HYDRAULIC / PNEUMATIC

JOSEPH J. PANDOLFO N.A.A.R.S.O. 2017

joeboy@ptd.net 570-350-3359

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BEFORE YOU DO ANYTHING ON OR WITH A

PNEUMATIC/HYDRAULIC SYSTEM

DO THE FOLLOWING!!!

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LOCK OUT/TAG OUT DE ENERGIZE IT

BLEED IT OFF KILL IT DEAD.

OR IT WILL KILL YOU!!!

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WHAT IS IT?

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NOT WHAT YOU THOUGHT.

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ANSI NFPA/JIC T2.24.1 + ISO 4413

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A high-pressure jet that sprays hydraulic oil

constitutes a physical danger and an

environmental problem

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HYDRAULIC SYSTEM: OIL FROM A TANK FLOWS THROUGH A

TUBE OR PIPE,INTO A PUMP. THE PUMP INCREASES THE PRESSURE OF

THE OIL. THE OIL IS MOVED TO A CYLINDER MOVING A PISTON,THERE BY DOING A JOB

OR MOVING A LOAD.

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PNEUMATIC SYSTEM AIR FROM THE ATMOSPHERE IS

PULLED INTO AN AIR COMPRESSOR. THE COMPRESSOR INCREASES THE

PRESSURE OF THE AIR IT IS DISCHARGED TO A PISTON MOVING IT TO DO A JOB,OR MOVE

A LOAD.

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BIG OR SMALL THE’RE ALL THE SAME. FLUID SYSTEM

OIL PUMP/AIR COMPRESSOR A DEVICE EITHER A PISTON OR A ROTATING

MEMBER DRIVEN BY THE FLUID. PIPING AND CONTROLS

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PRESSURE; FORCE PER UNIT AREA

[POUNDS PER SQUARE INCH]

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Pressure Gage

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PRESSURE AND TEMPERATURE 1/7/2017 NAARSO 21

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The HYDRAULIC

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prime mover

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FLUID PUMP MECHANICAL ENERGY IS CONVERTED INTO

FLUID ENERGY

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hydraulic (pressure) energy

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FLUID MOTORS FLUID ENERGY IS CONVERTED TO

MECHANICAL WORK.

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ACTUATORS DEVICE THAT CONVERTS FLUID ENERGY TO

MECHANICAL

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PARTS OF THE SYSTEM PUMP

OIL RESERVOIR INTAKE FILTER

PRESSURE GAGE RELIEF VALVE

OUT PIPING

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HYDRAULIC SYSTEMS PUMPS

1.GEAR-TYPE 2.VANE-TYPE

ROTARY PISTON-TYPE 4.RECIPROCATING PISTON

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HYDRAULIC FLUIDS 1.PETROLEUM-BASE FLUIDS 2.SYNTHETIC-BASE FLUIDS

3.WATER

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FUNCTION OF FLUID 1.TRANSMISSION OF FLUID POWER

2.MEANS OF LUBRICATION 3.ACTS AS SEALANT

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TYPES OF 1.PENNSYLVANIA/PARAFFIN-BASE OILS

2.GULF COAST/NAPHTHENIC&ASPHALTIC 3.MIDCONTINENT/MIXED-BASE OILS

CONTAIN BOTH NAPHTHENIC &PARAFFIN

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SYNTHETIC-BASE FIRE RESISTANT

SLUDGE/GUM REDUCED LITTLE EFFECT ON TEMPERATURE

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DIRECTIONAL CONTROL VALVES FUNCTION OF VALVE IS TO DIRECT OIL OR

AIR TO A GIVEN PLACE IN A SYSTEM.

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TYPES OF VALVES TWO WAY

TWO PORTS/TWO PASSAGES

THREE WAY THREE PORTS/THREE PASSAGES

FOUR WAY 4/4

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MANUAL CONTROL BY HAND OR FOOT/BODY PART

MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN

ELECTRICAL OPERATION MOTOR/SOLENOID

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PRESSURE CONTROL FUNCTION OF TO CONTROL PRESSURES IN

THE FLUID POWER SYSTEM. 1.RELIEF VALVE

2.REDUCING VALVE 3.SEQUENCE VALVE UNLOADING VALVE

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FLOW CONTROLS FUNCTION OF TO CONTROL THE VOLUME OF FLUID THAT PASSES`A CERTAIN POINT

IN A CIRCUIT. USED TO CONTROL

SPEED

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MANUAL CONTROL BY HAND OR FOOT/BODY PART

MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN

ELECTRICAL OPERATION MOTOR/SOLENOID

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TYPES OF 1.METERING-IN

2.METERING-OUT 3.METERING BOTH DIRECTIONS

4.BLEED OFF

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ACCUMULATORS STORAGE DEVICE

BATTERY CHEMICAL TO ELECTRICITY

PIPE WITH CAP ACTS AS A CUSHION

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HYDRAULIC ACCUMULATORS

1.SHOCK ABSORBER 2.OIL MAKE UP

3.COMPENSATE FOR LEAKAGE 4.SOURCE OF EMERGENCY POWER

5.STEADY DELIVERY PRESSURE 6.TRANSFER BARRIER BETWEEN OIL AND

OTHER FLUID

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TYPES OF 1.WEIGHT-LOADED 2.SPRING-LOADED

3.AIR OR GAS NONSEPARATOR/SEPARATOR[DIAPHRAGM]

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TYPES OF CYLINDERS; 1.SINGLE -ACTING 2.SPRING -RETURN

3.DOUBLE-END 4.TANDEM 5.DUPLEX

TWO PISTONS/ROD INSIDE

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ROTATING & NONROTATING CYLINDERS

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safety valve

• n. • A valve in a pressure container, as in a

vessel, that automatically opens when pressure reaches a dangerous level.

• An outlet for the release of repressed energy or emotion.

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Safety valve

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The PNEUMATIC

system

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AIR COMPRESSORS 1.POSITIVE-DISPLACEMENT/PRESSURE

2.VELOCITY/DYNAMIC

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PARTS OF SYSTEM; AIR INTAKE

AFTERCOOLER WATER SEPARATOR

AIR RECEIVER AIR DISHARGE

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Air Receiver

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Aftercooler

Filter, Regulator, Lubricator

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PNEUMATIC MOTOR 1.ROTARY

2.RECIPROCATING

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AIR FILTERS REMOVE ALL FOREIGN MATTER

REGULATORS REDUCES OR REGULATES PRESSURE

LUBRICATORS STORES OIL

INJECTS OIL MIST OR FOG

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AIR FILTERS,REGULATORS, LUBRICATORS

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PIPING 1.RIGID

2.SEMI-RIGID/TUBING 3.FLEXIBLE/HOSE

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Hose Routing

Replacement hoses must be restrained,

protected, or guided (using clamps),

to minimize risk of damage due to excessive flexing and

whipping.

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Flared tube

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THE BAD GUYS DIRT HEAT

MISAPPLICATION IMPROPER FLUIDS

FAULTY INSTALLATION MAINTENANCE

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THE SAFE WAY IS THE ONLY WAY!

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A pressure vessel • a closed, rigid container designed to hold gases

or liquids at a pressure different from the ambient pressure.

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other examples of pressure vessels are:

• diving cylinder, recompression chamber, distillation towers, autoclaves nuclear reactor vessel, habitat of a space ship, habitat of a submarine, pneumatic reservoir, hydraulic reservoir under pressure, rail vehicle airbrake reservoir, road vehicle airbrake reservoir and storage vessels for liquefied gases such as ammonia, chlorine, propane, butane and LPG

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How about now?

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Date of 1980 32 years old?

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VARIOUS TYPES OF CORROSION

• ATMOSPHERIC • GALVANIC • UNIFORM/GENERAL • PITTING • STRESS CORROSION CRACKING • CREVICE CORROSION • HIGH TEMPERATURE

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A RECIPE FOR RUST " Take 2 parts iron (FE).

Combine with 3 parts Oxygen (O). Add water and salt to taste.

Increase temperature to speed up process.

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© QSI Training Services, Inc. 2004 all rights reserved 1/7/2017 NAARSO 83

MOTOR

8 QSI Training Services 2004 all rights reserved

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RELIEF Valve

© QSI Training Services, Inc. 2004 all rights reserved 1/7/2017 NAARSO 85

Some other IMPORTANT Components

Bladder Accumulator

DRY Nitrogen

Oil Check Valve

Flow Control Valve

8 QSI Training Services 2004 all rights reserved

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Filter or Strainer

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Pneumatics: Symbols

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HOSES AND THINGS

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• Notice the hose coming off the top of the pump and going into the filter. It is bent in two planes. Most hose-specification literature recommends that hose not be bent in more than one plane. Doing so can cause uneven distribution of tension to reinforcing wires within the hose. As pressure pulsations occur in the hydraulic system, the overloaded strands undergo excessive tensile stress. After continuous cycling, the over-stressed strands can fail due to fatigue and eventually cause the hose to rupture. Worse yet, the failure can be catastrophic in nature, providing little or no warning of the impending failure.

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PIPING FAILURES

• PRESSURE TOO HIGH. • NOT PROPERLY SUPPORTED • INCORRECTLY SIZED. TOO SMALL. • HARDENING OF COPPER TUBING.

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DEFINITION OF AN INDUSTRIAL HOSE

• An industrial hose is a flexible reinforced tube for conveying liquids, solids, and gases.

• A typical industrial hose is dragged, coiled, run over, kinked and subjected to all kinds

• of abuse. Therefore, the application and its environment must be taken into consideration

• for proper hose selection. Selection of the proper hose and materials will increase

• hose life, improve performance, and ensure safety. • Industrial hose is used for three purposes: • 1. To transfer gases, liquids, solids and mixtures of these materials. • 2. As a flexible connector to absorb surges and vibrations. • 3. As a conduit to protect other hose, pipes and wires.

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Three Basic Elements of a Hose

• Tube – Its purpose is to handle specific fluids or solids. It is the innermost rubber or

• plastic component of the hose that must be resistant to the material that it is intended

• to convey because it is the part of the hose in contact with the material. A variety of

• compounds can be used depending on the application. 1/7/2017 NAARSO 96

• Reinforcement – Its purpose is to withstand a specific amount of working pressure

• measured in pounds per square inch (psi) or Pascal (Pa) or vacuum (In Hg, inches of

• mercury). The reinforcement may consist of many layers of fabric, yarn or wire placed

• on top of the tube and referred to as “plies.”

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• Cover – Its primary purpose is to protect the tube and reinforcement from external factors

• such as ozone, weather, abrasion and heat. A variety of compounds can be used,

• depending on the application.

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Caution!

1. Hose should not be used in “out-of-sight”

applications, where the hose is buried, encased, or submerged .Use rigid pipe in those applications.

2. Hose has a finite service life and is not to be used in permanent applications.

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P R O P E R H O S E S E L E C T I O N

• Proper hose selection is the first step in preventive maintenance. Selecting the best

• product for the application will allow you to obtain the maximum life expectancy from

• the product for the best value.

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S - Size:

• I.D. (Inside Diameter) • O.D. (Outside Diameter) • Based on the machinery sizing. • Flow rate requirements (GPM for liquids;

CFM for gases).

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T - Temperature:

• Consider exterior and interior temperature, as well as

• temperature impact on the material being conveyed.

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A - Application: • Where will the hose be used? • How will the hose be used? • How often will the hose be used (continuous, intermittent, • seldom)? • What are the environmental conditions? • Special hose construction (crush resistant)? • Conductivity requirements? • Is the hose used in a critical application? • Government or Industrial Standard requirements? • Use hoses that are specifically designed for these applications: • Steam • LP Gas • Aircraft Ground Refueling • Corrosive Chemicals

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M - Material

• Chemical name(s) and state(s) - (liquid, solid or gas)

• Food • Dry or powder • Liquid

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P - Pressure

• What is the working pressure? • What is the maximum surge pressure? • Is there a vacuum?

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E - End requirements

• What type of thread ends? • Proper Coupling Selection ?

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H O S E I N S P E C T I O N S

• Periodic Inspections – • Planning for Safety and Maximum

Performance

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• Achieving safety and performance in the use of a hose requires periodic inspections of

• the hose and its fittings prior to, during and after use. Hoses that have become old,

• worn, or damaged can present a danger to individuals and to the environment. Hoses

• that are not properly maintained can fail which may result in costly material spills,

• cleanup, downtime and injury. Planned inspections, corrective actions, and hose replacements

• can be less expensive than replacement or repairs made after a failure occurs.

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When and how often should you inspect hose?

• Inspection requirements will vary with each application type. The following factors

• should be considered: • Critical nature of application • Operating temperatures • Operating pressures • Environmental factors 1/7/2017 NAARSO 109

•It is helpful to think of hose

inspection at two levels:

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Level 1 Inspection

• An inspection of hose on an on-going daily basis looking for signs such as:

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• 1. Hose cover damage. • Cuts, cracks, abrasion, exposed reinforcement, • etc. • 2. Stiffness or hardness of the hose. • As a hose ages and is exposed to sunlight, • ozone, extreme temperatures or chemicals • it can lose some of its resiliency and • become stiff and hard. When flexed, a stiffened • hose can crack, leading to a failure.

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• 3. Changes in color. • May indicate chemical attack. • Ozone or aging. • 4. Cover blisters. • Chemical incapability. • Permeation in the early stages of leakage. The

blister can break and expose reinforcement • that can degrade from contact with • environmental factors.

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• 5. Kinked or flattened hose. • Restricted material flow and hose • performance. • 6. Leakage. • Puddles or spilled material under the • hose assembly. • Problem with coupling interface or • attachment. • Weeping from the hose.

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• 7. Damaged hose reinforcement. • Weakened hose.

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Level 2 Inspection

• An inspection that requires equipment shutdown in order to conduct a more thorough evaluation

• of the hose in a safe manner.

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1. Visually inspect for leakage. • NEVER inspect a hose for leaks by running • your hand over it while it is under pressure • or contains the material being transferred. • Escaping fluid under high pressure can exert • enough force to penetrate and cut flesh, • causing painful and severe injury. • Hot materials and chemicals can cause serious • burns. • ALWAYS conduct close inspection of hose • when pressure is released and the hose does • not contain potentially dangerous material.

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2. Hydrostatic Pressure Testing

•Test at regular intervals. •Essential for hoses used in hazardous applications such as chemical, steam, petroleum and compressed gas transfer. •Always use water for pressure testing. •Never use flammable or corrosive fluids or compressed gas

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RMA HYDROSTATIC TESTING PROCEDURES

• All hose and couplings should be hydrostatic tested at regular intervals. • Intervals for testing vary with each hose type. • Procedure: • 1. The hose should be at room temperature. • 2. The testing area should be clean and dry. • 3. Lay the hose out straight to its full length. • 4. Place the hose on rollers. This allows the hose to be moved while under pressure. • 5. Restrain the hose if there is danger of uncontrolled movement during the test. • 6. Conduct a visual inspection. • Look for cuts, gouges, bulges, soft spots, coupling slippage or any signs of wear or • failure. • 7. A hose which does not pass a visual inspection should be replaced. • 8. A hose which does pass a visual inspection is then connected to a test pump and the • free end is fitted with a quick-opening valve. • 9. Elevate the free end and fill the hose with water from the pump. • Always use water. Never test with flammable or corrosive fluids, solvents or • compressed gas. • 10. As the hose fills with water, bleed the air out through the open valve. Close the • valve and lower it to the ground when all the air is out. • 11. RMA has testing literature available for each hose type. It is imperative to pressure • test the hose at the proper pressure. • 12. Drain the hose and allow it to dry before returning it to service.

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• 3. Inspect hose tube for hardness, color • change, cracks, blisters, erosion, etc.

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• Level 2 inspections should be conducted, if possible, during regular equipment shutdown

• or at least every three months even if it means shutting the equipment down for

• the specific purpose of hose inspection

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H O S E M A I N T E N A N C E T I P S

• 1. Never exceed the rated working pressure of a hose. • Never allow pressure spikes or surges above the maximum rated

working pressure • of the hose. • Excessive pressure can shorten the life of a hose. • 2. Never run over a hose with equipment or vehicles such as fork

lifts. • Running over a hose can damage the tube, reinforcement, and cover. • A build up of pressure can cause damage at the coupling. • 3. Never pull a hose by its coupling. • Pulling a hose at the coupling can kink the hose and weaken the

coupling bond to • the hose. • When moving a hose always lift the hose and coupling together.

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• 4. Never lift a heavy, large-diameter hose by the middle with the ends hanging • down. • The internal reinforcement can be damaged at the middle point. • Support large hose every ten feet with rope saddles or slings. • Use dollies, rollers or derricks when moving large hoses. • 5. Never over-bend a hose to the point of kinking. • Never bend the hose tighter than the recommended bend radius. • Never kink a hose to stop the flow of material. • Kinking a hose can seriously damage the tube and reinforcement. • If needed, install bend restricters at the coupling to prevent the hose from being • bent past the bend radius. • 6. A hose cover exposed to excessive wear can be protected with an extra cover, • such as a nylon sleeve or pad. • Make the cover slightly longer than the hose to accommodate any change in the • hose length when in use. • 7. Remove kinked or crushed hose from service immediately. Inspect and test

the • hose before putting it back in service. • An outside diameter of a hose which has been permanently reduced by more than • 20 percent should be removed from service. • An outside diameter of a hose which has been reduced by 20 percent or less, • should have a hydrostatic test done before being put back into service. See RMA • Hydrostatic Testing Procedures 1/7/2017 NAARSO 123

• 8. Remove and test any hose assembly that is subjected to abuse. • This includes hose that has been severely pulled at the coupling, flattened, • crushed or kinked. • 9. Visually inspect and pressure test hose at regular intervals. • This is extremely important for critical application hoses, such as acid/chemical, • steam, LPG and petroleum. • Check for kinks, bulges, soft spots, loose areas, abrasions and cuts. • Cuts or abrasions which expose the reinforcement are signs that the hose should • immediately be removed from service. • 10. Always check for fluid seepage by pushing down at the base of the coupling • with your thumbs. A hose softened by fluid seepage must be replaced. • Check for coupling slippage. • Remove any hose that does not pass your visual inspection.

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