Page 1
Safety Guide
for Selecting and Using Hose Assemblies and Fittings
Page 2
Contents
Introduction ............................................................1
Instructions .............................................................1
Scope .....................................................................1
Fail Safe ...................................................................1
Distribution ...............................................................1
User Responsibility ........................................................2
Contact ...................................................................2
Hose Assembly and Fitting Selection Instructions .........2
Electrical Conductivity .....................................................2
Pressure ...................................................................3
Vacuum ...................................................................3
Temperature ..............................................................3
Fluid Compatibility ........................................................4
Permeation ...............................................................4
Size .......................................................................4
Routing ...................................................................4
Environment ..............................................................4
Mechanical Loads .........................................................4
Physical Damage ..........................................................5
Specications and Standards ...............................................5
Hose Assembly Cleanliness .................................................5
Fire Resistant Fluids ........................................................5
Radiant Heat ..............................................................5
Welding or Brazing ........................................................5
Atomic Radiation ..........................................................5
Aerospace Applications ....................................................5
Use of Hose Assemblies and Fittings ...........................6
Component Inspection ....................................................6
Hose Assemblies and Fitting Assembly or Connections ......................6
Reusable/Permanent ......................................................6
Pre-Installation Inspection .................................................6
Minimum Bend Radius .....................................................6
Twist Angle and Orientation ................................................6
Securement ...............................................................6
Proper Connection of Ports ................................................7
External Damage ..........................................................7
System Checkout ..........................................................7
Routing ...................................................................7
Hose Assemblies and Fitting Maintenance and
Replacement Instructions
Visual Inspection–Hose Assembly/Fitting ...................................7
Visual Inspection - All Other ................................................8
Functional Test ............................................................8
Replacement Intervals .....................................................8
Hose Assembly Inspection and Failure ......................................8
Elastomeric (o-ring) Seals ..................................................9
Refrigerant Gases ..........................................................9
Compressed Natural Gas (CNG) .............................................9
..........................................7
Page 3
INTRODUCTION
WARNING: Failure or improper selection or improper use of Hose Assemblies, or ttings (“Products”) can cause death, personal injury and property
!
—
Fittings thrown o at high speed.
•
High velocity uid discharge.
•
Explosion or burning of the conveyed uid.
•
Contact with suddenly moving or falling objects that are controlled by the conveyed uid.
•
Injections by high-pressure uid discharge.
•
Dangerously whipping Hose Assemblies.
•
Contact with conveyed uids that may be hot, cold, toxic or otherwise injurious.
•
Sparking or explosion caused by static electricity buildup or other sources of electricity.
•
Sparking or explosion while spraying paint or ammable liquids.
•
Electrocution from high voltage electric powerlines.
•
Injuries resulting from inhalation, ingestion or exposure to uids.
•
Note: Before selecting or using any of these Crystal Engineering Products, it is important that you read and follow the instructions below. None of Crystal
damage. Possible consequences of failure or improper selection or improper use of these Products include but are not limited to:
Engineering’s Hose Assemblies and Fittings are approved for in ight aerospace applications.
Crystal Safety Guide for Using Hose Assemblies and Fittings 1
INSTRUCTIONS
Scope
—
This safety guide provides instructions for selecting and using (including installing and maintaining) these products. For convenience, all assemblies made
with Hose are called “Hose Assemblies”. All products commonly called “ttings”, “adapters”, or “couplings” are called “Fittings”. This safety guide is a supplement
to and is to be used with, the specic Crystal Engineering publications for the specic Hose Assemblies and Fittings that are being considered for use.
Fail Safe
Hose Assemblies and Fittings can and do fail without warning for many reasons. Design all systems and equipment in a fail-safe mode, so that failure of the
Hose Assembly or Fitting will not endanger persons or property.
Distribution
Provide a copy of this safety guide to each person that is responsible for selecting or using Hose Assembly and Fitting products. Do not select or use Crystal
Engineering Hose Assemblies or Fittings without thoroughly reading and understanding this safety guide as well as the specic Crystal Engineering publica-
tions for the products considered or selected.
Page 4
Crystal Safety Guide for Using Hose Assemblies and Fittings 2
User Responsibility
Due to the wide variety of operating conditions and applications for Hose Assemblies and Fittings, Crystal Engineering and its distributors do not represent
or warrant that any particular Hose Assembly or Fitting is suitable for any specic end use system. This safety guide does not analyze all technical parameters
that must be considered in selecting a product. The user, through its own analysis and testing, is solely responsible for:
Making the nal selection of the Hose Assembly and Fitting.
•
Assuring that the user’s requirements are met and that the application presents no health or safety hazards.
•
Providing all appropriate health and safety warnings on the equipment on which the Hose Assemblies and Fittings are used.
•
Assuring compliance with all applicable government and industry standards.
•
Contact
Call Crystal Engineering at 1-805-595-5477 or go to crystalengineering.net if you have any questions or require any additional information.
HOSE ASSEMBLY AND FITTING SELECTION INSTRUCTIONS
Crystal Engineering does not manufacture Hose Assemblies and Fittings that are specically designed to be electrically conductive or electrically
nonconductive.
—
Electrical Conductivity
Certain applications require that the Hose Assemblies be nonconductive to prevent electrical current ow. Other applications require the Hose Assemblies/
Fitting interface to be suciently conductive to drain o static electricity. Extreme care must be exercised when selecting Hose Assemblies and Fittings for
these or any other applications in which electrical conductivity or nonconductivity is a factor. The electrical conductivity or nonconductivity of Hose Assem
blies and Fittings is dependent upon many factors and may be susceptible to change. These factors include but are not limited to the various materials used
o make the Hose Assemblies and the Fittings, Fitting nish (some Fitting nishes are electrically conductive while others are nonconductive), manufacturing
t
methods (including moisture control), how the Fittings contact the Hose Assemblies, age and amount of deterioration or damage or other changes, moisture
content of the Hose Assemblies at any particular time, and other factors.
Electrically Conductive Hose Assemblies: Crystal Engineering does not manufacture special Hose Assemblies for certain applications that require electri
cally conductive Hose Assemblies. These Hose Assemblies may be labeled “Electrically Conductive Airless Paint Spray Hose Assemblies” on its layline and
aging. These Hose Assemblies must be properly connected to appropriate Fittings and properly grounded in order to dissipate dangerous static charge
pack
buildup, which occurs in all airless paint spraying applications.
Airless Paint Systems Use: Do not use any Crystal Engineering Hose Assemblies for airless paint spraying. Use of any other Hose Assemblies or failure to
properly connect the Hose Assemblies can cause a re or an explosion resulting in death, personal injury, and property damage.
-
-
Page 5
Crystal Safety Guide for Using Hose Assemblies and Fittings 3
CNG Applications: Crystal Engineering does not manufacture special Hose Assemblies for certain compressed natural gas (“CNG”) applications where static
electricity buildup may occur. These Hose Assemblies must be properly connected to the appropriate Fittings and properly grounded in order to dissipate
dangerous static charge buildup, which occurs in, for example, high velocity CNG dispensing or transfer. Do not use any Crystal Engineering Hose Assemblies
for CNG applications where static charge buildup may occur. Use of Crystal Engineering Hose Assemblies in CNG applications or failure to properly connect
or ground this Hose Assemblies can cause a re or an explosion resulting in death, personal injury, and property damage. Care must also be taken to protect
against CNG permeation through the Hose Assemblies wall.
Aerospace Use: Crystal Engineering does not manufacture special Hose Assemblies for aerospace in ight applications. Aerospace in ight applications em
ploying Hose Assemblies to transmit fuel, lubricating uids and hydraulic uids require a special Hose Assemblies with a conductive inner tube. Use of other
Hose A
ssemblies for in ight applications or failure to properly connect or ground this Hose Assemblies can cause a re or an explosion resulting in death, per-
sonal injury, and property damage. These Hose Assemblies for in ight applications must meet all applicable aerospace industry, aircraft engine, and aircraft
equirements.
r
X
Electrically Nonconductive Hose Assemblies
Certain applications require that the Hose Assemblies be nonconductive to prevent electrical current ow or to maintain electrical isolation. Do not use any
Crystal Engineering Hose Assemblies or Fitting for any such application requiring nonconductive Hose Assemblies, including but not limited to applications
near high voltage electric lines. For these applications that require Hose Assemblies to be electrically nonconductive, including but not limited to applications
near high voltage electric lines, only special nonconductive Hose Assemblies can be used. The manufacturer of the equipment in which the nonconductive
Hose Assemblies is to be used must be consulted to be certain that the Hose Assemblies and Fittings that are selected are proper for the application.
-
Pressure
Hose Assembly selection must be made so that the published maximum allowable working pressure (MAWP) of the Hose Assemblies is equal to or greater
than the maximum system pressure. Surge pressures or peak transient pressures in the system must be below the published maximum allowable working
pressure (MAWP) for the Hose Assemblies. Surge pressures and peak pressures can usually only be determined by sensitive electrical instrumentation that
measures and indicates pressures at millisecond intervals. Mechanical pressure gauges indicate only average pressures and cannot be used to determine
surge pressures or peak transient pressures. Published burst pressure ratings for Hose Assemblies is for manufacturing test purposes only and is no indication
that the Product can be used in applications at the burst pressure or otherwise above the published maximum allowable working pressure (MAWP).
Vacuum
Hose Assemblies used for suction applications must be selected to insure that the Hose Assemblies will withstand the vacuum and pressure of the system.
Temperature
Be certain that uid and ambient temperatures, both steady and transient, do not exceed the limitations of the Hose Assemblies. Temperatures below and
above the recommended limit can degrade Hose Assemblies to a point where a failure may occur and release uid. Properly insulate and protect the Hose As-
semblies when routing near hot objects (e.g. manifolds). Do not use any Hose Assemblies in any application where failure of the Hose Assemblies could result
onveyed uids (or vapors or mist from the conveyed uids) contacting any open ame, molten metal, or other potential re ignition source that could
in the c
cause burning or explosion of the conveyed uids or vapors.
Page 6
Crystal Safety Guide for Using Hose Assemblies and Fittings 4
Fluid Compatibility
Hose Assembly selection must assure compatibility of the Hose Assemblies tube, cover, reinforcement, and Fittings with the uid media used. Actual service
life can only be determined by the end user by testing under all extreme conditions and other analysis.
Permeation
Permeation (that is, seepage through the Hose) will occur from inside the Hose to outside when the Hose is used with gases, liquid and gas fuels, and refriger-
ants (including but not limited to such materials as helium, diesel fuel, gasoline, natural gas, or LPG). This permeation may result in high concentrations of va-
pors which are potentially ammable, explosive, or toxic, and in loss of uid. Dangerous explosions, res, and other hazards can result when using the wrong
or such applications. The user must take into account the fact that this permeation will take place and must not use Crystal Engineering Hose Assem-
Hose f
blies if this permeation could be hazardous. The user must take into account all legal, government, insurance, or any other special regulations which govern
the use of fuels and r
can result from permeation through the Hose Assembly. Permeation of moisture from outside the Hose to inside the Hose will also occur in Hose Assemblies,
regardless of internal pressure. If this moisture permeation would have detrimental eects (particularly, but not limited to refrigeration and air conditioning
systems), incorporation of sucient drying capacity in the system or other appropriate system safeguards should be selected and used.
efrigerants. Never use a Hose even though the uid compatibility is acceptable without considering the potential hazardous eects that
Size
Transmission of power by means of pressurized uid varies with pressure and rate of ow. The size of the components must be adequate to keep pressure
losses to a minimum and avoid damage due to heat generation or excessive uid velocity.
Routing
Attention must be given to optimum routing to minimize inherent problems (kinking or ow restriction due to Hose Assembly collapse, twisting of the Hose
Assembly, proximity to hot objects or heat sources).
Environment
Care must be taken to insure that the Hose Assemblies and Fittings are either compatible with or protected from the environment (that is, surrounding condi-
tions) to which they are exposed. Environmental conditions including but not limited to ultraviolet radiation, sunlight, heat, ozone, moisture, water, salt water,
chemicals
, and air pollutants can cause degradation and premature failure.
Mechanical Loads
External forces can signicantly reduce Hose Assembly life or cause failure. Mechanical loads which must be considered include excessive exing, twist, kink-
ing, tensile or side loads, bend radius, and vibration. Use of swivel type Fittings or adapters may be required to insure no twist is put into the Hose Assembly.
Unusual applica
tions may require special testing prior to Hose Assembly selection.
Page 7
Crystal Safety Guide for Using Hose Assemblies and Fittings 5
Physical Damage
Care must be taken to protect Hose Assemblies from wear, snagging, kinking, bending smaller than minimum bend radius, and cutting, any of which can
cause premature Hose Assembly failure. Any Hose Assembly that has been kinked or bent to a radius smaller than the minimum bend radius and any Hose
Assembly that has been cut or is cracked or is otherwise damaged, should be removed and discarded.
Specications and Standards
When selecting Hose Assemblies and Fittings, government, industry, and Crystal Engineering specications and recommendations must be reviewed and
followed as applicable.
Hose Assembly Cleanliness
Hose Assembly components may vary in cleanliness levels. Care must be taken to insure that the Hose Assembly selected has an adequate level of cleanliness
for the application.
Fire Resistant Fluids
Some re resistant uids that are to be conveyed by Hose Assemblies require use of the same type of Hose Assemblies as used with petroleum base uids.
Some such uids require a special Hose Assemblies, while a few uids will not work with any Hose Assemblies at all. The wrong Hose Assemblies may fail after
a very short service. In addition, all liquids but pure water may burn ercely under certain conditions, and even pure water leakage may be hazardous.
Radiant Heat
Hose Assemblies can be heated to destruction without contact by such nearby items as hot manifolds or molten metal. The same heat source may then initi-
ate a re. This can occur despite the presence of cool air around the Hose Assemblies.
Welding or Brazing
When using a torch or arc-welder in close proximity to hydraulic lines, the hydraulic lines should be removed or shielded with appropriate re resistant materi-
als. Flame or weld spatter could burn through the Hose Assemblies and possibly ignite escaping uid resulting in a catastrophic failure. Heating of plated
ts, including Hose Assemblies Fittings and adapters, above 450°F (232°C) such as during welding, brazing, or soldering may emit deadly gases.
par
Atomic Radiation
Atomic radiation aects all materials used in Hose Assemblies. Since the long-term eects may be unknown, do not expose Hose Assemblies to atomic radia-
tion.
Aerospace Applications
Do not use any Crystal Engineering Hose Assemblies or Fittings for in ight applications. Do not use any Crystal Engineering Hose Assemblies or Fittings with
any other in ight approved Hose Assemblies or Fittings.
Page 8
Crystal Safety Guide for Using Hose Assemblies and Fittings 6
USE OF HOSE ASSEMBLIES AND FITTINGS
Component Inspection
—
Prior to use, a careful examination of the Hose Assemblies and Fittings must be performed. All components must be checked for correct style and size, part
number, and length. The Hose Assemblies must be examined for cleanliness, obstructions, blisters, cover looseness, kinks, cracks, cuts or any other visible
defects. Inspect the Fitting and sealing surfaces for burrs, nicks, corrosion or other imperfections. Do not use any component that displays any signs of non
conformance.
Hose Assemblies and Fitting Assembly or Connections
Do not assemble a Crystal Engineering Fitting on a Crystal Engineering Hose Assembly that is not specically listed by Crystal Engineering for that Fitting.
Do not assemble a Crystal Engineering Fitting on another manufacturer’s Hose Assembly or a Crystal Engineering Hose Assembly on another manufacturers
Fitting unless that combination is expressly approved in the appropriate Crystal Engineering literature for the specic Crystal Engineering product. For Crystal
Engineering Hose Assemblies that do not specify a Crystal Engineering Fitting, the user is solely responsible for the selection of the proper Fitting and Hose
Assembly combination. Crystal Engineering published instructions must be followed for assembling the Fittings on the Hose Assemblies. Contact Crystal
Engineering at 1-805-595-5477, or at crystalengineering.net for further information if required.
Reusable/Permanent
Do not reuse any eld attachable (reusable) Hose Assemblies Fitting that has blown or pulled o a Hose Assemblies. Complete Hose Assemblies may only be
reused after proper inspection. Do not assemble Fittings to any previously used hydraulic Hose Assemblies that was in service, for use in a uid power applica-
tion.
-
Pre-Installation Inspection
Prior to installation, a careful examination of the Hose Assemblies must be performed. Inspect the Hose Assembly for any damage or defects. Do not use any
Hose Assembly that displays any signs of nonconformance.
Minimum Bend Radius
Installation of a Hose Assembly at less than the minimum listed bend radius may signicantly reduce the Hose Assembly life. Particular attention must be
given to preclude sharp bending at the Hose Assembly to Fitting juncture. Any bending during installation at less than the minimum bend radius must be
avoided. If any Hose Assembly is kinked during installation, the Hose Assembly must be discarded.
Twist Angle and Orientation
Hose Assembly installation must be such that relative motion of machine components does not produce twisting.
Securement
In many applications, it may be necessary to restrain, protect, or guide the Hose Assembly to protect it from damage by unnecessary exing, pressure surges,
and contact with other mechanical components. Care must be taken to insure such restraints do not introduce additional stress or wear points.
Page 9
Crystal Safety Guide for Using Hose Assemblies and Fittings 7
Proper Connection of Ports
Proper physical installation of the Hose Assembly requires a correctly installed port connection insuring that no twist or torque is transferred to the Hose As-
sembly when the Fittings are being tightened or otherwise during use.
External Damage
Proper installation is not complete without insuring that tensile loads, side loads, kinking, attening, potential abrasion, thread damage, or damage to sealing
surfaces are corrected or eliminated.
System Checkout
All air entrapment must be eliminated during hydraulic applications, and the system pressurized to the maximum system pressure (at or below the Hose
Assembly maximum allowable working pressure (MAWP)) and checked for proper function and freedom from leaks. Personnel must stay out of potential
hazardous areas while testing and using.
Routing
The Hose Assembly should be routed in such a manner so if a failure does occur, the escaping media will not cause personal injury or property damage.
In addition, if uid media comes in contact with hot surfaces, open ame, or sparks, a re or explosion may occur.
HOSE ASSEMBLIES AND FITTING MAINTENANCE AND REPLACEMENT INSTRUCTIONS
Even with proper selection and installation, Hose Assembly life may be signicantly reduced without a continuing maintenance program. The severity of the
application, risk potential from a possible Hose Assembly failure, and experience with any Hose Assembly failures in the application or in similar applications
—
should determine the frequency of the inspection and the replacement for the Products so that Products are replaced before any failure occurs. A mainte
nance program must be established and followed by the user and, at minimum, must include Visual Inspection, Functional Test, Replacement Intervals,
ssembly Inspection and Failure, and Elastomeric (o-ring) Seals as outlined in the sections below.
Hose A
Visual Inspection–Hose Assembly/Fitting
Any of the following conditions require immediate shut down and replacement of the Hose Assembly:
Fitting slippage on Hose Assemblies;
•
Damaged, cracked, cut or abraded cover (any reinforcement exposed);
•
Hard, sti, heat cracked, or charred Hose Assemblies;
•
Cracked, damaged, or badly corroded Fittings;
•
Leaks at Fitting or in Hose Assembly;
•
Kinked, crushed, attened or twisted Hose Assemblies; and
•
Blistered, soft, degraded, or loose cover.
•
-
Page 10
Crystal Safety Guide for Using Hose Assemblies and Fittings 8
Visual Inspection - All Other
The following items must be tightened, repaired, corrected or replaced as required:
Leaking port conditions;
•
Damaged, cracked, cut or abraded o-rings (internal or external);
•
Excess dirt buildup;
•
Worn clamps, guards or shields; and
•
System uid level, uid type, and any air entrapment (hydraulic applications).
•
Functional Test
Operate the system at maximum operating pressure and check for possible malfunctions and leaks. Personnel must avoid potential hazardous areas while
testing and using the system.
Replacement Intervals
Hose Assemblies and elastomeric (o-ring) seals used on Hose Assembly Fittings and adapters will eventually age, harden, wear and deteriorate under thermal
cycling and compression set. Hose Assemblies and elastomeric seals should be inspected and replaced at specic replacement intervals, based on previous
service life, government or industry recommendations, or when failures could result in unacceptable downtime, damage, or injury risk.
Hose Assembly Inspection and Failure
Hydraulic power is accomplished by utilizing high-pressure uids to transfer energy and do work. Hose, Fittings, and Hose Assemblies all contribute to this
by transmitting uids at high pressures. Fluids under pressure can be dangerous and potentially lethal and, therefore, extreme caution must be exercised
when working with uids under pressure and handling the Hose Assemblies transporting the uids. From time to time, Hose Assemblies will fail if they are not
replaced at proper time intervals. Usually these failures are the result of some form of misapplication, abuse, wear, or failure to perform proper maintenance.
When Hose Assemblies fail, generally the high-pressure uids inside escape in a stream which may or may not be visible to the user. Under no circumstances
should the user attempt to locate the leak by “feeling” with their hands or any other part of their body. High-pressure uids can and will penetrate the skin
and cause severe tissue damage and possibly loss of limb. Even seemingly minor hydraulic uid injection injuries must be treated immediately by a physician
with knowledge of the tissue damaging properties of hydraulic uid. If a Hose Assembly failure occurs, immediately shut down the equipment and leave the
area until pressure has been completely released from the Hose Assembly. Simply shutting down the hydraulic pump may or may not eliminate the pressure
in the Hose Assembly. Many times check valves, etc., are employed in a system and can cause pressure to remain in a Hose Assembly even when pumps or
equipment are not operating. Tiny holes in the Hose Assembly, commonly known as pinholes, can eject small, dangerously powerful but hard to see streams
of hydraulic uid. It may take several minutes or even hours for the pressure to be relieved so that the Hose Assembly may be examined safely. Once the
pressure has been reduced to zero, the Hose Assembly may be taken o the equipment and examined. It must always be replaced if a failure has occurred.
Never attempt to patch or repair a Hose Assembly that has failed. Consult the nearest Crystal Engineering distributor or Crystal Engineering for Hose Assembly
replacement information. Never touch or examine a failed Hose Assembly unless it is obvious that the Hose Assembly no longer contains uid under pressure.
The high-pressure uid is extremely dangerous and can cause serious and potentially fatal injury.
Page 11
Crystal Safety Guide for Using Hose Assemblies and Fittings 9
Elastomeric (o-ring) Seals
Elastomeric (o-ring) seals will eventually age, harden, wear and deteriorate under thermal cycling and compression set. Elastomeric seals should be inspected
and replaced.
Refrigerant Gases
Special care should be taken when working with refrigeration systems. Sudden escape of refrigerant gases can cause blindness if the escaping gases contact
the eye and can cause freezing or other severe injuries if it contacts any other portion of the body.
Compressed Natural Gas (CNG)
Do not inspect CNG systems using matches, candles, open ame or other sources of ignition. Leak check solutions should be rinsed o after use.
Page 12
5215.A
© 2013 Crystal Engineering Corporation
708 Fiero Lane, Suite 9, San Luis Obispo, California 93401-8701
Loading...