Choosing The Right Hydraulic Hose Diameter: A Guide To ...

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Hydraulic hoses are critical components in hydraulic systems, responsible for transferring fluid power from one component to another. These hoses come in different diameters, which affect their performance, efficiency, and safety. Choosing the right hydraulic hose diameter is crucial to ensure optimal system performance and prevent downtime due to equipment failure or safety hazards.

Understanding Hydraulic Hose Diameter

Hydraulic hose diameter refers to the inside diameter of the hose. It is measured in inches or millimeters and determines the maximum flow rate of the hydraulic fluid through the hose. The diameter affects the pressure drop, which is the difference between the inlet and outlet pressures of the hose.

Hydraulic Hose I.D and O.D

Hydraulic hoses have both an inner diameter (I.D.) and an outer diameter (O.D.). The I.D. is the measurement of the inside diameter of the hose, while the O.D. is the measurement of the outside diameter of the hose.

The I.D. of a hydraulic hose is important because it determines the flow rate of the hydraulic fluid through the hose. A larger I.D. will allow for a higher flow rate, while a smaller I.D. will restrict the flow rate.

The O.D. of a hydraulic hose is important because it determines the size of the fittings that can be used with the hose. The fittings must match the O.D. of the hose in order to create a secure and leak-free connection.

When selecting a hydraulic hose, it is important to consider both the I.D. and O.D. to ensure that it is compatible with your system and can handle the required flow rate and pressure.

Importance of Choosing the Right Hydraulic Hose Diameter

Choosing the right hydraulic hose diameter ensures that the fluid flow rate is sufficient to meet the system’s demands. If the hose diameter is too small, it can cause excessive pressure drop, leading to poor performance and increased wear and tear on the system’s components. On the other hand, if the diameter is too large, it can result in unnecessary fluid flow, which can increase energy consumption and cause heating issues.

How to Measure Hydraulic Hose Diameter?

measure hydraulic hose diameter

Measuring the hydraulic hose diameter is a critical step in determining the appropriate hose size for your hydraulic system. Here is a step-by-step guide to measure hydraulic hose diameter accurately:

1. Obtain a ruler or measuring tape with inches or millimeters as the unit of measurement.
2. Determine the hose’s inside diameter by measuring the distance between the inner edges of the hose.
3. If the hose has a cover or coating, peel it back to expose the inner diameter.
4. Measure the diameter at the center of the hose to ensure accuracy.
5. If the hose has a wire braid or spiral reinforcement, measure the diameter of the reinforcement as well.
6. Record the measurement in inches or millimeters, depending on the unit of measurement on the ruler or measuring tape.
7. Compare the measured diameter with the manufacturer’s specifications to determine the appropriate hose size for your hydraulic system.

It is crucial to measure the hydraulic hose diameter accurately to ensure optimal system performance and prevent equipment failure or safety hazards. If you are unsure about how to measure the diameter or select the appropriate hose size, consult a hydraulic systems expert or the manufacturer’s specifications for guidance.

Hydraulic Hose Diameter Chart

A hydraulic hose diameter chart provides a reference guide to the most common hydraulic hose diameter sizes and their corresponding measurements in both inches and millimeters. Here is a hydraulic hose diameter chart:

Hydraulic Hose Diameter Chart:

Size (inches)Size (mm)1/463/8101/2135/8163/420125

It is essential to note that there may be variations in hydraulic hose diameter sizes depending on the manufacturer and the specific hydraulic system’s requirements. Therefore, it is crucial to consult the manufacturer’s specifications or an expert in hydraulic systems to determine the appropriate diameter size for your specific application.

3/8 Hydraulic Hose Outside Diameter

The outside diameter of a 3/8 hydraulic hose depends on the type and construction of the hose. However, the outside diameter of a typical 3/8 hydraulic hose ranges from 0.75 inches (19.05 mm) to 0.96 inches (24.38 mm).

It is essential to know the outside diameter of the hydraulic hose as it affects the routing and installation of the hose. The outside diameter determines the minimum bend radius and the amount of space required to accommodate the hose.

When selecting a hydraulic hose size, it is crucial to consider both the inside diameter and outside diameter of the hose. It is also essential to select a hydraulic hose that meets or exceeds the manufacturer’s specifications and industry standards.

Using the wrong size or type of hydraulic hose can result in system failure, damage, or injury. Therefore, it is crucial to consult an expert in hydraulic systems or the manufacturer’s specifications for guidance and recommendations on selecting the appropriate hydraulic hose size and type for your specific application.

Hydraulic Hose Size Calculator

hydraulic hose caculator

A hydraulic hose size calculator is a tool used to determine the appropriate hydraulic hose size based on the flow rate, velocity, pressure, and temperature of the hydraulic system. Here is a simple hydraulic hose size calculation:

1. Determine the flow rate (Q) in gallons per minute (GPM) or liters per minute (LPM).
2. Calculate the velocity (V) in feet per second (FPS) or meters per second (MPS) using the formula:

V = (Q x 0.3208) / A

Where: Q = Flow rate in GPM or LPM A = Cross-sectional area of the hose in square inches (in²) or square centimeters (cm²)

3. Determine the pressure drop (ΔP) in pounds per square inch (PSI) or bars using the formula:

ΔP = K x (V² / 2g)

Where: K = Pressure drop coefficient (0.017 for smooth bore hoses, 0.027 for convoluted hoses) V = Velocity in FPS or MPS g = Acceleration due to gravity (32.2 ft/s² or 9.81 m/s²)

4. Calculate the maximum allowable pressure (MAP) in PSI or bars using the formula:

MAP = (ΔP x SF) + EP

Where: SF = Safety factor (typically 4:1 or 2.5:1) EP = End pressure (pressure at the end of the hose)

5. Select the hydraulic hose size based on the maximum allowable pressure (MAP) and the manufacturer’s specifications or recommendations.

It is crucial to note that this hydraulic hose size calculator is a basic tool and may not account for all variables or factors that affect hydraulic system performance. Therefore, it is essential to consult an expert in hydraulic systems or the manufacturer’s specifications for guidance and recommendations on selecting the appropriate hydraulic hose size for your specific application.

Factors to Consider When Choosing Hydraulic Hose Diameter

kingdaflex hydraulic hose

When choosing the hydraulic hose diameter, there are several factors to consider to ensure optimal hydraulic system performance and safety. These factors to choose a hydraulic hose include:

1. Flow Rate: The flow rate of the hydraulic system is the volume of fluid that passes through the hose per unit time. It is essential to choose a hydraulic hose with an appropriate inside diameter that can accommodate the required flow rate.
2. Velocity: The velocity of the fluid passing through the hydraulic hose should be within the manufacturer’s recommended limits. An excessively high velocity can cause erosion, while a low velocity can result in the formation of sediment or contamination.
3. Pressure: The hydraulic hose must be able to handle the maximum working pressure of the hydraulic system. A hose with a smaller inside diameter may not handle the required pressure, resulting in hose failure and potential damage to the system.
4. Temperature: The temperature of the hydraulic fluid can affect the performance and lifespan of the hydraulic hose. It is important to choose a hose with a suitable temperature range that can withstand the maximum operating temperature of the system.
5. Application: The specific application and environment of the hydraulic system can influence the choice of hydraulic hose diameter. For example, a hydraulic hose used in a harsh environment may require a larger diameter to ensure adequate flow and pressure.
6. Hose Length: The length of the hydraulic hose can impact the flow rate, pressure, and velocity of the system. It is important to choose a hose with an appropriate inside diameter and length to minimize pressure drop and ensure optimal system performance.

In summary, choosing the appropriate hydraulic hose diameter requires consideration of various factors such as flow rate, velocity, pressure, temperature, application, and hose length. It is crucial to consult an expert in hydraulic systems or the manufacturer’s specifications for guidance and recommendations on selecting the appropriate hydraulic hose diameter for your specific application.

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Common Hydraulic Hose Diameter Sizes

Shelley Digital Common Hydraulic Hose Diameter Sizes

The most common hydraulic hose diameter sizes are ¼ inch, ⅜ inch, ½ inch, ⅝ inch, and ¾ inch. The selection of the diameter depends on the system’s requirements, such as the flow rate, pressure, and temperature. It is essential to consult the manufacturer’s specifications or an expert in hydraulic systems to determine the appropriate diameter size.

Here is a table showing common hydraulic hose diameter sizes and their corresponding inside and outside diameters:

Hose SizeInside DiameterOutside Diameter1/40.25 in (6.35 mm)0.52 in (13.21 mm)3/80.38 in (9.53 mm)0.75 in (19.05 mm)1/20.50 in (12.70 mm)0.87 in (22.10 mm)5/80.63 in (15.88 mm)1.00 in (25.40 mm)3/40.75 in (19.05 mm)1.16 in (29.46 mm)11.00 in (25.40 mm)1.50 in (38.10 mm)1 1/41.25 in (31.75 mm)1.85 in (46.99 mm)1 1/21.50 in (38.10 mm)2.17 in (55.12 mm)22.00 in (50.80 mm)2.65 in (67.31 mm)

Note that the outside diameter may vary depending on the type and construction of the hose. It is important to consult the manufacturer’s specifications and industry standards when selecting a hydraulic hose diameter to ensure optimal system performance and safety.

Proper Hydraulic Hose Diameter Ensures Efficiency and Safety

Hydraulic systems are commonly used in heavy-duty equipment, manufacturing plants, and many other industries. These systems rely on hydraulic hoses to transmit fluid and power between different components. The proper hydraulic hose diameter is essential for ensuring efficiency and safety in these systems.

Choosing the right hydraulic hose diameter involves several factors, such as flow rate, pressure, temperature, and hose length. Using a hose with an inappropriate diameter can cause various problems, such as:

1. Inefficient system performance: If the hose diameter is too small, it can restrict fluid flow and reduce system efficiency. This can lead to increased energy consumption, slower operation, and decreased overall performance.
2. Increased pressure drop: Pressure drop occurs when the fluid flow encounters resistance, such as when it passes through a hose. A hose with an inadequate diameter can result in excessive pressure drop, reducing the system’s ability to deliver fluid to its intended destination.
3. Premature hose failure: Using a hose with an incorrect diameter can lead to excessive stress on the hose, resulting in premature hydraulic hose failure, leaks, and potential safety hazards.
4. Safety risks: In some cases, using an inappropriate hose diameter can result in safety risks, such as hose bursts, fluid injection injuries, or other accidents.

In summary, selecting the right hydraulic hose diameter is crucial for ensuring efficient and safe system operation. When choosing a hydraulic hose diameter, it is important to consider the manufacturer’s recommendations, industry standards, and specific application requirements. Working with a hydraulic system expert can also help ensure the optimal performance and safety of the system.

Conclusion

In summary, choosing the right hydraulic hose diameter is critical to ensure optimal system performance and prevent equipment failure or safety hazards. It is essential to consider the system’s requirements, such as the flow rate, velocity, pressure, and temperature, when selecting the diameter size.

By selecting the appropriate diameter, the hydraulic system can operate efficiently and safely, reducing downtime and maintenance costs.

Choosing a hydraulic hose must be done with careful thought and consideration.

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Contributed by Carl Dyke, CD Industrial Group, Inc.

With a new hydraulic machine design, or with a machine that has undergone a rebuild process, there comes the moment when it is time to specify and install the hoses that conduct fluid from point to point throughout the system.

While the main functions of a machine and perhaps the most clever aspects of its design are likely contained within the mechanical works including the valves and actuators, the required hoses are not minor accessories. Careful thought and consideration are needed in order to make the best hose selection.

While inside diameter and the working pressure rating of a hose are typical factors to start with, outer diameter and the weight of a particular hose model are often critical on mobile machines.

A press in a factory setting or a mining drill maker may be quite concerned with the expected life of a hose as indicated by the pressure impulse cycle rating. Impulse cycles are sudden on-off pressures that cause stress to a hose. The test is typically conducted with pressure impulses at 133% of the working pressure rating. A rating of 200,000 cycles is considered minimal, with 1,000,000 cycle products available for those who wish to pay for them.

Many readers might be accustomed to selecting a different hose product line for the larger diameter applications. Typically the working pressure decreases as the hose diameter gets larger within a single product line. A hose manufacturer may also offer a convenient single-pressure option where all diameters within a particular product line have the same working pressure rating.

The types of fittings to be used, the nature of the fluid, abrasion resistance, the flexing cycles of a hose and a range of installation challenges all add to the list of factors to be considered.
Objective information concerning the properties and construction of the common 100R-series hose can be found in the standard, SAE 517. Recommended Practices for Hydraulic Hose Assemblies, covered under SAE J1273, provides a wealth of advice on installation and on wear/maintenance issues. If you’ve seen Society of Automotive Engineers (SAE) approval markings on hoses and have wondered what they mean, simply purchase the matching standards and practices documents from the www.sae.org website. For those who work with ISO standards, similar documents are available from the ISO website.

Important words about safety
It shouldn’t need to be said that a hose burst failure is always a catastrophic incident. In the best case scenario, a hose failure might cause production downtime or environmental contamination concerns. In a worse scenario, persons could be seriously injured or even killed.

Using economics as the only or primary hose selection criteria can easily leave human risks at a very high level. A colleague recently contacted me regarding concerns about the pressure ratings of hydraulic hoses in use at the plant where he had just been hired on. He noticed that the normal system pressure was routinely at levels that were slightly higher than the working pressure rating of the hoses. Management assured him that with the known burst pressure rating for the hose at several multiples above the working pressure rating, there was no cause for concern and that the added expense for a higher rated hose was unnecessary. This is one example of a very poor hose selection process. In this case, safety was being neglected.

Never use hoses regardless of their age if you are aware of incidents of system overpressuring that have exceeded the normal working pressure. Cracked, blistered or abrasion worn hoses should never be put back into service.

What is “hose whip?”—Hose whip, (a shorter name for what happens if a hose or fitting breaks, and the hose then flails freely) can easily dismember or kill. Most hydraulic hoses are made up of layers of wire braid and include steel fittings on the end of the hose assembly. Imagine getting hit by a steel cable moving at high speed, and you’ll have an idea of the damage a hydraulic hose can do if it breaks away. In the case of a compressed fluid, the distance travelled and acceleration rate add to the carnage.

Correct selection for your application

Whether you are replacing an existing hose, or building a new system, you’ll need to select a hose of the correct pressure rating, diameter, and length and with the best material properties for your application. Here are a few factors to consider carefully.

Pressure rating— A hose must be chosen with a maximum working pressure (WP) rating that is at or preferably above the normal maximum hydraulic system pressure. Momentary pressure surges for a hydraulic system are not to exceed this pressure rating. Hose fittings that are rated below the working pressure of the selected hose cause the entire hose assembly to be derated to the lower rating of the fittings.

Hoses typically become heavier for any given length, with added layers of reinforcing wire, as the working pressure requirement increases.

Many of the hose models in the common 100R series have lower working pressure ratings at the larger diameters. Often a -16 (1 in.) hose has a working pressure that half of the rating for the -8 (½ in.) hose in the same product line. This can be inconvenient and costly for a machine manufacturer. Look for SAE 100R17 series compact hoses to find a constant working pressure of approximately 3000 psi for all available diameters, or consider ISO 18752 rated hoses for a constant working pressure of approximately 4000 psi for all available diameters. Many of the ISO 18752 rated hoses also feature test impulse pressure cycle ratings of 500,000.

Burst pressure is a built-in safety factor for a hydraulic hose. A hose manufacturer verifies the burst pressure in a destructive test. The SAE standard J517 for the common series of 100R hydraulic hoses also categorizes leakage and also hose separation from hose fitting, as burst pressure failures. The hose does not have to violently break apart completely to have suffered a burst failure. The burst pressure rating of a hydraulic hose if often 4x the working pressure rating or greater.

Inside diameter—It’s very important to use a hose of the correct inside diameter. If the diameter is too small for a given rate of flow, the linear velocity will be too high. Excessive velocity will translate into friction and turbulence, which when combined will surely result in noticeably higher system pressure and heat.

Hose manufacturers typically supply a nomograph or a table that allows for the easy calculation of the optimum diameter for a given flow rate and hose length. Long hose lengths require a larger inner diameter to avoid excessive restriction and friction.

Length — Correct hose length needs to allow for bending and flexing as a machine moves and articulates, and to make sure that no undue stress is caused at the crimped fittings. A hose that connects in a perfectly straight path from one component to another may shrink in length up to 4% at maximum pressure. Allow this extra length when making up the hose assembly. An excessively long hose adds restriction to flow, increasing system pressure and reducing system efficiency.

Material — Next, consider the conditions that a hose will operate under. The outer layer or cover of a hose can come in a variety of synthetic rubber materials. Some compositions can help with applications where abrasion may occur but may not bend as readily. Neoprene is one popular synthetic cover material that remains flexible across a wide range of temperatures, yet handles abrasion well. Most rubber hoses perform reasonably well from –40°C (–40°F) to 100°C (212°F). Look for the date of manufacture code on any rubber hydraulic hose that you are considering. The maximum shelf life is generally ten years at the most.

Where weight and space are a concern, as is often the case with mobile machines, look for hoses with a thin-wall inner tube. Advances in synthetic rubber compounds allow for higher wall strength allowing for a final product with a smaller outside diameter. Some manufacturers have moved to a reinforcement wire with an oval cross-section as opposed to round, offering additional outside diameter (O.D.) and hose weight savings. These smaller O.D. hoses, referred to as compact models in many catalogs, also offer much tighter bend radiuses.

Thermoplastic hoses are generally much lighter than rubber hoses. The inner tube of copolyester or nylon is typically braided or spiral wrapped with a synthetic reinforcement fiber instead of steel. Synthetic fiber is also needed for electrically non-conductive (orange cover), aerial lift hoses. In many cases the outer cover of thermoplastic hoses will be polyurethane and provide a longer shelf life than rubber, better flexibility at low temperatures such as –60°C (–75°F), and higher resistance to UV and chemicals.

Thermoplastic hoses are not always available for diameters above once inch.

Hose laylines — Hoses should have their part number, pressure rating, and size stamped along the outer cover. Industry standards and approvals will also be shown. They may also display manufacturer-specific information, such as the trade name of the specific product line. Different manufacturers will have slightly different ways of presenting this information. This strip of information is called the layline.

Let’s decode this generic layline shown in the pictures.

Section by section:

• ACME = Manufacturer
• Jupiter = Hose Model
• 170-04 = Manufacturer’s Product/Part Number (Note: dash size -04 denotes the inside diameter in 1/16″ increments, ie. 4/16″ or ¼”)
• ¼” = Inside Diameter in Inches
• 5000 PSI WP = Maximum Working Pressure
• SAE 100R2AT = SAE (Society of Automotive Engineers) specification for a hose with two layers of reinforcement wire.
• MSHA IC-215/0 MSHA (Mine Safety and Health Administration) approval

Information is not always presented in the same order. However, you should always find the maximum working pressure, the size, and the hose product number. The product number can be used to gather other information you’ll need from the manufacturer’s catalog and website.

Ensure proper installation
So now that you’ve selected the correct hose, let’s talk about best practices for installing it.

Minimum bend radius — You’ll find the minimum radius for a hose in the product catalog. This refers to the arc that the hose follows in order to prevent restriction, damage due to kinking. Bends should not begin immediately after the hose end fitting.

For example, the manufacturer’s catalog tells us that our hose has a minimum bend radius of 3.9 in. Let’s look at what this really means.

Plan out the hose path to avoid tight bends. This will improve the life of your hose, and it will promote laminar (straight) flow inside of the hose. Turbulence from excessively tight bends can cause the inner tube to become eroded and damaged.

Bending and twisting — Twisting is a very serious stress that can lead to failure on most any hydraulic hose. Prevent twisting of the hose as it is installed between two ports or fittings. Pay attention to the layline to make sure that is not spiralling around the hose, as you tighten fittings. The use of fittings with swivels also helps in this regard.

A hose that actively bends in two or three planes during machine motion may produce stresses and twisting that dramatically shorten hose life. Work towards single plane bends as much as possible.

Brackets/support — For lengthy hydraulic hoses you may need to install brackets or another method of support. Don’t rely on the fittings to hold a hose in the correct position. Install brackets or other means of support as necessary.

Cleanliness — New rubber hoses need to be cleaned after they are sawn to length. Cleaning projectiles and the hands tools (guns) that propel the projectiles through the hose are more affordable than ever and pay for themselves quickly. With particle contaminants clearly identified as the leading cause of hydraulic valve malfunctions, the days of cut-and-crimp should be behind us. A freshly cut length of hydraulic hose has rubber and also metal wire particles within it. It is the sawing process that produces these particles. It takes only thirty seconds in most cases to complete the hose cleaning process before crimping the fittings onto the hose end.

Thermoplastic hoses are cleaner from the start as they are cut/sheared to length as opposed to being sawn to length.

Conclusion
Using a hose with a working pressure rating that is too low is a very serious safety concern. Always err on the side of caution by choosing a hose with a working pressure rating that provides a safety margin. Burst pressure ratings should never be used to deliberately allow a system to work above the working pressure rating. If you are concerned about pressure surges, look for hoses with a high impulse cycle rating.

When choosing a hose you should consider the pressure rating, temperature range, cover material and bend diameter among other factors. Before assembling a rubber hydraulic hose, clean it internally! Use brackets and supports wherever required to maintain the best hose position, and to avoid unnecessary flexing. Ensure that the hose is never forced into a tighter bend than the minimum radius allowed. Consider thermoplastic hoses for lightweight options and for tighter than normal bend radiuses.

Finally, if you are not sure how to objectively sort through the information provided by a sales rep, purchase and read the standards documents (SAE, ISO, ANSI, DIN etc.) for the types of hoses you are considering.

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