperatures or hose-tubefatigue.Incorrect assembly operation could be another cause of thistype of failure.

Connector has become detached (blow-off)The possible causes of such a severe failure can be:• Connector and hose are mix-matched between two differ-

ent manufacturers, therefore there is not the correct level ofconnector retention on the hose (fig. 12).

• The internal pressure, may be over the rated one, lateralstretch, axial twist or a combination of all the stress/strainresulted in a critical assembly failure.

• Connector has been incorrectly installed onto the hoseand/or not swaged/crimped according to the manufacturerprocedures (fig. 13).

• A connector may be damaged due to incompatible insertsand ferrules being used resulting in a material fracture.

• A ferrule may crack resulting in a hose assembly failure. Thismay be due to incorrect swaging assembly equipment or toa material fault (fig. 14).

Leakage is observed from connectorsConnector leakage can be linked to the following causes:• The connector may have become loose due to incorrect

tightening or as a result of machinery vibration. The fluidmay be seen leaking from the end of the connector orbehind the nut (fig. 15).

• The sealing surface of the connector and/or the mating sur-face may be incorrectly manufactured, old and/or corrodedor damaged (fig. 16).

• Where an O-Ring is specified, it may have been damaged oraged after a long period in service or simply was fallen outof the insert or mating surface allowing leakage (fig. 17).

• The connector nut, thread or clamp bolt thread may havebeen damaged misaligning the components while tighten-ing.

Leakage between the insert and the top of the ferrule(hose-fitting area)• This may be the result of incorrectly matched or assembled

hose and connectors, hose deterioration due to extremetemperatures, too high working pressure for the selectedhose type (presence of uncontrolled pressure peaks), vibra-

fig. 12

fig. 13

fig. 14

fig. 15

fig. 11


Fig. 10

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Fig. 15

• This may also be caused by insufficient hose insertion during assembly and/or undercrimping. Also excessive vibration and flexing movements may weaken the interface and reduce the assembly ability to prevent fluid leakage. Whether it has been undercrimped or the insert and ferrule have been improperly assembled, the hose assembly must be replaced with one properly assembled.

Hose leaks without burstingHigh fluid velocity or aggressive fluid erodes hose tube (in-ternal layer). Fluid velocity may be too high or a jet stream of fluid through an orifice may impact the tube in a concentrat-ed area. Contamination particles can add to the erosion. In this case it is necessary to consider a larger diameter hose to handle the flow rate at a lower velocity. Make sure that hoses come straight away from any port that has an orifice. Fluid should be clean, check fluid and filters.

Hose tube failureTube is swollen and badly deteriorated, it could also be par-tially washed out. The fluid used may not be compatible with the hose tube; the effect of very high temperature of the fluid can be a concomitant cause too. In this case it is necessary to check the Manuli fluid chart on the catalogue, verifying also details regarding the maximum temperature recom-mended. For further specific assistance contact Manuli Rub-ber Industries (fig. 20).

Reinforcement failure: hose is flattened out in several areas and appears twisted.Hose was installed in a twisted position and when pres-surised tries to return to a neutral position causing the reinforcement to tear apart. The twist of the hose can reduce the hose service life. The cause is an incorrect installation problem: using the hose branding as visual indication of proper installation it is possible to realise a correct routing and installation of the assembly (eventually using also live swivel adaptors if necessary).

Leakage on a tapered male termination endThread has been re-used without proper installation proce-dure. The use of a proper sealant, like a PTFE tape or othersealant material on the threads is necessary.

tions, hose stretch or twist (severe routing with reducedbend radius near the fittings or twist), chemical incompatibil-ity with the service fluid (fig. 18-19).

• This may also be caused by insufficient hose insertion duringassembly and/or undercrimping. Also excessive vibrationand flexing movements may weaken the interface andreduce the assembly ability to prevent fluid leakage.Whether it has been undercrimped or the insert and ferrulehave been improperly assembled, the hose assembly mustbe replaced with one properly assembled.

Hose leaks without burstingHigh fluid velocity or aggressive fluid erodes hose tube (inter-nal layer). Fluid velocity may be too high or a jet stream of fluidthrough an orifice may impact the tube in a concentratedarea. Contamination particles can add to the erosion. In thiscase it is necessary to consider a larger diameter hose to han-dle the flow rate at a lower velocity. Make sure that hosescome straight away from any port that has an orifice. Fluidshould be clean, check fluid and filters.

Hose tube failureTube is swollen and badly deteriorated, it could also be partiallywashed out. The fluid used may not be compatible with thehose tube; the effect of very high temperature of the fluid can bea concomitant cause too. In this case it is necessary to check theManuli fluid chart on the catalogue, verifying also details regard-ing the maximum temperature recommended. For further spe-cific assistance contact Manuli Rubber Industries (fig. 20).

Reinforcement failure: hose is flattened out in several areasand appears twisted.Hose was installed in a twisted position and when pressurisedtries to return to a neutral position causing the reinforcement totear apart. The twist of the hose can reduce the hose servicelife. The cause is an incorrect installation problem: using thehose branding as visual indication of proper installation it is pos-sible to realise a correct routing and installation of the assembly(eventually using also live swivel adaptors if necessary).


The reuse of tapered fittings is not recom-mended, the use of a new fitting isadvised.

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fig. 16

fig. 17

fig. 18

fig. 19

fig. 20


The reuse of tapered fittings is not recommended,the use of a new fitting is advised.

Fig. 16

Fig. 17

Fig. 18

Fig. 19

Fig. 20

tions, hose stretch or twist (severe routing with reducedbend radius near the fittings or twist), chemical incompatibil-ity with the service fluid (fig. 18-19).

• This may also be caused by insufficient hose insertion duringassembly and/or undercrimping. Also excessive vibrationand flexing movements may weaken the interface andreduce the assembly ability to prevent fluid leakage.Whether it has been undercrimped or the insert and ferrulehave been improperly assembled, the hose assembly mustbe replaced with one properly assembled.

Hose leaks without burstingHigh fluid velocity or aggressive fluid erodes hose tube (inter-nal layer). Fluid velocity may be too high or a jet stream of fluidthrough an orifice may impact the tube in a concentratedarea. Contamination particles can add to the erosion. In thiscase it is necessary to consider a larger diameter hose to han-dle the flow rate at a lower velocity. Make sure that hosescome straight away from any port that has an orifice. Fluidshould be clean, check fluid and filters.

Hose tube failureTube is swollen and badly deteriorated, it could also be partiallywashed out. The fluid used may not be compatible with thehose tube; the effect of very high temperature of the fluid can bea concomitant cause too. In this case it is necessary to check theManuli fluid chart on the catalogue, verifying also details regard-ing the maximum temperature recommended. For further spe-cific assistance contact Manuli Rubber Industries (fig. 20).

Reinforcement failure: hose is flattened out in several areasand appears twisted.Hose was installed in a twisted position and when pressurisedtries to return to a neutral position causing the reinforcement totear apart. The twist of the hose can reduce the hose servicelife. The cause is an incorrect installation problem: using thehose branding as visual indication of proper installation it is pos-sible to realise a correct routing and installation of the assembly(eventually using also live swivel adaptors if necessary).


The reuse of tapered fittings is not recom-mended, the use of a new fitting isadvised.

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fig. 16

fig. 17

fig. 18

fig. 19

fig. 20


CALCULATION OF HOSE LENGTH - LOW/HIGH PRESSURE

CALCULTION OF HOSE LENGTH – Low/high pressure

HOSEI.D 3/4” 1” 1 1/4" 1 1/2" 2” 2 1/2" 3” 4” 5” 6” 8”

A mm 4”100

5”125

6”150

7”175

8”200

8”250

10”250

10”250

10”250

10”250

12”300

2 A 8”200

10”250

12”300

14”350

16”400

20”500

20”500

20”500

20”500

20”500

24”600

INNSTIKK:http://tess.webon.net/tess2/frontend/mediabank2/6946/del5_final.pdf|id=10247|sourcepage=8

DEL 5 - Teknisk informasjon 1761

1761

Hvis ikke annet spesifiseres kan den angitte slangelengde avvike med følgende toleranser (i.h.t. standard DIN 20 066):

BEREGNING SLANGELENGDE – LAV-/HØYTRYKK

SLANGE I.D. 3/4" 1" 1.1/4" 1.1/2" 2" 2.1/2" 3" 4" 5" 6" 8"

A mm4" 5" 6" 7" 8" 8" 10" 10" 10" 10" 12"

100 125 150 175 200 200 250 250 250 250 300

2 A8" 10" 12" 14" 16" 16" 20" 20" 20" 20" 24"

200 250 300 350 400 400 500 500 500 500 600

LENGDETOLERANSER - LAV-/HØYTRYKKSLANGER

Lengde mmDimensjon

T.o.m. DN 25(t.o.m. 1")

DN 32 - DN 50(1.1/4" - 2")

F.o.m. DN 60(over 2")

Opp til 630 + 7 mm + 12 mm

- 3 mm - 4 mm

630 - 1250 + 12 mm + 20 mm + 25 mm

- 4 mm - 6 mm - 6 mm

1250 - 2500 + 20 mm + 25 mm

- 6 mm - 6 mm

2500 - 8000 + 1,5 %

- 0,5 %

over 8000 + 3,0 %

- 1,0 %

LENGDETOLERANSER - STÅLSLANGER

Lengde mmDimensjon

T.o.m. DN 20(t.o.m. 3/4")

DN 25 - DN 100(1" - 4")


Opp til 200 + 6 mm + 10 mm- 6 mm - 10 mm

200 - 450 + 8 mm + 13 mm + 16 mm- 8 mm - 13 mm - 16 mm

450 - 900 + 10 mm + 16 mm + 23 mm- 10 mm - 16 mm - 23 mm

900 - 1800 + 13 mm + 20 mm + 25 mm- 13 mm - 20 mm - 23 mm

1800 - 3600 + 25 mm + 32 mm + 50 mm- 25 mm - 32 mm - 25 mm

Over 3600 + 1 % + 1,5 % + 1,5 %- 1 % - 1,5 % - 1,5 %



1761



SLANGE I.D. 3/4" 1" 1.1/4" 1.1/2" 2" 2.1/2" 3" 4" 5" 6" 8"

A mm4" 5" 6" 7" 8" 8" 10" 10" 10" 10" 12"

100 125 150 175 200 200 250 250 250 250 300

2 A8" 10" 12" 14" 16" 16" 20" 20" 20" 20" 24"

200 250 300 350 400 400 500 500 500 500 600


Lengde mmDimensjon

T.o.m. DN 25(t.o.m. 1")

DN 32 - DN 50(1.1/4" - 2")


Opp til 630 + 7 mm + 12 mm

- 3 mm - 4 mm

630 - 1250 + 12 mm + 20 mm + 25 mm

- 4 mm - 6 mm - 6 mm

1250 - 2500 + 20 mm + 25 mm

- 6 mm - 6 mm

2500 - 8000 + 1,5 %

- 0,5 %

over 8000 + 3,0 %

- 1,0 %


Lengde mmDimensjon

T.o.m. DN 20(t.o.m. 3/4")

DN 25 - DN 100(1" - 4")


Opp til 200 + 6 mm + 10 mm- 6 mm - 10 mm

200 - 450 + 8 mm + 13 mm + 16 mm- 8 mm - 13 mm - 16 mm

450 - 900 + 10 mm + 16 mm + 23 mm- 10 mm - 16 mm - 23 mm

900 - 1800 + 13 mm + 20 mm + 25 mm- 13 mm - 20 mm - 23 mm

1800 - 3600 + 25 mm + 32 mm + 50 mm- 25 mm - 32 mm - 25 mm

Over 3600 + 1 % + 1,5 % + 1,5 %- 1 % - 1,5 % - 1,5 %

MOVING INSTALLATION:T = the distance the hose moves. The formula for calculating the hose unit’s length is:

L = 2 A + X + T.

FIXED INSTALLATION:Length A is fixed for each hose dimension. Radius R must never be less than the smallest bend radius specified for each hose.

The hose unit’s length is: L = 2 A + X.

The value of X is found by multiplying R with 3,14.

INDICATION OF LENGTHS FOR HOSES ASSEMBLED WITH COUPLINGS



1761



SLANGE I.D. 3/4" 1" 1.1/4" 1.1/2" 2" 2.1/2" 3" 4" 5" 6" 8"

A mm4" 5" 6" 7" 8" 8" 10" 10" 10" 10" 12"

100 125 150 175 200 200 250 250 250 250 300

2 A8" 10" 12" 14" 16" 16" 20" 20" 20" 20" 24"

200 250 300 350 400 400 500 500 500 500 600


Lengde mmDimensjon

T.o.m. DN 25(t.o.m. 1")

DN 32 - DN 50(1.1/4" - 2")


Opp til 630 + 7 mm + 12 mm

- 3 mm - 4 mm

630 - 1250 + 12 mm + 20 mm + 25 mm

- 4 mm - 6 mm - 6 mm

1250 - 2500 + 20 mm + 25 mm

- 6 mm - 6 mm

2500 - 8000 + 1,5 %

- 0,5 %

over 8000 + 3,0 %

- 1,0 %


Lengde mmDimensjon

T.o.m. DN 20(t.o.m. 3/4")

DN 25 - DN 100(1" - 4")


Opp til 200 + 6 mm + 10 mm- 6 mm - 10 mm

200 - 450 + 8 mm + 13 mm + 16 mm- 8 mm - 13 mm - 16 mm

450 - 900 + 10 mm + 16 mm + 23 mm- 10 mm - 16 mm - 23 mm

900 - 1800 + 13 mm + 20 mm + 25 mm- 13 mm - 20 mm - 23 mm

1800 - 3600 + 25 mm + 32 mm + 50 mm- 25 mm - 32 mm - 25 mm

Over 3600 + 1 % + 1,5 % + 1,5 %- 1 % - 1,5 % - 1,5 %

The lengths shall be given in mm (millimetres) and as indicat-ed in the illustration, i.e. the length between sealing surfaces or between the centres of sealing surfaces.

This specification is used for all hose types. In addition to that indicated by the illustration. Unions can be used on steel hoses. These shall be dimensioned to the sealing surface, i.e. corresponding BSP.

ORIENTATION OF COUPLINGS



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SLANGE I.D. 3/4" 1" 1.1/4" 1.1/2" 2" 2.1/2" 3" 4" 5" 6" 8"

A mm4" 5" 6" 7" 8" 8" 10" 10" 10" 10" 12"

100 125 150 175 200 200 250 250 250 250 300

2 A8" 10" 12" 14" 16" 16" 20" 20" 20" 20" 24"

200 250 300 350 400 400 500 500 500 500 600


Lengde mmDimensjon

T.o.m. DN 25(t.o.m. 1")

DN 32 - DN 50(1.1/4" - 2")


Opp til 630 + 7 mm + 12 mm

- 3 mm - 4 mm

630 - 1250 + 12 mm + 20 mm + 25 mm

- 4 mm - 6 mm - 6 mm

1250 - 2500 + 20 mm + 25 mm

- 6 mm - 6 mm

2500 - 8000 + 1,5 %

- 0,5 %

over 8000 + 3,0 %

- 1,0 %


Lengde mmDimensjon

T.o.m. DN 20(t.o.m. 3/4")

DN 25 - DN 100(1" - 4")


Opp til 200 + 6 mm + 10 mm- 6 mm - 10 mm

200 - 450 + 8 mm + 13 mm + 16 mm- 8 mm - 13 mm - 16 mm

450 - 900 + 10 mm + 16 mm + 23 mm- 10 mm - 16 mm - 23 mm

900 - 1800 + 13 mm + 20 mm + 25 mm- 13 mm - 20 mm - 23 mm

1800 - 3600 + 25 mm + 32 mm + 50 mm- 25 mm - 32 mm - 25 mm

Over 3600 + 1 % + 1,5 % + 1,5 %- 1 % - 1,5 % - 1,5 %

Korreksjonsfaktor for stålslanger

Temp. ºC

2050

100150

1,000,950,850,77

200250300350

0,710,670,630,60

400450500550

0,580,570,560,55

600650700750

0,50

800

CORRECTION FACTOR FOR STEEL HOSES AISI 316/304

The above figures are to be used as guidelines only. The actual values will depend on specific areas of application and on demands for the use of standards.

SPIRALGUARD - CALCULATION OF USE

Calculating how much Spiralguard is needed is a simple task. You divide the external diameter of the hose by the internal diameter of the Spiralguard, then multipy the result by the number of metres of hose to be covered with Spiral-guard.

E.g.:

● 25-metre hose with external diameter of 40 mm ● Spiralguard 91333-37 will be used (this covers hoses

sizes 27-44 mm).

Amount of Spiralguard required =

external diameter of hose x length of hose in metres

internal diameter of Spiralguard

Spiralguard must be wrapped tightly around the hose.

SPIRALGUARD – CALCULATION OF USETESS part. no Internal

diameter, mmFor external

hose size, mm91333-18 13 12-18

91333-24 16 16-26

91333-37 27 27-44

91333-120 65 65-120

91333-200 80 80-200

2

1Example

Orientation is determined by the number of degrees between the fitting furthest from the viewer, measured in a clockwise direction.

CHEMICAL RESISTANCE CHARTINNSTIKK:http://tess.webon.net/tess2/frontend/mediabank2/6946/del5_final.pdf|id=10247|sourcepage=31

1784 DEL 5 - Teknisk informasjon

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KJEMIKALIETABELLGjelder til max. 20° hvis ikke annet er spesifisert.Veiledende og ikke forpliktende.1 = Foretrekkes og beste service2 = God service3 = Betinget brukbar0 = Må ikke brukesIngen karakter = Ikke vurdert, da det ikke finnes klare alternativSBR = Lu-Va, gullslange etc.PVC = Heliflex T31, Helisoft, Coldflex etc.Polyamid = Nylaflow 321, 344 og nylonrørEPDM = damp T-28, 44, varmeapp.slange etc.Nitril (NBR) = Bunkerflex/ST - Bunkerflat ST type 516,

525 HydraulikslangerEPR = Cheflex og Chem syreslangeTeflon = Type 20, 21,81 og teflonrørPP/Polypropylene = CellotessPE/Polyethylene = Kjemitess og type 306Stål 316 = StålslangerHypalon = Fra verkViton = Vitonslange type ENMerk: Tabellen tar kun hensyn til kjemikaliebestandighet.

Forhold som diffusjon, temperatur, slitasje o.l. må avklares spesielt.

All the data are considered valid at 20°C (70°F) except where specified1 = Excellent2 = Good 3 = Fair0 = Not suitableNo character = No data

SBR = Often used in industrial hoses for air, water etcSPDM = Used in industrial hoses for steam, hot water, some chemicals etcEPR = Used in industrial hoses, especially for chemicalsViton = Used in industrial hoses, especially for chemicalsNitrile/NBR/Buna N = Used in industrial hoses and hydraulic hoses for oil.Hypalon = Used in industrial hoses for special applicationsPVC = Used in “allround” industrial hosesPolyamid/Nylon = Used in hydraulic hoses and pneumatic pipingTeflon = Used in industrial- and hydraulic hosesPP/Polypropylene = Mostly used in chemical hoses and couplingsPS/Polyethylene = Mostly used in chemical hoses and couplingsSteel A316 = Used in steel hoses and couplings

NB: The chart is based on highly reliable laboratory test. The chart should be used only as a guide since we must assume that when choosing the rubber compound, things may vary such as the temperature, fluid concentration, type of solvent, and working conditions. For heavy duty applications please contact TESS

1 = Excellent2 = Good3 = Fair0 = Not suitableNo character = No Data




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CHEMICAL RESISTANCE CHART



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CHEMICAL RESISTANCE CHART

THREAD ABBREVIATIONS THREAD ABBREVIATIONS

AISI ASAE ASSPT

American Petroleum Institute Taper ThreadAmerican Society of Agricultural EngineersAmerican National Straight Pipe Thread

ASSPT BSPBSTP

American National Taper Pipe ThreadBritish Standard Parallel Pipe ThreadBritish Standard Taper Pipe Thread

FIEIFPT GHT

Farm and Industrial Equipment InstituteFemale Pipe ThreadGarden Hose Thread

IPTJIC JIS

American Iron Pipe Thread - StraightJoint Industry Conferance (SAE 37o)Japanese Industrial Standard

M/MMNPS NPSM

Metric ThreadAmerican National Pipe Thread - StraightAmerican National Pipe Thread - Straight Mechanical

NPTNPTFNST

American National Pipe Thread – TaperAmerican National Pipe Thread - Taper (Dry Seal)American National Standard Thread - Straight

ORFSRRT

O-ring front sealParallett threads (BSP)British Round Thread

SAEURTUNC

Society of Automative Engineers (45o)URT Dennis Urgan Round ThreadUNC Unified Coarse Thread

UNFVEEW

Unified Fine ThreadVEE Shelvoke & Drewry "VEE" Round ThreadW Whithworth Thread

STANDARD ABBREVIATIONS STANDARD ABBREVIATIONS

AISI American Iron and Steel InstituteANSI American National Standards InstituteAPI American Petroleum InstituteASA American Standards AssociationASM American Society for MetalsASME American Society for Mechanical EngineersASTM American Society for testing and MaterialsBS British StandardCEN European Committee for standardisationCWA CEN Workshop AgreementDIN Deutche Industrie NormenEN European StandardISO International Organization for StandardizationJIS Japanese Industrial StandardMED Marine Equipment DirectiveMIL-STD Military Standard (USA)

MSS Manufacturers Standardizaion Society(Valve and Fittings Industry)

NF Norme FrancaiseNS Norwegian StandardPED Pressure Equipment DirectivePSA Petroleum Safety AuthoritySAE Society of Automotive EngineersSIS Swedish StandardSMS Swedish Mechanical Assosiation StandardSSG Standardisation Group of the Swedish Forest IndustryUL Underwriters LaboratoriesUNI Instituto Nationale per Unifacacione (Italia)USCG United States Coast Guard

GJENGETABELL FOR HYDRAULIKKUPLINGER

Outer diam. mm Inner diam. mm Type

8,009,73

10,00

6,928,578,92

MMBSPMM

8 x 11/8” x 2810 x 1

10,2711,1112,0012,7013,1613,57

8,779,7410,3811,3311,4511,31

NPTFJICMMJICBSPNPTF

1/8” x 277/16” x 2012 x 1,51/2” x 201/4” x 191/4” x 18

14,0014,1014,2915,88

12,3813,0012,7614,35

MMORFSJICSAE

14 x 1,59/16” x 189/16” x 185/8” x 18

16,0016,6617,06

14,3814,9514,80

MMBSPNPTF

16 x 1,53/8” x 193/8” x 18

17,4018,0019,0520,00

15,9016,3817,3318,38

ORFSMMJICMM

11/16” x 1818” x 1,53/4” x 1,520 x 1,5

20,5020,9621,2222,00

19,2018,6318,3220,38

ORFSBSPNPTFMM

13/16” x 161/2” x 141/2” x 1422 x 1,5

22,2322,9124,00

20,2620,5922,38

JICBSPMM

7/8” x 145/8” x 1424 x 1,5

25,2026,0026,4426,57

23,8024,3824,1223,67

ORFSMMBSPNPTF

1” x 1426 x 1,53/4” x 143/4” x 14

26,9928,0029,9030,00

25,1026,3828,1027,38

JICMMORFSMM

1 1/16” x 1228 x 1,51 3/16” x 1230 x 2

30,1630,2031,23

28,2027,8829,61

JICBSPNPTF

1 3/16” x 127/8” x 141” x 11,5

33,2533,3436,0036,3041,28

30,2931,4033,8334,5039,30

BSPJICMMORFSJIC

1” X 111 5/16” x 1236 x 21 7/16” x 121 5/8” x 12

41,9141,9942,00

38,9538,4539,83

BSPNPTFMM

1 1/4” x 111 1/4” x 11,542 x 2

42,9045,0047,6347,80

41,0042,8345,8044,85

ORFSMMJICBSP

1 11/16” x 1245 x 21 7/8” x 121 1/2” x 11

48,0552,0059,6160,09

44,5249,8356,6656,56

NPTFMMBSPNPTF

1 1/2” x 11,552 x 22” x 112” x 11,5

63,2065,7172,7075,18

60,8062,7567,6272,23

JICBSPNPTFBSP

2 1/2 “ x 122 1/4” x 112 1/2” x 82 1/2” x 11

87,8888,61113,03

84,9383,53

110,07

BSPNPTFBSP

3” x 113” x 84” x 11

113,97140,95167,79218,44

NPTNPTNPTNPT

4” x 85” x 86” x 88” x 8

THREAD TABLE

THREAD/SEALING CONE

THREAD ANGLE OF SEALING CONE

BSP MALE

NPTF MALE

BSP FEMALE

NPSM FEMALE

JIC FEMALE

JIC MALE

METRIC MALE 24°

METRIC FEMALE



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STANDARD FORKORTELSER

GJENGETABELL FOR HYDRAULIKKUPLINGERAPI American Petroleum Institute Taper Thread ASAE American Society of Agricultural EngineersASSPT American National Straight Pipe ThreadASTPT American National Taper Pipe ThreadBSP British Standard Parallel Pipe ThreadBSTP British Standard Taper Pipe ThreadFIEI Farm and Industrial Equipment InstituteFPT Female Pipe ThreadGHT Garden Hose ThreadIPT American Iron Pipe Thread - StraightJIC Joint Industry Conferance (SAE 37o)JIS Japanese Industrial StandardM / MM Metric ThreadNPS American National Pipe Thread - StraightNPSM American National Pipe Thread - Straight MechanicalNPT American National Pipe Thread - TaperNPTF American National Pipe Thread - Taper (Dry Seal)NST American National Standard Thread - StraightORFS O-ring front sealR Rørgjenger (BSP)RT British Round ThreadSAE Society of Automative Engineers (45o)URT Dennis Urgan Round ThreadUNC Unified Coarse ThreadUNF Unified Fine ThreadVEE Shelvoke & Drewry "VEE" Round ThreadW Whithworth Thread

AISI American Iron and Steel InstituteANSI American National Standards InstituteAPI American Petroleum InstituteASA American Standards AssociationASM American Society for MetalsASME American Society for Mechanical MaterialsBS British StandardDIN Deutche Industrie NormenEN Europeisk StandardISO International Organization for StandardizationJIS Japanese Industrial StandardMIL-STD Military Standard (USA)MSS Manufacturers Standardizaion Society

(Valve and Fittings Industry)NF Norme FrancaiseNS Norsk StandardSAE Society of Automotive EngineersSIS Svensk StandardSMS Sveriges Mekanfôrbunds StandardcentralSSG Standardisation Group of the Swedish Forest IndustryUL Underwriters LaboratoriesUNI Instituto Nationale per Unifacacione (Italia)USCG United States Coast Guard

Ytterdiam. mm Innerdiam. mm Type8,00 6,92 MM 8 x 19,73 8,57 BSP 1/8" x 28

10,00 8,92 MM 10 x 110,27 8,77 NPTF 1/8" x 2711,11 9,74 JIC 7/16" x 2012,00 10,38 MM 12 x 1,512,70 11,33 JIC 1/2" x 2013,16 11,45 BSP 1/4" x 1913,57 11,31 NPTF 1/4" x 1814,00 12,38 MM 14 x 1,514,10 13,00 ORFS 9/16” x 1814,29 12,76 JIC 9/16" x 1815,88 14,35 SAE 5/8" x 1816,00 14,38 MM 16 x 1,516,66 14,95 BSP 3/8" x 1917,06 14,80 NPTF 3/8" x 1817,40 15,90 ORFS 11/16” x 1818,00 16,38 MM 18" x 1,519.05 17,33 JIC 3/4" x 1620,00 18,38 MM 20 x 1,520,50 19,20 ORFS 13/16” x 1620,96 18,63 BSP 1/2" x 1421,22 18,32 NPTF 1/2" x 1422,00 20,38 MM 22 x 1,522,23 20,26 JIC 7/8" x 1422,91 20,59 BSP 5/8" x 1424,00 22,38 MM 24 x 1,525,20 23,80 ORFS 1” x 1426,00 24,38 MM 26 x 1,526,44 24,12 BSP 3/4" x 1426,57 23,67 NPTF 3/4" x 1426,99 25,10 JIC 1.1/16" x 1228,00 26,38 MM 28 x 1,529,90 28,10 ORFS 1.3/16” x 1230,00 27,83 MM 30 x 230,16 28,20 JIC 1.3/16" x 1230,20 27,88 BSP 7/8" x 1431,23 29,61 NPTF 1" x 11,533,25 30,29 BSP 1" x 1133,34 31,40 JIC 1.5/16" x 1236,00 33,83 MM 36 x 236,30 34,50 ORFS 1.7/16” x 1241,28 39,30 JIC 1.5/8" x 1241,91 38,95 BSP 1.1/4" x 1141,99 38,45 NPTF 1.1/4" x 11,542,00 39,83 MM 42 x 242,90 41,00 ORFS 1.11/16” x 1245,00 42,83 MM 45 x 247,63 45,80 JIC 1.7/8" x 1247,80 44,85 BSP 1.1/2" x 1148,05 44,52 NPTF 1.1/2" x 11,552,00 49,83 MM 52 x 259,61 56,66 BSP 2" x 1160,09 56,56 NPTF 2" x 11,563,20 60,80 JIC 2.1/2" x 1265,71 62,75 BSP 2.1/4" x 1172,70 67,62 NPTF 2.1/2" x 875,18 72,23 BSP 2.1/2" x 1187,88 84,93 BSP 3" x 1188,61 83,53 NPTF 3" x 8

113,03 110,07 BSP 4" x 11113,97 NPT 4" x 8140,95 NPT 5" x 8167,79 NPT 6" x 8218,44 NPT 8" x 8



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60°



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60°

24°



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NPSM

37°

37°

24°

SEALS BETWEEN THREADS1. Standard Taper Thread (NPT-National Pipe Thread) seals between the thread flanks as there is a negative clearance between the threads at this point. There will be a clearance between the top and bottom of the threads. In order to avoid leaks in this clearance, a sealant must be used, such as a thread paste or teflon tape.

2. Dryseal Taper Thread (NPTF) gives a negative clearance between the threads at the top and bottom prior to the threads flanks making contact. When the threads are screwed in, the crests of the threads are crushed and create a seal. Sealant is not necessary, but can be used as a lubricant.

3. NPT and NPTF threads are interchangeable, but sealant must be used when these are used together.



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CONVERSION TABLES – Inches - mm

Inches mm

1/161/8

1/322/323/324/32

2/644/646/648/64

= 0,03125= 0,0625= 0,9375= 0,125

0,791,592,383,18

3/16

1/4

5/326/327/328/32

10/6412/6414/6416/64

= 0,15625= 0,1875= 0,21875= 0,25

3,974,765,566,35

5/16

3/8

9/3210/3211/3212/32

18/6420/6422/6424/64

= 0,28125= 0,3125= 0,34375= 0,375

7,147,948,739,53

7/16

1/2

13/3214/3215/3216/32

26/6428/6430/6432/64

= 0,40625= 0,4375= 0,46875= 0,50

10,3211,1111,9112,70

9/16

5/8

17/3218/3219/3220/32

34/6436/6438/6440/64

= 0,53125= 0,5625= 0,59375= 0625

13,4914,2915,0815,88

11/16

3/4

21/3222/3223/3224/32

42/6444/6446/6448/64

= 0,65625= 0,6875= 0,71875= 0,75

16,6717,4618,2619,05

13/16

7/8

25/3226/3227/3228/32

50/6452/6454/6456/64

= 0,78125= 0,8125= 0,84375= 0,875

19,8420,6421,4322,23

15/16

16/16

29/3230/3231/3232/32

58/6460/6462/6464/64

= 0,90625= 0,96875= 0,96875= 1,000

23,0224,6124,6125,40

CONVERSION TABLES Inches - mm

FACTORSFAKTORER

1 American gallon = 3,79 litres1 Imperial gallon = 4,55 litres1 Cubic feet = 28,3 litres1 American barres(fat) = 158,99 litres1 Cubic meters = 6,29 American barrels1 Metric tons = 0,98 Long ton1 Metric tons = 1,10 Short ton1 Metric tons = 2 204,60 Lbs1 kWh = 859,80 Kcal1 kWh = 3,60 megajoules2 Btu = 0,25 Kcal1 litre heating oil = 7,50 kWh1 tons of oil = 1,50 tonnes of coal1 tons of oil = 1 167,00 cubric metres of natural gas1,487 kg/m = Lbs/ft

PSI x 00068948 = megapascals (Mpa) PSI x 070307 = kilogram-force cm2 1 MPa = 10 Bars 1 bar = 14,5 PSI

PSI MPa Kgf/cm2 BARS ATMOS PHERES

PSI Mpa Kgf/cm2 BARS ATMOS PHERES



2550

1734

1.76 3.52

1.72 3.45

1.70 3.40

25002600

17.24 17.93

175.77 182.80

172.50 179.40

170.00 176.80

52005300

35.85 36.54

365.60 372.63

358.80 365.70

353.60 360.40

79008000

54.47 55.16

555.42 562.46

545.10 522.00

537.20 544.00

75100

5269

5.27 7.03

5.18 6.90

5.10 6.80

27002800

18.62 19.30

189.83 196.86

186.30 193.20

183.60 190.40

54005500

37.23 37.92

379.66 386.69

372.60 379.50

367.20 374.00

81008200

55.85 56.54

569.49 576.52

558.90 565.80

550.80 557.60

200300

1.38 2.07

14.06 21.09

13.80 20.70

13.60 20.40

29003000

19.99 20.68

203.89 210.92

200.10 207.00

197.20 204.00

56005700

38.61 39.30

393.72 400.75

386.40 393.30

380.80 387.60

83008400

57.23 57.92

583.55 590.58

572.70 579.60

564.40 571.20

400500

2.76 3.45

28.12 35.15

27.60 34.50

27.20 34.00

31003200

21.37 22.06

217.95 224.98

213.90 220.80

210.80 217.60

58005900

39.99 40.68

407.78 414.81

400.20 407.10

394.40 401.20

85008600

58.61 59.30

597.61 604.64

586.50 593.40

578.00 584.80

600700

4.14 4.83

42.18 49.21

41.40 48.30

40.80 47.60

33003400

22.75 23.44

232.01 239.04

227.70 234.60

224.90 231.20

60006100

41.37 42.06

421.84 428.87

414.00 420.90

408.00 414.80

87008800

59.98 60.67

611.67 618.70

600.30 607.20

591.60 598.40

800900

5.52 6.20

56.24 63.28

55.20 62.10

54.40 61.20

35003600

24.13 24.82

246.07 253.10

241.50 248.40

238.00 244.80

62006300

42.75 43.44

435.90 422.93

427.80 434.70

421.60 428.40

89009000

61.36 62.05

625.73 632.76

614.10 621.00

605.20 612.00

10001100

6.90 7.58

70.31 77.34

69.00 75.90

68.00 74.80

37003800

25.51 26.20

260.14 267.17

255.30 262.20

251.60 258.40

64006500

44.13 44.82

449.96 457.00

441.60 448.50

435.20 442.00

91009200

62.74 63.43

639.79 646.82

627.90 634.80

618.80 625.60

12001300

8.27 8.96

84.37 91.40

82.80 89.70

81.60 88.40

39004000

26.89 27.58

274.20 281.23

269.10 276.00

265.20 272.00

66006700

45.51 46.20

464.03 471.06

455.40 462.30

448.80 455.60

93009400

64.12 46.18

653.86 660.89

641.70 648.60

632.40 639.20

14001500

9.65 10.34

98.43 105.46

96.60 103.50

95.20 102.00

41004200

28.27 28.96

288.26 295.29

282.90 289.80

278.80 285.60

68006900

46.88 47.57

478.09 485.12

469.20 476.10

462.40 469.20

95009600

65.50 66.19

667.92 974.95

655.50 622.40

646.00 652.80

16001700

11.03 11.72

112.49 119.52

110.40 117.30

108.80 115.60

43004400

29.65 30.34

302.32 309.35

296.70 303.60

292.40 299.20

70007100

48.26 48.95

492.15 499.18

483.00 489.90

476.00 482.80

97009800

66.88 67.57

681.98 689.01

699.30 676.20

659.60 666.40

18001900

12.41 13.10

126.55 133.58

124.20 131.10

122.40 129.20

45004600

31.03 31.72

316.38 323.41

310.50 317.40

306.00 312.80

72007300

49.64 50.33

506.21 513.24

496.80 503.70

489.60 496.40

990010000

68.26 68.95

696.04 703.07

683.10 690.00

673.20 680.00

20002100

13.79 14.48

140.61 147.64

138.00 144.90

136.00 142.80

47004800

32.41 33.10

330.44 337.47

324.30 331.20

319.60 326.40

74007500

51.02 51.71

520.27 527.30

510.60 517.50

503.20 510.00

1100012000

75.84 82.74

733.38 843.68

759.00 828.00

748.00 816.00

220023002400

15.17 15.86 16.55

154.68 161.71 168.74

151.80 158.70 165.60

149.60 156.40 163.20

490050005100

33.78 34.47

356.16

344.50 351.54 358.57

338.10 345.00 351.90

333.20 340.00 346.80

760077007800

52.40 53.09 53.78

534.33 541.36 548.39

524.40 531.30 538.20

516.80 523.60 530.40

130001400015000

89.63 96.53 103.42

913.99 984.30 1054.60

897.00 966.00 1035.00

884.00 952.00 1020.00

PSI x 0690 = Bars PSI x 0680 = Atmospheres 1 kgf/cm2 = 14,22 PSI 1 PSI = 00689 Mpa

PSI MPa Kgf/cm2 BARS ATMOS PHERES




2550

1734

1.76 3.52

1.72 3.45

1.70 3.40

25002600

17.24 17.93

175.77 182.80

172.50 179.40

170.00 176.80

52005300

35.85 36.54

365.60 372.63

358.80 365.70

353.60 360.40

79008000

54.47 55.16

555.42 562.46

545.10 522.00

537.20 544.00

75100

5269

5.27 7.03

5.18 6.90

5.10 6.80

27002800

18.62 19.30

189.83 196.86

186.30 193.20

183.60 190.40

54005500

37.23 37.92

379.66 386.69

372.60 379.50

367.20 374.00

81008200

55.85 56.54

569.49 576.52

558.90 565.80

550.80 557.60

200300

1.38 2.07

14.06 21.09

13.80 20.70

13.60 20.40

29003000

19.99 20.68

203.89 210.92

200.10 207.00

197.20 204.00

56005700

38.61 39.30

393.72 400.75

386.40 393.30

380.80 387.60

83008400

57.23 57.92

583.55 590.58

572.70 579.60

564.40 571.20

400500

2.76 3.45

28.12 35.15

27.60 34.50

27.20 34.00

31003200

21.37 22.06

217.95 224.98

213.90 220.80

210.80 217.60

58005900

39.99 40.68

407.78 414.81

400.20 407.10

394.40 401.20

85008600

58.61 59.30

597.61 604.64

586.50 593.40

578.00 584.80

600700

4.14 4.83

42.18 49.21

41.40 48.30

40.80 47.60

33003400

22.75 23.44

232.01 239.04

227.70 234.60

224.90 231.20

60006100

41.37 42.06

421.84 428.87

414.00 420.90

408.00 414.80

87008800

59.98 60.67

611.67 618.70

600.30 607.20

591.60 598.40

800900

5.52 6.20

56.24 63.28

55.20 62.10

54.40 61.20

35003600

24.13 24.82

246.07 253.10

241.50 248.40

238.00 244.80

62006300

42.75 43.44

435.90 422.93

427.80 434.70

421.60 428.40

89009000

61.36 62.05

625.73 632.76

614.10 621.00

605.20 612.00

10001100

6.90 7.58

70.31 77.34

69.00 75.90

68.00 74.80

37003800

25.51 26.20

260.14 267.17

255.30 262.20

251.60 258.40

64006500

44.13 44.82

449.96 457.00

441.60 448.50

435.20 442.00

91009200

62.74 63.43

639.79 646.82

627.90 634.80

618.80 625.60

12001300

8.27 8.96

84.37 91.40

82.80 89.70

81.60 88.40

39004000

26.89 27.58

274.20 281.23

269.10 276.00

265.20 272.00

66006700

45.51 46.20

464.03 471.06

455.40 462.30

448.80 455.60

93009400

64.12 46.18

653.86 660.89

641.70 648.60

632.40 639.20

14001500

9.65 10.34

98.43 105.46

96.60 103.50

95.20 102.00

41004200

28.27 28.96

288.26 295.29

282.90 289.80

278.80 285.60

68006900

46.88 47.57

478.09 485.12

469.20 476.10

462.40 469.20

95009600

65.50 66.19

667.92 974.95

655.50 622.40

646.00 652.80

16001700

11.03 11.72

112.49 119.52

110.40 117.30

108.80 115.60

43004400

29.65 30.34

302.32 309.35

296.70 303.60

292.40 299.20

70007100

48.26 48.95

492.15 499.18

483.00 489.90

476.00 482.80

97009800

66.88 67.57

681.98 689.01

699.30 676.20

659.60 666.40

18001900

12.41 13.10

126.55 133.58

124.20 131.10

122.40 129.20

45004600

31.03 31.72

316.38 323.41

310.50 317.40

306.00 312.80

72007300

49.64 50.33

506.21 513.24

496.80 503.70

489.60 496.40

990010000

68.26 68.95

696.04 703.07

683.10 690.00

673.20 680.00

20002100

13.79 14.48

140.61 147.64

138.00 144.90

136.00 142.80

47004800

32.41 33.10

330.44 337.47

324.30 331.20

319.60 326.40

74007500

51.02 51.71

520.27 527.30

510.60 517.50

503.20 510.00

1100012000

75.84 82.74

733.38 843.68

759.00 828.00

748.00 816.00

220023002400

15.17 15.86 16.55

154.68 161.71 168.74

151.80 158.70 165.60

149.60 156.40 163.20

490050005100

33.78 34.47

356.16

344.50 351.54 358.57

338.10 345.00 351.90

333.20 340.00 346.80

760077007800

52.40 53.09 53.78

534.33 541.36 548.39

524.40 531.30 538.20

516.80 523.60 530.40

130001400015000

89.63 96.53 103.42

913.99 984.30 1054.60

897.00 966.00 1035.00

884.00 952.00 1020.00

CONVERSION TABLE PRESSURE

VACUUM

CELSIUS-FAHRENHEIT

Based on the formula:TC = 5/9 (TF - 32º)TF = 9/5 (TC +32°)

ºC ºF ºC ºF-90-80-70-60-50-40-30-20-10010203040

-130-112-94-76-58-40-22-4-1432506886

104

5060708090

100125150200250300350400500

122140158176194212257302392482572662752932

PRESSURE-TEMPERATURE

For saturated water vapour based on 1 atm. pressure

BAR °C1 1202 1333 1434 1515 1586 1657 1718 1759 17910 18411 18812 19213 19614 20215 19916 20417 20718 20919 21220 21622 22124 225

VAKUUM

1 atm. pressure equals: Vacuum equals:763 mm mercury column 0 mm mercury column0 TORR 763 TORR0 % Vacuum 100 % Vacuum10,3 metre water column 0 metre water column1,03 kp/cm2 0 kp/cm21013 mBAR 0 mBAR

Positive pressure: More than 1 atm.Negative pressure: Less than 1 atm.

CELSIUS - FAHRENHEIT PRESSURE-TEMPERATURE

SAFETY INSTRUCTIONS FOR STEAM HOSESSelect the right hose ■ Select a hose which is suitable for steam ■ The label on the hose should be printed on permanently, not just appear on the packaging. ■ Identifies how the hose is to be used: 1. Should the hose be handled manually? 2. What is the estimated frequency of use? 3. What is the working pressure of the steam? 4. Could a pressure surge occur? 5. What is the temperature of the steam? 6. Is the steam saturated (wet) or superheated (dry)? ■ Remember that chemicals and petroleum-based fluids from the surroundings can destroy the external casing of the hose.

Installation ■ Use couplings designed for steam hoses. Steam hose couplings are fitted using clamps which are tightened with bolts. These can be tightened again once the hose has been used, and this has to be allowed for as long as the hose is being used. Always check the tightness before starting work. ■ Avoid bending the hose near to the coupling. ■ Ensure that the hose has its own storage place when it is not being used. A permanent stand or the like will minimise damage to the hose while it is in storage. Do not hang the hose on a hook, nail or any other object which may cut or damage the hose.

Safety ■ Ensure that operators are given the correct protective clothing. Wear gloves, boots, full protective equipment and safety goggles. This should provide protection against burns or scalds should steam or hot water spurt out.

■ Ensure that the installation area is clear of equipment which may damage the hose unexpectedly. ■ Regularly check the tightness of the clamps for leaks between the hose and the coupling. ■ Do not leave the hose pressurised when it is not being used. If the pressure is reduced, the service life of the hose will be extended considerably. Periodic maintenance and inspection of steam hose It is to be expected that all steam hoses will wear out over time. It is important to continuously check the hose for signs of wear which may impair its safety. Operators should be on the lookout for the following signs: ■ External blisters or wear damage. ■ External cuts which mean that the reinforcement is visible. ■ Leakage of steam at the couplings or elsewhere along the length of the hose. ■ Areas damaged which have been pressed flat or over- bent. ■ Reduction of the flow of steam, which indicates that the internal rubber has expanded. ■ Steam hoses have a limited service life, which is estimated to be around 1000 hours of operation.

When any of the above damage occurs, it is recommended that the hose be taken out of use immediately. As soon as the hose has been disconnected, it can be inspected before being commissioned once again where appropriate.

Faults in steam hoses usually occur close to the ends on ac-count of movements and stretching at the couplings.In cases of this kind, the hose may be cut and refitted. Any hose which is used at constant high pressure or temperatureshould be inspected periodically for signs of greater hard-ness as regards the internal rubber. In most cases, it is necessary to remove the coupling for inspection.

Hydraulic Hose, International Standards

Wire braid hoses EN 853 (1ST, 1SN, 2ST, 2SN) SAE J517 (R1, R2)*Textile braided hoses EN 854 (1TE, 2TE, 3TE, R3, R6) SAE J517 (R3, R6)

Thermoplastic hoses EN 855 (R7, R8) SAE J517 (R7, R8)

Wire spiral hoses EN856 (4SP, 4SH, R12, R13) SAE J517 (R9, R12, R13, R15)

Compact wire braided hoses EN 857 (1SN, 2SN) SAE J517 (R16, R17)* 100R1A, 100R1AT, 100R2A, 100R2AT

In an effort to consolidate all norms ISO standards are designed to merge both SAE and EN. Gradually ISO specifications are going to take place in the whole market:

Wire braid hoses EN 853 (1ST, 1SN, 2ST, 2SN)SAE J517 (R1, R2) ISO 1436-1 TESS 5166-

TESS 5256-

Textile braided hoses EN 854 (1TE, 2TE, 3TE, R3, R6)SAE J517 (R3, R6) ISO 4079-1 TESS 533-

Thermoplastic hoses EN 855 (R7, R8)SAE J517 (R7, R8) ISO 3949-1 TESS 5705-

TESS 5380-

Wire spiral hoses EN856 (4SP, 4SH, R12, R13)SAE J517 (R9, R12, R13, R15) ISO 3862-1 TESS 547-

TESS 548

Compact wire braided hoses EN 857 (1SC, 2SC)SAE J517 (R16, R17) ISO 11237-1 TESS 5528-

HYDRAULIC HOSE, INTERNATIONAL STANDARDS

ASSMEBLY INSTRUCTIONS FOR CUT RING FITTINGS



1756

Høytrykkslanger, monteringsanvisning Det henvises generelt til gjeldende pressetabell, men i prinsippet kan følgende benyttes:

Snittringsarmatur, monteringsanvisning

SLANGER HVOR YTTERGUMMI MÅ FJERNES FØR MONTERING

1. Kutt slangen.Fjern yttergummien i riktig lengde i henhold til gjeldende pressetabell, med stålbørste eller spesialverktøy. Stålarmeringen må være helt bar.

2. Sett på hylser. (Kontroller målene på hylsen før press-ing, se pressetabell)

3. Glidemiddel som bør brukes ved montering av innsat-sene, kan kjøpes hos rørleggerforretninger landet over. Det finnes mange merker, men det bør brukes silikon-spray som «herder» etter en tid.

4. Sett inn innsatser, og press til rett diameter (se tabell). Hvis hylsen er lengre enn pressbakkenes lengde, skal hylsepartiet nærmest gjengene/tilslutningene presses først.

SLANGER SOM IKKE SKAL SKRELLES FØR MONTERING

1. Kutt slangen.Fortsett med punkt 2, 3 og 4 som over.

SLANGER HVOR BÅDE YTTERGUMMI OG INNER-GUMMI MÅ FJERNES FØR MONTERING

1. Kutt slangen. Fjern yttergummien i riktig lengde (se tabell) med kniv, stålbørste eller spesialverktøy. Stålarm-eringen må være helt bar. Fjern innergummien, bruk spesialverktøy. Verktøyet må justeres slik at all gummi fjernes, og riktig skrellelengde oppnås.

Fortsett med punkt 2, 3 og 4 som over.



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Before assembly After assembly

1. This figure shows a correctly assembled sleeve coupling in accordance with DIN 2353. We shall go through the steps for correct assembly.

2. The pipe is cut perpendicular and carefully deburred. The pipe’s end face must be flat so that it touches the bottom of the coupling. Ensure that the seal face under the sleeve is not damaged.

3. Mount the nut and place the sleeve correctly. Lubricate the sleeve, the coupling’s inner cone and threads with oil.

4. The use of and hardened pre assembly nipple is recommended. If you don’t have this, a normal sleeve coupling can be used for pre assembly. Do not perform more than 3 pre assemblies on the same coupling.

5. The pipe with nut and sleeve is pressed against the stop in the coupling end. The pipe must always be touching the bottom. Screw the nut until the pipe cannot be turned by hand.

6. Tighten the nut 3/4 - 1 revolution. The pipe should not turn with the nut.

7. Dismantle the pipe and check that the sleeve has cut a collar all the way round the pipe. The sleeve springs back and can therefore be turned round, but it should not be able to move along the pipe.

8. On final assembly, the parts are put together and tightened a further 1/2 revolution. Re- menber to hold the coupling in place when the nut is being tightened.

9. For any subsequent dismantling, the coupling must always be held in place when the nut is being tightened.

INSTRUMENTATION FITTINGS – ASSEMBLY INSTRUCTIONS 1/2

1. TESS instrumentation fittings come individually bagged and completely assembled for immediate use. There is no need for disassembly prior to use. Simply remove the instrumentation fitting from its bag, insert the tube (Tubing ends should be cut as straight as possible with all O.D. and I.D. burrs removed. Use of a tubing cutter and guide blocks with a hacksaw is recommended) until it bottoms in the instrumentation fitting body and then hand tighten. (Fig. 1) Note: For extreme system applications using high pressures or requiring an extra factor of safety, it may be desirable to use a “common makeup starting point” to alleviate the inherent variations in tub ing diameters. Installation should begin from a “snug” position, which is achieved by wrench tightening the TESS instrumentation fittings nut until the inserted tubing will not move freely by hand (approximately 1/8 turn), From this new “snug” staring point, continue witch the recommended installation intstructions.

Initial installation

Reassembly instructions1. To reassemble a TESS instrumentation fitting, simply insert the tubing with the previosly coined ferrule and fitting nut into the body until the front ferrule seats within the fitting body, and then tighten the nut by hand. (Fig. 5)

2. While holding the fitting body stable with a back up wrench, use a wrench to rotate the TESS instrumenta tion fitting nut to the fitting’s original installation position (approximately 1/4 turn from hand-tight, snug position) then continue to tighten the nut slightly.

Component assembly1. Should individual component assembly of a TESS instrumentation fitting ever be required, careful attention must be given to the proper sequence and direction of the com ponents. (Fig. 6)

a. 2 mm – 5 mm and 1/16” – 3/16” shall be tighten 3/4 turn. (Fig. 3)

2. While holding the fitting body stable with a back-up wrench, scribe the nut for a reference point and wrench tighten the nut. (Fig. 2)

b. 5 – 25 mm and 1/4” – 1” shall be tighten 1.1/4 turn (Fig. 4)

c. Assembly of TESS instrumentation over 25 mm or 1” requires special assembly equipment.

2. While holding the fitting body stable with a back up wrench, us another wrench to rotate the TESS instrumentation fitting nut approxemately 1/4 turn. Remember to mark up the reference point on the nut before tightening more. For extreme application with higher pressure and high or low temperature, you tighten the nut up to 1/2 turn.

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

5. Reassembly of the tube are done by instructions under chapter Reassembly. (Fig. 10)

3. Special assembly tool and pre-setting tool can be ordered by your local TESS brach or TESS as. Phone: +47 32 84 40 00.

Pre-setting instructions

Gageability

1. Secure the pre-setting tool in a vise.

2. Remove the protective nut , and assemble the TESS instrumentation fitting nut and ferrule loosely to the pre- setting tool. Insert the tubing through the nut and ferrules until it bottoms in the pre-setting tool and then follow the standard installation instructions. Remember to use some lubricant that are compatible with the media that shall go through the tube. (Fig. 7) and (Fig. 8)

4. Loosen the nut from the pre-setting tool and put on thread protection.(Fig. 9)

1. If you follow proper installation instructions, you can get a indication if you have assembled correct or not.

2. After completion of the installation instructions and prior to pressuring the system, choose the proper size Gap Gage and try to insert between the fitting’s nut and body hex. If the Gap Gage will not enter between the fitting’s nut and body hex, no additional tightening is required (Notice that you will not see if you have been overtightening). If the Gap Gage will enter between the fitting’s nut and bodyhex, additional tightening is required. (Fig. 11 og fig. 12)

INSTRUMENTATION FITTINGS – ASSEMBLY INSTRUCTIONS 2/2

Fig. 7

Fig. 8

Fig. 11

Fig. 10

Fig. 12

Fig. 9

Recommended pressure values in bar for threaded steel adapters:Various factors have to be taken into account when determining the recommended pressure values in piping. These are:

1. The actual working pressure

2. Mechanical load

3. Pipe dimensions

4. Vibration

5. Temperature and changes

Manufacturers produce pipes in accordance with various production methods and pipe dimensions, and with varying mechani-cal properties in the material. The design of piping is determined by dynamic, chemical and mechanical factors witch can affect the system when å product’s safety factor is to be specified. The following recommended values are used for various pipe components with JIC threads used as threaded adapters:

Veiledende trykkverdier i BAR for gjengede overganger i stål:

MINIMUM BURST PRESSURE (BAR) RecommendedWP BARPIPES MM JIC – JIC JIC - MM JIC - UNF JIC - BSP JIC - NPT

6 2350 1860 1920 1980 2250 3808 2450 1440 1780 1760 2480 380

10 2560 1480 1720 1740 2050 38012 2190 1440 1330 1330 1630 34016 1950 1480 1450 1120 1450 28020 1870 960 1080 1180 1380 28025 1180 830 980 960 1120 19032 1140 720 810 840 960 19038 680 630 600 580 680 180

Flare fittingsYou need tools for fitting the coupling, and both manual and automatic equipment is available. The tool is used to flange the pipe. The pipe is cut at right angles, graduated and flanged to the recommended dimensions in accordance with the following values:

External pipe diam. mm 6 8 10 12 16 20 25 30 38Ext. collar diam.

DMax. 9,0 10,6 12,3 16,7 19,8 24,5 30,2 38,0 44,5

Min. 8,5 10,0 12,0 16,0 19,4 23,4 29,5 37,0 43,5

FLARE TUBE FITTINGS, SAE J514

External pipe diam. mm 6 8 10 12 16 20 25 30 38Ext. collar diam.

DMax. 9,0 10,6 12,3 16,7 19,8 24,5 30,2 38,0 44,5

Min. 8,5 10,0 12,0 16,0 19,4 23,4 29,5 37,0 43,5

MÅL PÅ RUNDE SAE FLENSER 3000 PSI

Dimensions Ext. diam. of flange, mm1/2" 30,23/4" 38,11” 44,4

1 1/4" 50,81 1/2" 60,3

2” 71,4Se denne mot målspesifikasjon flenser i gr. 12, stålslanger.

6000 PSI

Dimension Ext. diam. of flange, mm1/2" 31,83/4" 41,31” 47,6

1 1/4" 54,01 1/2" 63,5

2” 79,4

DIMENSIONS OF ROUND SAE FLANGESMÅL PÅ RUNDE SAE FLENSER 3000 PSI

Dimensions Ext. diam. of flange, mm1/2" 30,23/4" 38,11” 44,4

1 1/4" 50,81 1/2" 60,3

2” 71,4Se denne mot målspesifikasjon flenser i gr. 12, stålslanger.

6000 PSI

Dimension Ext. diam. of flange, mm1/2" 31,83/4" 41,31” 47,6

1 1/4" 54,01 1/2" 63,5

2” 79,4

3000 PSI

6000 PSI

Compare this to the dimensional specification for flanges in group 12, steel hoses.

General information for hoses and hose assemblies - TESS AS

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Transcript of General information for hoses and hose assemblies - TESS AS