Design and Specification of Hose Assemblies Published by NAHAD – The Association for Hose & Accessories Distribution, Inc. (This page intentionally left blank) 2 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) Table of Contents Section 1 – Scope & How to Use This Document .............. 7 1.1 Scope .......................................................................................................... 7 1.2 How to Use This Document .......................................................................... 8 1.3 Thanks and Recognition .............................................................................. 9 1.4 History of Changes ...................................................................................... 9 Section 2 – Application Requirements – STAMPED ....... 11 2.1 Purpose ...................................................................................................... 11 2.2 General ...................................................................................................... 11 2.3 Directions ................................................................................................... 11 2.4 Critical Applications ................................................................................ 16 Section 3 - Hose Assembly General Information ............ 17 3.1 Scope ......................................................................................................... 17 3.2 Hose Constructions – Tube, Reinforcement, Cover ................................... 17 3.3 Hose Characteristics – Flexibility & Bend Radius, Suction & Vacuum, Electrical Characteristics ................................................................................. 19 3.4 Hose Routing ............................................................................................. 20 Section 4 – Corrugated Metal Hose ................................... 23 4.1 General ..................................................................................................... 23 4.2 STAMPED ................................................................................................. 24 4.3 Hose Construction ..................................................................................... 27 4.4 Pressure Rating ......................................................................................... 30 4.5 Corrugated Metal Hose Assembly Dimensions ........................................... 31 4.6 Corrugated Metal Hose Fittings .................................................................. 36 4.7 Corrugated Metal Hose Attachments & Common Accessories ................... 40 4.8 Attachment Methods .................................................................................. 42 4.9 Testing Procedures for Corrugated Metal Hose ........................................ 45 Section 5 - Industrial Hose ................................................. 47 5.1 General ...................................................................................................... 47 5.2 STAMPED ................................................................................................. 48 5.3 Industrial Hose Assembly – Component Selection Chart and Pressure Ratings Chart ................................................................................................... 51 5.4 Hose Data Sheets ...................................................................................... 55 5.5 Industrial Hose Fittings ............................................................................... 69 5.6 Industrial Hose Attachments...................................................................... 81 5.7 Custom-Made Hose ................................................................................... 87 5.7.1 Background .................................................................................................... 87 5.7.2 Application Requirements – STAMPED .................................................... 92 5.7.3 Custom Hose ................................................................................................ 95 5.7.4 Custom Hose Ends ....................................................................................... 97 5.8 Ducting ...................................................................................................... 99 5.8.1 General .......................................................................................................... 99 5.8.2 Types of Duct Construction ...................................................................... 100 5.8.3 Ends for Ducting .......................................................................................... 105 5.8.4 Ducting Accessories .................................................................................. 108 Section 6 - Composite Hose ............................................. 113 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 3 6.1 General .................................................................................................... 113 6.2 STAMPED ............................................................................................... 114 6.3 Hose Materials and Construction ............................................................ 116 6.4 Composite Hose Fittings .......................................................................... 117 6.5 Testing Procedures for Composite Hose ................................................. 117 6.6 Installation and Usage for Composite Hose ............................................ 119 Section 7 - Hydraulic Hose ............................................... 123 7.1 Introduction to Hydraulics ........................................................................ 123 7.2 STAMPED ............................................................................................... 127 7.3 Hose and Hose Selection ........................................................................ 130 7.4 Coupling Selection .................................................................................. 135 7.5 Hose Assemblies: Length, Orientation, Measurement & Testing ............ 138 7.7 Cleanliness Considerations ...................................................................... 149 Section 8 Fluoropolymer Hose ........................................ 151 8.1 General ................................................................................................... 151 8.2 STAMPED ............................................................................................... 153 8.3 Measurements for Fluoropolymer Hose Assemblies ................................. 155 8.4 Fluoropolymer Hose Fittings and Attachments ......................................... 157 8.5 Performance Characteristics ................................................................... 158 8.6 Hose Assembly Length Determination For Various Movements ............... 159 8.7 Hose Routing – Fluoropolymer Hose ........................................................ 165 8.8 Assembly Methods ................................................................................... 168 8.9 Testing Procedures for Fluoropolymer Hose ........................................... 169 Section 9 – Testing Procedures ....................................... 173 9.1 Purpose .................................................................................................... 173 9.2 Testing Procedures for Industrial Hose ................................................... 173 9.3 Testing Procedures for Composite Hose ................................................. 178 9.4 Testing Procedures for Hydraulic Hose ................................................... 179 9.5 Testing Procedures for Corrugated Metal Hose ...................................... 183 9.6 Testing Procedures for Fluoropolymer Hose ........................................... 188 9.7 Calibrations .............................................................................................. 190 9.8 Test Documentation ................................................................................. 190 9.9 Other Documentation ............................................................................... 190 Section 10 – Quality Plan ................................................. 193 10.1 Purpose .................................................................................................. 193 10.2 Sampling Plan ........................................................................................ 193 10.3 Material Receiving Inspection ................................................................. 194 10.4 Hose Assembly Dimensional Inspection (if applicable) ......................... 194 10.5 Storage (Labeling, Environment, Time) .................................................. 195 Section 11 – Assembly Identification, Cleaning and Packaging .......................................................................... 197 11.1 Purpose .................................................................................................. 197 11.2 Hose Assembly Markings ....................................................................... 197 11.3 Cleaning ................................................................................................. 198 11.4 Packaging .............................................................................................. 202 Section 12 – Installation and Handling ........................... 203 12.1 General .................................................................................................. 203 4 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 12.2 Safety & Environmental Considerations .................................................. 203 12.3 Hose Installation and Replacement........................................................ 205 12.4 Maintenance Inspection ......................................................................... 209 Section 13 – Definitions .................................................... 217 Section 14 – Appendices .................................................. 235 Appendix A – Pressure Conversion Chart ..................................................... 235 Appendix B – Additional Conversion Charts .................................................. 238 Appendix C – Hose Materials ........................................................................ 239 Appendix D – Nomographic Flow Chart ......................................................... 245 Appendix E - Temperature Derating and Limitations ..................................... 246 Appendix F – Coupling Thread Configurations .............................................. 248 Appendix G – Hydraulic Audit List ................................................................. 265 Appendix H – Relevant ARPM (was RMA) Publications ................................ 266 Appendix I – References ............................................................................... 267 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 5 (This page intentionally left blank) 6 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) Section 1 – Scope & How to Use This Document 1.1 Scope This NAHAD Hose Specification Guideline is intended to complement existing industry standards and federal regulations. This document aids in the selection and recognition of suitable hose assemblies, including those using industrial, hydraulic, composite, corrugated metal and fluoropolymer hose. This document is not intended to prohibit either supplier or customer from attaching additional requirements for hose, couplings or hose assemblies, if necessary, to satisfy the application. It is the responsibility of the fabricator and user to separately qualify these applications and their unique requirements necessary to ensure performance capability. The fabricator should be able to prove the safety, quality and reliability of the fabrication process and/or the hose assembly. This document assumes that all equipment used in the fabrication of the hose assembly has been properly maintained, and calibrated on an annual basis. There are specific applications that require additional design, fabrication installation and maintenance considerations over and above the requirements set forth in these Hose Assembly Guidelines. Please see Section 2.4 and Appendix I of this document for further information. DISCLAMER: Hose, hose fittings and hose couplings come in various sizes and designs. Although there are standards published by manufacturers and independent testing organizations, such as ANSI, ASTM, UL, SAE and ARPM, which relate to hoses and hose fittings, there are no generally recognized standards for hose assemblies. NAHAD, The Association for Hose and Accessories Distribution, has published these Guidelines in order to create a single reference work that compiles information of value to NAHAD members, manufacturers and customers in developing hose assemblies that meet specific individual needs. To the extent that each assembly has unique characteristics, it must be custom designed, engineered and tested. Hopefully, these Guidelines will be useful in the process. In compiling standards and recommendations published by others and in developing these Guidelines, NAHAD has not and will not engage in independent testing or verification of the information provided to it. Users of these Guidelines should not and cannot rely on these Guidelines as a standard, certification or approval of the data published herein. NAHAD does not assume and expressly declines and denies any and all liability for any product failures, damages or injuries that result in any way from utilization of these Guidelines or products based on these Guidelines. The NAHAD Guidelines incorporate pressure recommendations, corrosion recommendations and temperature recommendations published by hose and coupling manufacturers. NAHAD has not independently verified these recommendations and specifically disclaims any and all liability, direct or indirect, for any failures, damages or injuries resulting in whole or in part from the failure of any product, including hoses, fittings, and assemblies described in the Guidelines. © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD). All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transcribed, in any form or by any means, electronic, mechanical or photocopying or otherwise, without the prior written permission of NAHAD. © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 7 1.2 How to Use This Document The following are the recommended procedures on how to use the NAHAD Hose Assembly Specification Guidelines: Description Section Number 1 This document recognizes that all hose assemblies are made up of at least two to three components: the hose, end connections, and Section 1 method of attachment. The method of attachment and end Scope connection varies depending on the hose selected. 2 The end user/customer/customer service/sales person should use Section 2 STAMPED to gather all the required application information to STAMPED proceed with an assembly selection. 3 For Industrial Hose assemblies, proceed to the Component Section 5 Selection Chart. Use the chart to select the appropriate hose, end Hose Assembly connections and method of attachment recommended. Component Selection Chart 4 Hose assembly pressure ratings vary by hose, fitting, and attachment combinations, and are always rated at the lesser of the hose, fittings, and attachment method used. * The Chart represents a guide to the assembly working pressure that can be expected from the combination of hose, fittings, and attachment methods, assuming the recommended assembly fabrication guidelines have been followed and the components Section 5 meet typical industry standards. Pressure Ratings Chart Increased assembly pressure ratings may be achieved using higher performance components available from NAHAD Hose Safety Institute manufacturer members. For assembly pressure ratings higher than those listed in this chart, please consult a NAHAD Hose Safety Institute Distributor. (Note: special tests may be required.) 5 More detailed information on hose, couplings, attachments, etc. for Sections 4-8 all hose groups can be found in Sections 4-8, Hose Assembly Hose Assembly Components and Data Sheets. Components and Data Sheets 6 Once the assembly is selected, additional information on fabrication processes can be found in the NAHAD Hose Assembly Fabrication Sections 9 - 13 Guide, which includes recommended assembly procedures, Assembly testing, quality limitations, and warnings. plan, shipping, handling, labeling, etc. The rest of this document includes related information on assembly testing, quality plan, shipping & handling, safety issues, etc. * The ARPM requires that hose working pressures include a safety factor commensurate with their intended application. Most hoses are required to meet a 4x safety factor, except the following: Water hose rated under 150 PSI requires a 3x safety factor; Steam hose requires a 10x safety factor; and hose conveying gas in a liquid state requires a 5x safety factor. (For example: a 150 PSI-rated air hose has a 4x safety factor and must be successfully tested to a minimum of 600 PSI.) Never exceed the working pressure of the lowest rated component in the hose system. Maximum working pressure includes the highest pressure the system will experience, such as spikes, surges, and water hammer effects. (For example: If a system consists of a hose rated to 150 PSI and the couplings are rated to 500 PSI, the system should never be used in excess of 150 PSI.) 8 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 1.3 Thanks and Recognition NAHAD wishes to acknowledge the contributions of many organizations which have made this document possible. In particular, the International Fluid Power Society (IFPS) has made significant contributions to Section 7 Hydraulic Hose; many portions of their Connector and Conductor Study Manual (rev. 4/1/11) were used by permission in whole, or in part. 1.4 History of Changes 1995 NAHAD commits to take on the multi-year challenge of creating a comprehensive set of performance recommendations for the Specification, Design and Fabrication of Industrial, Hydraulic, Fluoropolymer, Corrugated Metal and Composite hose assemblies. Scores of volunteer member engineers are recruited to serve on five different technical teams to draft what will become NAHAD’s Hose Assembly Guidelines. The comprehensive 420-page document is produced and presented to the membership at the 2000 Convention in Monterey, CA. 2003 The NAHAD Board appoints a new Standards Committee to re-craft the Guidelines to be more useful for members and end-users. 2005 Version 1: Hose Assembly Specification Guides are created for Corrugated Metal, Industrial, Composite, Hydraulic and Fluoropolymer Hose assemblies. These are made available for purchase and use with customers, for supporting internal training, and for providing guidance for related hose assembly technical and business processes. 2008-9 Custom Hose Guide added 2008 Ducting Guide added 2009 2010-12 NAHAD creates the Hose Safety Institute to formalize the work of driving safety, quality and reliability of hose assemblies. The Hose Assembly Guidelines are updated and republished as this document, the Hose Safety Institute Handbook. Changes: Materials updated and all 7 Specification manuals plus Design Guides for industrial, hydraulic, composite, fluoropolymer and corrugated metal hoses integrated in one master document. © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD) 9 (This page intentionally left blank) 10 © Copyright 2012 by the Association for Hose & Accessories Distribution, Inc. (NAHAD)