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Hydraulic Hose Safety: Recognizing and Correctly Managing Pressure Limits
In hydraulic systems, hoses are one of the critical components that ensure the safe and efficient delivery of fluid. However, for these systems to operate safely, pressure limits must be correctly set and managed. Exceeding pressure limits in hydraulic hoses can lead to system failures, injury to operators and environmental damage. Therefore, knowledge of pressure management is one of the cornerstones of improving the safety of hydraulic systems.
Let's take a look at hydraulic hose pressure limits, basic concepts such as working pressure, burst pressure and test pressure, factors to be considered in hose selection and precautions to be taken for safe use.
Pressure Concepts in Hydraulic Hoses
For the safe use of hydraulic hoses it is necessary to know basic concepts such as working pressure, burst pressure and test pressure.
Working Pressure
The working pressure is the maximum pressure level that the hydraulic hose can safely carry continuously. It is expressed in PSI (Pounds per Square Inch) or bar.
This value ensures safe and efficient operation of the hose within the system. The working pressure helps to maintain the mechanical integrity of the hose, ensuring a long service life.
The working pressure should not be confused with the burst pressure or instantaneous peak pressure of the hose. The burst pressure is the highest limit the hose can withstand and is much higher than the working pressure.
Burst Pressure
The burst pressure is the highest pressure level that the hose can withstand for a short time. This value is usually calculated as four times the working pressure.
However, operating the hose at this pressure is extremely dangerous and can cause accidents. The burst pressure is a test criterion used by manufacturers to measure the durability of the hose, but this value should never be taken as a reference for operational use.
Testing Pressure
Test pressure is a pressure test applied within the scope of safety and quality control processes during the production phase of hydraulic hoses.
Hoses are usually tested by subjecting them to twice the working pressure. Hydrostatic or pneumatic pressure applications are used during this test.
The test pressure helps to detect potential leaks or material defects in the hose. If this test is successful during the production phase, it shows that the hose meets the standards and is reliable.
Factors Affecting Hydraulic Hose Compressive Strength
The pressure limits and durability of hydraulic hoses depend on various factors such as the material used, the design and diameter of the hose and environmental factors.
Hose Construction Material and Reinforcement Layers
Hydraulic hoses are usually made of materials such as synthetic rubber, thermoplastic or PTFE (Polytetrafluoroethylene).
- Synthetic Rubber: Widely used in medium and high pressure applications.
- PTFE Hoses: They have high chemical resistance and can maintain their form even under high pressure.
- Thermoplastic Hoses: It attracts attention with its light structure and flexibility.
In addition, the hoses have single or multi-layer reinforcements inside. These are:
- Braided Reinforcements (Braided Hoses): Ideal for medium pressure applications.
- Spiral Wire Reinforcements (Spiral Hoses): Used in high pressure applications.
These reinforcement layers increase the kink resistance of the hose, increase the compressive strength and protect against mechanical abrasion.
Hose Diameter and Pressure Capacity
The hose diameter has a direct impact on the pressure resistance of the hose.
- While narrow diameter hoses better withstand high pressure levels,
- Large diameter hoses provide more flow volume but are generally suitable for lower pressures.
Correct diameter selection prevents pressure fluctuations in the system and ensures efficient operation of the hydraulic system.
Temperature and Environmental Impacts
Hydraulic hoses can be affected by temperature changes.
- High temperatures can soften the hose material and reduce its compressive strength.
- Low temperatures can cause the hose to harden and lead to cracking.
It is therefore necessary to carefully determine the operating temperature range when selecting a hose.
In addition, external factors such as UV rays, ozone and chemical exposure can also affect the durability of the hose.
Safety Precautions for Hydraulic Hoses
The precautions to be taken to ensure safe operation of hydraulic hoses are as follows:
- Choosing the Right Hose
The hose must comply with the system requirements. Operating pressure, temperature resistance, chemical compatibility and suitability of reinforcement layers must be considered. - Periodic Maintenance and Inspection
Hoses should be subjected to regular visual and mechanical tests. If cracks, bubbles, abrasions or leaks are detected, the hose must be replaced immediately. - Use of Pressure Regulating Devices
- Pressure Relief Valves: Prevents sudden pressure spikes.
- Accumulators: Regulate pressure fluctuations within the system. - Correct Assembly Techniques
Incorrect bending or over-tightening of hoses can lead to damage to the inner layers. The recommended bending radius of the hose must be observed and the connection points must be installed firmly but without excessive force.
Exceeding pressure limits in hydraulic hoses can cause major system failures, personnel injuries and environmental damage. Therefore, it is critical to understand concepts such as working pressure, burst pressure and test pressure correctly and to manage pressure correctly.
Choosing the right hose, regular maintenance and taking safety precautions ensure safe and efficient operation of hydraulic systems. By choosing the most suitable hose for your system, you can both increase efficiency and maximize safety.
