Hydraulic Hoses - Keeping the Mining Industry Moving - HoseMate

How many machines on your site are hydraulically operated?

If you are looking for more details, kindly visit HT-HYDRAULICS.

One of the greatest challenges in the mining industry is balancing an increase in output productivity, while minimising machine downtime, and keeping equipment well-maintained. This is a tricky task, with many systems contingent on each other, causing a knock-on domino effect if one fails. So, what can be done to make this process easier?

Don’t stop the flow with hydraulic hoses!

A hydraulic hose plays a vital role in keeping mining operations running smoothly. Featured on most machinery – from surface to underground – the humble hose can make or break a system. Hydraulic hoses are typically featured on the following industrial mining equipment:

• Dozers

• Haul trucks

• Hydraulic shovels

• Scrapers

• Continuous miners

• Drills

Advances in industrial processes and hydraulic powered mining equipment now demand better quality hoses, higher pressure flow, and advanced assemblies. Hoses are pushed to their limits when companies demand more out of them to meet productivity goals.

Purchasing quality hydraulic hoses and fittings for mining activities can be a costly investment, so how can you extend its service life and ensure you get the most out of the hose?

What is a hydraulic hose service life?

Hydraulic hose service life terminates when the hose is not safe, there is a heightened likelihood of failure, and generally the hose is no longer fit for use. Generally, a hose lifespan is 8 years. This is of course dependant on its operating conditions, maintenance, and ensuring a correct assembly. The NSW Resources Regulator highlights key factors that an reduce the service life of a hydraulic hose – these include:

• External damage: Damage to the outer hose layer caused by abrasion, impact, rubbing

• Environmental factors: The effect of extreme temperatures, UV, chemicals

• Mechanical loads: This includes vibration, tensile, shear

• Incorrect routing: Not adhering to minimum bend radius, twisting, orientation, equipment extension, inappropriate fittings

• Fluid: Incompatible with hose, velocity, contamination

• Accidental damage caused by: Falling debris, crushes, fires, collisions

• Corrosion of hydraulic fittings: alkalinity, acidic water, coal and sulphur

To maximise a hydraulic hose service life, and ensure your equipment is producing an effective output, hose assemblies should comply with SAE J or ISO -2. These hydraulic hose assembly standards provide guidance against poor design, a leading factor in premature hose failure, and suggest best practice procedures for hose fabrication, fittings, and equipment.

How to maximise hydraulic assembly efficiency

As the humble hose drives a significant number of mining operations, it is important that your hydraulic hose assembly is maximised to achieve an efficient output. No matter what machine, it all starts at the beginning – planning your system. You may be asking questions like “how to choose the right hydraulic hose”, “what hydraulic fittings do I need”, and “what preventative maintenance can I perform to enhance the performance of a hydraulic hose?”.

Firstly, how do I choose the right hydraulic hose?

Selecting a hydraulic hose and fittings to for your assembly is dependent on the circumstance in which the hose will be operating. For example, underground mining operations might demand a FRAS (fire-retardant, anti-static) certified hydraulic hose, and haul trucks require a large width hose. When choosing hydraulic hoses remember the STAMPED acronym; Size, Temperature, Application, Material, Pressure, Ends, Delivery.

Routing your hydraulic hose assembly is now the next daunting task. This involves planning the path of the hoses according to assembly requirements. Mining operations often require complex assemblies, processes, and systems – so it is important to be aware of minimum bend radius requirements, abrasion points, and twisting.

Secondly, what preventative maintenance can I perform on my hydraulic hose?

Hydraulic hose repair for the mining industry is a costly expenditure – time and money are power – and waiting for a repair to reach your remote site can cause a significant loss in production. Routine inspections play a vital role in identifying the potential for premature hose failure before it occurs. Failures caused by abrasion, incorrect clamping, and flexing can all be resolved when identified during a preventive maintenance inspection. Mine machine operators should also be trained on identifying issues within a hydraulic system and reporting these to site supervisors for immediate action to be taken.

Find out the top 5 causes of hydraulic hose failure to look out for during your next site inspection.

So where does HoseMateTM fit in?

HoseMateTM is an engineered control against hydraulic hose failure caused by external abrasion. External abrasion is identified as one of the leading causes of failure. Current ‘statistics on the failure of flexible hose assemblies in workplaces indicate that the major mechanism of hose failure is abrasion followed by stresses inducing pin holing near the hose ends.’

HoseMateTM is an innovative hose clamp designed to separate hydraulic hose hoses, while allowing flexible hose movement through 360-degree rotation, and no requirement of being mounted on a stabilising surface.

We encourage HoseMateTM to be fitted during hose routing and installation. HoseMateTM can also be integrated into existing mining processes where abrasion has been identified as an issue during routine maintenance inspection.

The company is the world’s best Hose Fittings for Mining Machinery supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Hydraulic systems are the backbone of modern industries, with an extensive range of applications, from precisely controlled conveyor systems and assembly lines to the operation of industrial robots and driving heavy-duty machinery and equipment. At the heart of these systems are hydraulic hose fittings, essential components responsible for securing leak-tight connections in hydraulic hose assemblies.

Available hydraulic fittings come in a variety of materials, sizes, sealing methods, temperature and pressure ratings, and thread types. Understanding these variations is key to selecting the right fitting for a specific hydraulic application. This article seeks to provide you with a comprehensive overview of hydraulic hose fittings.

Types of Hydraulic Fittings

The hydraulic hose fittings supplied by Marshall Equipment vary depending on fitting material, installation method, sizes and shapes, thread types, and sealing methods, among other factors. With that in mind, let’s look at the common classifications of hydraulic fittings:

Permanent vs. Reusable Fittings

Permanent hydraulic hose fittings, also known as crimped fittings, are designed for one-time use, creating a robust and long-lasting leak-tight seal essential for high-pressure and critical hydraulic applications. They are also easier and faster to install, which makes them highly suitable for fluid power applications. Note, that to secure these fittings in a hydraulic hose assembly, you will require a stationary crimping machine or a portable hydraulic crimper.

On the other hand, reusable or field-attachable hydraulic hose fittings can be assembled and disassembled as many times as necessary using simple hand tools. They include a nipple and socket and can be installed anywhere without the need for crimping equipment. These fittings provide a versatile solution for hydraulic systems requiring frequent adjustments or immediate replacements in a breakdown situation, but these reusable fittings are only available for certain types of hydraulic hoses.

Sealing Methods

The choice of sealing elements in hydraulic hose fittings is crucial in ensuring secure and leak-free hydraulic connections. Hydraulic sealing elements are primarily divided into three categories, with the appropriate sealing type depending on the pressure rating of the intended hose fitting application:

1. Metal-to-Metal Seals: Metal-to-metal seals are often preferred due to their ability to withstand high working pressure and extreme environmental conditions, offering a reliable solution for heavy-duty hydraulic applications.
2. Tapered Threads Sealing: Tapered threads provide self-sealing capabilities, in which the male and female threads in hydraulic fittings compress and wedge together, creating a robust and leak-tight seal.
3. Soft Seals: Soft seals, such as gaskets and O-rings, are well-suited for low-pressure applications and can readily accommodate slight misalignments.

The appropriate sealing type depends on the pressure rating of the intended hose fitting application.

Fitting Types

Here are some of the most common types of hydraulic hose fittings, with varying materials, sealing methods, and thread types.

• Joint Industry Council (JIC) Fittings are metal-to-metal sealing type hydraulic fittings with a machined 37-degree sealing surface angle (flare). They include parallel threads and are widely used in fluid conveyance hydraulic systems due to their exceptional sealing capabilities. They are usually manufactured in carbon steel, brass, stainless steel, and nickel alloys.
• National Pipe Thread (NPT) Fittings include American-standard tapered threads that offer self-sealing capabilities, providing leak-proof hydraulic connections for fluid transfer applications. They are available in brass and iron for low-pressure hydraulic applications and stainless and carbon steel for applications requiring vibration resistance and higher working pressures.
• O-Ring Face Seal (ORFS) Fittings are versatile hydraulic hose fittings that use an O-ring to create a leak-tight seal between the hose fitting and mating surface. They are ideal for high-pressure hydraulic systems requiring frequent maintenance of hydraulic hose assemblies or periodic replacement of system components. They are commonly manufactured in stainless steel.

Learn more about hydraulic hose fitting types in How To Identify Hydraulic Hose Fittings.

How to Choose a Hydraulic Hose Fitting?

Selecting the right hydraulic hose fitting involves several considerations to ensure the optimal performance and longevity of your hydraulic system. Proper selection is crucial for maintaining secure connections, preventing leaks, and ensuring overall system efficiency and safety.

1. Determine the Application Requirements:  Before selecting hydraulic hose fittings, you should have a comprehensive understanding of the specific requirements of your hydraulic system. This includes knowing the maximum pressure the system will be handling, its operating temperature range, and the type of hydraulic fluid it will be conveying. These factors are fundamental in determining the material, sealing method, thread type, and size of the hose fittings you will use to ensure optimal performance and longevity of your hydraulic system.
2. Select the Fitting Material: The material of the hydraulic hose fittings plays a pivotal role in their performance and durability. When choosing a fitting material, consider the conditions of the intended working environment, including the level of exposure to corrosive agents, maximum and minimum ambient temperatures, and the possibility of physical hazards. Materials such as carbon steel, stainless steel, brass, and plastics each offer distinct advantages in different environments, making fitting material selection critical to balance cost-efficiency and system reliability.
3. Identify the Fitting Type: The choice between permanent and reusable hydraulic hose fittings hinges on the design of your hydraulic hose assembly and the anticipated need for future modifications. Permanent fittings, which are crimped onto hydraulic hoses, offer a robust and long-lived leak-proof connection ideal for critical or high-pressure applications.  On the contrary, reusable fittings allow for easier disassembly and reassembly, offering system maintenance and reconfiguration flexibility. Additionally, the sealing type—whether metal-to-metal, soft seal or tapered thread—must be selected based on the pressure requirements of your hydraulic system and compatibility with the system’s hydraulic fluid.
4. Compatibility: Ensuring compatibility between the selected hydraulic hose fittings and existing hydraulic hoses and other components of your hydraulic system is essential for creating a cohesive and efficient system. This involves checking the fitting sizes, thread types, and materials against those of the hoses and other components in the hydraulic system. Incompatibility can lead to fluid leaks, reduced system efficiency, and even system failure under high working pressures.

Note: Compatibility extends beyond physical dimensions to include chemical compatibility between the fitting material and hydraulic fluid being conveyed, further emphasizing the need for a thorough hose fitting selection process to maintain system integrity and optimal performance.

Adhering to Safety Standards and Regulations in Hydraulic Hose Fittings Selection

Rigorous safety standards and regulations govern the selection and use of hydraulic hose fittings to ensure safe and efficient hydraulic system performance. Key standards include those established by the International Organization for Standardization (ISO) and the Society of Automotive Engineers (SAE), which provide guidelines on dimensions, pressure ratings, and compatibility requirements.

Adhering to these standards helps prevent failures and ensures system integrity. Hydraulic engineers and technicians must stay updated on these regulations, as compliance not only enhances system safety but also ensures legal adherence in industrial applications, mitigating equipment/personnel risks and enhancing operational reliability.

Ensuring the Right Fit for Optimal Performance

A comprehensive understanding of the different materials, sealing methods, and thread types used in hydraulic hose fittings will help you identify the right fitting for your hydraulic system, ensuring safe and efficient operation. By carefully considering factors such as application requirements, fitting materials, fitting types, and compatibility, you can make informed decisions that will enhance the performance and longevity of your hydraulic system.

For further guidance on hydraulic fittings, be sure to check out our detailed article on How to Identify Hydraulic Hose Fittings. This resource provides additional insights and tips to help you confidently navigate the selection process.

Selecting the right hydraulic hose fitting is a crucial step toward a safe and durable hydraulic hose assembly and secured system. Our experts can not only help you choose the right fitting but also handle the assembly for you. Visit our hydraulic hose assembly services page for more information.

If you want to learn more, please visit our website Hydraulic Hose Fitting for Metallurgical and Petroleum Equipment.