Facility operators in the oil and gas industry have raised concerns on how to solve their top failure modes: extremely short or non-existent dry run pump time limits and unacceptable levels of cavitation when pumping extremely light liquids with high vapor pressures. 

Pump cavitation and dry run related failures cost companies millions of dollars annually, including replacement costs for damaged equipment and lost sales due to poor performance. With an improving economy and anticipated fuel production increase, sales of fluid-handling pumps are forecast to rise 5.5% annually to $84 billion in 2018. Given this proliferation, the historical pattern suggests that costs associated with repairs or replacements also will increase dramatically.

Learn how Parker's innovation in pump technology can reduce your operational downtime, decrease operating costs, and improve performance. Download our white paper now.

Dry running occurs when a pump operates without sufficient lubricating liquid around the pumping element. This can be caused by either widespread vapor formation, also known as cavitation, inside the pump or absence of pumping fluid altogether. These adverse conditions can lead to dangerously unstable pressure, flow, or overheating which may cause the pumping element to seize or break.

When cavitation occurs, vapor bubbles form and expand in the pumping liquid on the suction side of the pump before reaching the higher-pressure discharge side of the pump and violently collapsing near the surface of the pumping element. This triggers shock waves inside the pump which cause significant damage to the pumping element. If left untreated, cavitation will destroy the pumping element and other components over time, drastically shortening the pump’s life.

Cavitation may also cause excessive vibration leading to premature seal and/or bearing failure, in addition to creating an immediate increase in power consumption and a decrease in flow and pressure output.

Cavitation itself may also be so widespread that it creates a dry run situation inside the pump due to excessive vapor formation. Pumps most often rely on the pumping fluid itself to lubricate the bearing surfaces of the pumping element – if a pump is operated without this fluid, the low to non-existent lubrication at these bearing surfaces will cause excess heat generation, increased wear, and potentially even failure of the pump if the pumping element seizes or breaks. The life of a pump subjected to dry run will be significantly reduced or, in the worst case, brought to an untimely end.

Whereas cavitation is a common cause of pump degradation and failure related to the physics involved in the pumping operation, dry running, on the other hand, is usually related to how pumps are actively operated by end users. The most immediate cause of dry running is usually human error. Companies rely on operators to monitor their pumps, but problems occur in cases where operators unintentionally leave pumps running after the pumping operation is complete.

Despite an operator’s best efforts, harmful events still may occur from:

• malfunctioning monitoring systems;

• improper use of even well-designed control equipment;

• pumps running overtime after the pumping operation is complete;

• unpredictable events.

Our engineers were up for the challenge and developed the next generation solution of fluid transfer systems. The new technology combines advanced engineering and manufacturing capabilities to deliver a rugged solution for stationary, mobile, and high vapor-pressure fluid applications.

The solution offers customers efficiency improvements as well as increases their uptime, which ultimately translates into revenue to the bottom line.

“What separates our solution from our competitors is, our technology is automated and integrated into the pump design. You don’t need to worry about pumps stopping and starting every 20 – 30 seconds, they will dry run continuously.”
James Chu, PE, chief engineer, Corporate Technology Ventures, Parker Hannifin

Learn how this innovation in pump technology can reduce your operational downtime, decrease operating costs, and improve performance. Download our white paper now.

Headed to OTC 2018?

Parker is leveraging a century of engineering expertise to help its partners in the onshore and offshore oil and gas industry increase performance, improve safety and eliminate unplanned downtime. Visit our engineers at booth 3639, April 30 - May 3 and test out our featured solutions. Learn more by visiting our OTC oil and gas solutions page.

Article contributed by Sara Weichman, business development manager, Fluid Transfer Solutions, Parker Hannifin

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You may have seen or heard of a “ParkerStore HOSE DOCTOR” but do you know what one is? Let us explain!

Say your backhoe, tractor, dump, plow or any other hydraulic equipment stops working. It may have a hose failure or you may not even know what the problem is. You just know you need it fixed fast so you can get back to work.

That’s when you call a ParkerStore HOSE DOCTOR – a skilled hydraulics technician, on-call 24/7, who is ready to help you get back to work. You see, ParkerStore HOSE DOCTORs understand that your downtime translates directly into lost productivity, time and money, so they’ll come to your jobsite or location with a vehicle stocked with hoses, fittings and the tools needed to diagnose your failure, make and install a new hose assembly, and provide the repairs you need to get back to work promptly.

ParkerStore HOSE DOCTORs are also trained to help you determine possible trouble spots in your hydraulic system and offer solutions to maintain your productivity and prevent downtime. Their services can include system troubleshooting, preventive maintenance and diagnostics, fluid sampling and even inventory services if you need regular product deliveries or other support.

Beyond that, a major benefit of working with a ParkerStore HOSE DOCTOR is gaining access to the full array of quality Parker products, and the service and support of the global ParkerStore distribution network. This extensive network supports a wide range of customers, markets and applications with more than 3600 service points in 90 countries.

So, while ParkerStore HOSE DOCTORs are skilled, on-call hydraulics system technicians with the parts and service you need to get back to work, they really are your 24/7 lifeline for productivity!

Want to learn more? Check out the video below, visit www.hosedoctor.com or in the US call 1-866-550-HOSE.

Post contributed by:
Suzanne Favri, digital marketing specialist
Global Distribution & Sales Services, Parker Hannifin

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In the onshore and offshore oil and gas industry, time is money. Managers for companies that operate fleets of drilling vessels conducting offshore, deep-water oil extraction in countries around the world clearly understand the cost of breakdowns and required maintenance overhauls.

For hose documentation, a client with a fleet of four drilling vessels used a manual filing and storage system that was kept aboard the vessels. Because documents didn’t always match the hoses being used, the system proved unreliable with low confidence in the data. This resulted in extensive time being spent in-port making hoses, as well as unreliable tracking of hose life and failure.

Workers had no idea how long the hoses were lasting, so replacement wasn’t “as needed.” This system created several risks, including:

• lack of inventory of critical spares,

• loss of valuable information in a catastrophic event,

• wasted time and money with unnecessary hose replacement, and

• extensive fines being levied if documentation doesn’t meet strict inspection and historical criteria, due to regulatory compliance policies.

To avoid these risks, the client needed a secure, cloud-based documentation system for all assets that was easily accessible. The Parker Tracking System (PTS) Pro provided the client with a single source for documentation and records management. This resulted in:

• accurate and organized information available at any time,

• hoses being replaced only when needed,

• decreased time spent docked to replace hoses during the reclassification (approximately every five years), and

• information is safe and easily updated.

PTS has been engineered specifically for the oil and gas industry with user profiles in mind. What makes PTS unique is the ability to move asset records between accounts or create “Affiliate” relationships between users. Parker recognizes that a specific product or asset may be manufactured by one company and serviced or maintained by another. Sometimes these activities are separated by oceans and times zones. This doesn’t mean that digital documentation should not be shared between these two organizations.

Durable metal tags and polyurethane labels can withstand the harsh environments at sea, which ensures hoses are easily identified, improving installation time. And with limited network availability at sea, having Parker’s Global Services team ensuring all information is updated, available, and easily managed is key.

So you've heard about digital asset tracking, and its ability to serialize parts for OEMs when they order them. But what about the longer term benefits of these digital asset management programs once the products get out in the field? How can maintenance teams located in offshore and mobile locations make use of this technology?

One important benefit is being able to record and track key lifecycle details for each of the critical components you use. Imagine being able to: 

• Download a report like "Carfax" on every hose system used on a fleet vessel -- some larger vessels have over 5,000 hose assemblies. 

• Having ongoing access to critical part-specific information, like component locations, performance events, maintenance needs and service histories, in real time and on-demand means that when the ship hits the dock, your team can get started with the right parts on hand at the right time.

• And what if those digital records also could organize for customers all the documentation needed with their builds, like updated parts manuals, certifications, maintenance schedules, warranties and even photographs, directly tied to the components in question?

PTS serializes and tags components for customers of all types. Tags and records are created prior to delivery, using the customer's private label if requested, and then these records are seamlessly transferred to the customer's PTS account.

This serialized information then serves as the foundation for a variety of component- and performance-related insights customers can record and track after equipment is put into service.

Maintenance teams benefit from PTS tags and records too: Each asset tag can be private-labeled with contact details, operators never have to question who to contact for service and exact OEM-quality replacements. And should they need to troubleshoot specific components within systems or compare one assembly's performance to another, PTS records can provide them a roadmap.
 

"It's a chronology of vitals that tracks life-cycle performance for specific parts, helping our customers understand use in the field, performance patterns and develop best practices over time."
William Sayavich, marketing manager, Global Services, Parker Hannifin

Article contributed by Bill Sayavich, marketing manager for Parker Hannifin Global Services.

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The mining industry, known for its harsh and unforgiving environments, demands reliable, high quality equipment to ensure safety and efficiency. Longwall mining, which accounts for around 50% of total underground production, has had the largest continual impact upon underground coal operations in the U.S. over the last two decades.

Longwall mining is an underground mining operation in which a large panel or block of coal spanning up to 1,500 feet across distances of two to three miles is extracted. Longwall mines are characterized by low ceilings and tight spaces in which workers must operate heavy duty machinery. Hydraulic-powered roof supports, also called shields, protect the working area of the mine by extending as the shearer cuts back and forth along the coal face. Once it is cut by the shearer, coal falls onto a large chain conveyor and is removed from the mine. The movable hydraulic shields in longwall mines advance with the shearer throughout the mining process, enabling increased productivity as well as improved safety of miners.

Safety is imperative in the mining industry, particularly when it comes to the dangers of roof falls and lack of clean air in underground coal mines. It is vital for the equipment used in mining to be thoroughly tested to meet internationally approved MSHA standards and provide consistently reliable performance to ensure safety of operations and individuals in extreme environments.

Parker's new GlobalCore 187 Hose is a 1,000 psi (7MPa) constant working pressure hose specifically engineered for the mining industry. The innovative design of 187 Hose, which can be used as a high-pressure return line or used to address an application where other hoses may be excessive, requires a lower force-to-flex and exceeds the ISO 18752 performance specification (AC and AS). The first of its kind in on the market, the 187 Hose is unmatched in performance and capability. For instance, the 187 Hose is designed for one-half of SAE and ISO 18752 bend radius specifications, which saves overall hose assembly length, facilitates easier routing in the restrictive areas of underground mines, and decreases the number of bent tube fittings necessary. The tighter bend radius capability also means longer hose life in applications where machinery movement causes hoses to bend sharply.

The hoses included in the GlobalCore family are constant working pressure hoses, which contradicts traditional hydraulic hoses where the pressure decreases as the inside diameter increases. For instance, if the maximum pressure requirement for your application is 1,000 psi, you could utilize one hose family operating with a constant working pressure of 1,000 psi across all diameters for your hydraulic system. Converting from various product lines to a singular hose family that provides constant working pressure across sizes means a simplified selection process as well as reduced inventories, maintenance costs, and downtime. 

At Parker Hannifin’s Hose Products Division, we understand the concerns facing our mining customers. We know that safety is your number one priority. The risk of serious injury resulting from the uncontrolled release of high pressure hydraulic fluids is an ongoing concern. Hydraulic fluid injection injuries are caused by a release of pressurized hydraulic fluid penetrating the skin. A pinhole-sized leak can travel at the same velocity as a bullet — 600 feet per second. According to research, more than 10% of mine safety incidents in the United States involve fluid power systems, with one percent resulting in serious injury or death. This being said, Parker has designed and engineered hoses to withstand the harsh environments of the mining industry to protect lives. The 187 Hose has three different cover options (standard, ToughCover, and SuperTough cover) to increase the service life and personnel safety.  Parker also offers a wide range of hose sleeves, wraps, hose shields and a hose whip restraint system designed to protect operators, equipment, and the environment from the hazards of hydraulic hose malfunctions. To further protect against potential fire hazards, Parker’s Firesleeve is a flame resistant sheath that protects the hose from extreme temperature conditions. 

In addition to the 187 Hose, Parker has an entire range of MSHA approved hoses, fittings, and equipment designed and engineered to service the needs of the mining industry. With a thicker, more durable outer cover to prevent impact damage from debris, Coalmaster hoses are ideal for tough underground conditions. Paired with the SteckO fitting system, Parker’s Coalmaster products provide increased performance and reliability in highly abrasive environments. 
 

Longwall mining has shown a significant increase in production and today accounts for the largest amount of tonnage mined among underground methods. Because of this shift, improved crimping equipment that can withstand the harsh environment and keep up with increased production is essential, however, it must be cost-efficient. Parker's Parkrimp family of crimping machines enable any user to make factory-quality hose assemblies quickly, easily and cost-effectively. The Parkrimp-style crimpers are designed to crimp fittings to the proper diameter every time. These crimpers are simple to operate and they're built to provide years of dependable service. Designed to produce accurate crimps from the first time it's used, Parkrimp crimpers require no calibration and continuously produce proper crimps, time after time. Parker's family of Parkrimp models can crimp straight or bent-stem fittings from ¼" to 2" in diameter and cover needs ranging from high-volume productivity to portable, on-site assembly. 

In order for crews to efficiently operate in the cramped conditions of underground mines, equipment must be easy to use, install, and change out. Adding a global asset tagging and identification system to your mining operations would provide a fast, accurate and convenient hose assembly replacement regardless of where or when the original assembly was made. Parker estimates that the addition of an asset tag, such as Parker’s PTS label, can save a customer at least 15 minutes of downtime (simply stated as the time spent waiting in a store, or as the additional time spent in first removing an assembly before proceeding with the repair). If the average cost of labor and machine downtime is calculated at the low end of $60 per hour, PTS can save the customer $15 in direct productivity losses. For customers with multiple, untimely failures per month, this can add up to considerable savings. Many customers have documented downtime of two to three hours or more due to hydraulic hose failure, and at labor and loss productivity rates of up to $500 per hour or more. In such circumstances, PTS can be invaluable in helping to ensure maximum machine or vehicle uptime.

To learn more about GlobalCore, visit our website or download our brochure. To learn more about Parker’s product solutions for the mining industry, visit our landing page. 

Article contributed by Kyri McDonough, marketing services manager at Hose Products Division, Parker Hannifin.

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It’s not an exaggeration to say oil is the lifeblood of all machines. Commercial fleet vehicles, heavy machinery and large-scale power generation equipment all rely on clean engine oil to lubricate, protect and cool. Regular oil changes are an essential preventive maintenance function to assure maximizing the productive life of equipment. If maintenance is neglected or not properly maintained, engines will run inefficiently, resulting in unreliable equipment and eventual costly breakdowns. 

The cost of downtime can be very significant. On average, manufacturers experience up to 80 hours of downtime annually. That’s 33 days out of the year lost to halted production, machine repairs and labor overhead, costing companies millions of dollars in potential profits. Knowing when, where and how downtime occurs is key to knowing how to prevent it.

With preventive maintenance, you are being proactive by consistently monitoring, inspecting and updating machinery while it’s operating in good standing order rather than wait until a problem arises. Regular maintenance checks are critical to ensuring equipment is operating at peak condition for long stretches of time. This includes an oil analysis to determine when it’s time to change engine oil. In fact, with regular oil checks in engines, you can lower the number of yearly oil changes.

Changing oil sounds simple enough, but there are many significant hidden costs associated with the oil change process that are not taken into account.

Lost production, providing staff with proper training and oil change equipment, consumable supplies and their disposal, labor, testing and inspection contribute to an oil change expense frequently exceeding 40 times the cost of the oil itself.

In addition, oil changes can be complicated and when not done properly, can lead to equipment damage and failure as the result of introducing the wrong oil, adding contaminated oil, over or under filling the sump or reservoir, and starting the equipment dry.

Unfortunately, one of the most common types of chemical spills in the workplace involves oil. It’s considered low toxicity, but is combustible and poses a direct threat to the safety of workers. Spills and leaks can occur at all phases of the oil change process including:

• Draining the old oil
• Adding the new oil
• Disposing of the used oil

The repercussions of oil spills can range from the need for solvents and cleaning agents to removing oil from equipment and walkways to replacing pavement or digging up soil. Based on the nature and severity of the occurrence, clean up costs may vary from hundreds of dollars to thousands. Most important though is the safety of workers. An employee changing oil is faced with numerous potential safety risks including injury from slipping and skin contact to toxic chemicals. When an injury occurs, the loss of time and productivity directly affects the bottom line. Providing a safe work environment ensures workers will be able to return home to their families unharmed by workplace hazards.

Oil spills can be eliminated by 100%. Parker has revolutionized the oil change experience with a simplified approach to deliver better, cleaner, and safer oil changes for engines and machinery in 30 minutes or less. By removing spills, leaks and drips from the equation with a more environmentally friendly solution, clean up costs associated with oil becomes nonexistent.

QuickFit’s three-step process is designed for ease of use and allows technicians to change oil faster and more effectively. An added plus is the savings on training and labor costs with a standardized solution that can be operated by anyone. Oil is drained directly to the waste containment and then a vacuum is applied to extract the used oil from the filter. This same connection point is then utilized to refill the system with new oil. By applying one connection per compartment, it results in less variability during maintenance checks.

Reducing the number of steps in the process simplifies training for operators and eliminates any risk of safety hazards or spills, which improves an organizations’ bottom line by creating less consumable waste. Plus, QuickFit’s streamlined process helps to lower operating costs, increase profitability and reduce oil change time by 50%.

The QuickFit System features an ergonomic design that allows for easier access to even the most cramped and isolated engine compartments. This greatly reduces operator’s exposure to fluids from fill to purge and lowers the possibility of slips, falls, and burns. In return, better safety conditions while changing oil saves time and costs on avoiding workplace injuries while increasing productivity.

Routine maintenance of industrial applications and equipment is critical to the sustainability and efficiency of machinery operations. A key aspect of maintaining the longevity of machines is through proper lubrication that can be accomplished with Parker’s QuickFit Oil Change System. By taking advantage of a single point of connection, oil spills are eliminated while improving safety conditions for employees and greatly reducing downtime and costs.

Ready to get started or have questions? Locate the Parker Distributor near you. 

Learn more about Parker's QuickFit Oil Change System. 

Contributed by Matt Walley, product sales manager, Quick Coupling Division, Parker Hannifin

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Considering the variables that require attention in the design and installation of a fluid conveyance system, it is no wonder that hydraulic system engineers, operators and technicians are concerned with the broad margins of error when it comes to assembly and installation. Some of the challenges faced by machine manufacturers include lack of standard routing protocols, misalignment of steel tubing, and how to reduce the number of leak points – while trying to contain costs at the same time.

Solutions to these issues come from proper assembly, installation, and specifying the right hoses and tubing for the application – factors that are critical to the trouble-free operation of mobile equipment employed in construction, forestry, mining and similar industries. 

This blog examines how formed thermoplastic hoses address these challenges and details how a skid-steer manufacturer reduced labor time and realized significant cost savings.

Applications requiring hoses installed in complex routings with tight tolerances create difficult installations. Many OEMs provide assembly part numbers, but not routing instructions. This can result in employees routing assemblies differently which can lead to quality issues like side load on the fitting or abrasion against edges of the frames on the equipment.

Formed hoses borrow from the principles of bent steel tubing and apply them to thermoplastics, creating an easy to drop in assembly that ensures consistent routing, mitigation of risk factors that lead to quality problems, and faster assembly times. 

Download the white paper and case study to learn how formed thermoplastic hoses reduce risk and lower labor costs.

If a hose is misaligned and cannot be successfully hooked up, or if routing causes kinking or other damage, production will halt, reducing productivity and output. 

“As little as 1/8” of misalignment to the connection could create enough issues to potentially shut down an operation and require the product to be re-worked.” 

 – Matt Davenport, product sales manager, Parker Parflex

With some consideration and the right choices in design, these threats can be mitigated, assuring reliable system operation.

Thermoplastic hose combines the forming characteristics of steel tubing with the flexibility of hose allowing for movement to eliminate misalignment concerns. 

Leaks and flow stoppage are two primary risks of misalignment and improper routing in fluid conveyance systems.  

Leaks are often caused by misaligned connections. Improper measurements, resulting in forced connection and incorrect actuation of connectors will cause leaks. Additionally, the actual number of connections in a fluid system will increase or decrease the potential for leak points; thus, careful consideration should be given to minimizing the number of connections in a system. One continuous formed thermoplastic hose reduces the number of fittings required and can decrease leak points by 50 percent when compared to hose to tube combinations.

Flow stoppage can occur when hoses and tubing kink. Kinks are common when hoses and tubing are routed in ways that create an excessive bend radius. A protocol that identifies the best routing for the run will ease the stress and assure that kinking does not interrupt the flow. Formed hoses take this a step further by standardizing the hose assembly for a custom fit to the optimum routing.

In addition to the trouble-free design enhancements, employing formed hoses allows for: 

• Standardized installation for faster assembly time.
• Part reduction – fewer fittings required.
• Lower shipping costs – formed hoses can be bent and placed in smaller boxes for shipping, whereas steel tubing/hose combinations require crates.

A skid-steer manufacturer who adopted ready to install formed hoses by Parker’s Parflex Division realized over $37,000 in labor savings associated with decreased assembly time and part complexity. 

To read the details of the case study and learn more about how formed thermoplastic hose technology is reducing risk and enhancing productivity, download the white paper - Engineering Solutions with Formed Thermoplastic Hose and Tubing.

This blog was contributed by Matt Davenport, product sales manager, Parker Parflex.

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Located in Rio Grande do Sul, the Port of Rio Grande is one of the main shipping ports for Brazilian products to the world. Geographically speaking, the Port of Rio Grande is ideally located and firmly established as the Southern Cone port. Known for its robust performance in the extreme south of Brazil, it is sited between the most important ports of the American continent, in terms of productivity, offering fast and quality services.

The port complex gives rise to expressive loads of soy, rice, wheat and oil, as well as to different manufactured products. Due to its relevance to the region, it is known as the Port of Mercosur, and in 2015 alone it handled more than 37 million tons of cargo.

Tecon Rio Grande, the container terminal of the Wilson Sons Group, operates at full capacity to keep up with this vessel loading work. After all, a faster terminal helps reduce the costs of the operation and benefits shipowner clients. For Tecon, a significant part of its operations involves equipment equipped with hydraulic drives, such as Super Post Panamax Ship to Shore cranes, and  Rubber Tire Gantry Cranes. The company identified the need to optimize the management of hoses on its machinery and reduce risk. They found in the Parker Tracking System (PTS) the ideal tool to achieve this goal.

"We needed a solution that would help us document and monitor our hoses in order to reduce downtime and improve our preventive maintenance,"

Jorge Roberto Corrêa Bacelo , Tecon, coordinator of maintenance planning.

The implementation of the PTS system in Tecon was a phased approach starting with documentation of hoses. The process is being led by Hidrautini - authorized Parker distributor for  Hydraulics, Filtration and Fluid Connectors Divisions in Porto Alegre. By means tracking labels with specific data for each component installed, the innovation will guarantee that Tecon has total control over the tracking of performance and life of the hydraulic hoses on their equipment.

According to Alexandre Martini, director of Hidrautini, in heavy-duty operations such as those practiced at the Port of Rio Grande, it is estimated that a hose will last on average two years. 

"Even knowing this parameter, it would be impossible to manually measure the efficiency of these parts in the day to day of a company that operates 50 different pieces of equipment with different types of hose. What Parker's system is offering us is the ability to control and measure the wear and tear of these products simply and efficiently."

 Alexandre Martini, director of Hidrautini, Parker Authorized Distributor

The process of implementation for PTS began with prioritization of the hoses considered high risk, which are subject to premature wear. Thus, from now on the predictive and preventive measures can be taken in a more agile way.

"For a company like Tecon, which seeks rigorous certifications such as ISO 14001, OHSAS 18001: 2007  and ISO 18000, any oil leakage is relevant," explains Jorge Bacelo. "Therefore, using a tracking technology as advanced as PTS and providing a differentiated service is essential to expedite possible replacement processes," he concludes.

Chosen as a starting point for documentation, container forklifts are the first Tecon equipment to receive Parker technology. Soon, mobile cranes will also be included in the project, as well as other machines - Rubber Tyred Gantry (RTG) cranes, portainers (port cranes handling containers) and cranes.

The Parker Tracking System (PTS) provides full traceability of hoses installed in the field. The system stores data digitally, allowing it to be accessed by any device connected to the internet, including cell phones.

This technology allows total control in the management of components and greater ease in the acquisition of items for replacement, which can be ordered directly from the workplace, ensuring agility in the exchange of parts, reduction in machine downtime and increased productivity.

The solution also allows to reduce stocks and subsidize dockage projects. The system uses polyurethane labels with a layer of resin tested at 150 ° C or metal labels for more aggressive applications, both resistant to UV radiation, sea spray, submersion in fuels and salt water.

Watch this video on our latest PTS Mobile Application

For more information on Parker technologies, visit our website on Parker Tracking System 

Featured image source: Port de Rio Grande Website

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Heavy-duty vehicles, such as trucks and trailers, use air brake systems to assure safe and effective stopping. Air brake tube fittings are a virtually invisible component on these vehicles, but they are instrumental to the reliable operation of the air brake system. A typical truck requires between 60-100 air brake tube fittings, and these components can have a significant effect on brake system performance, cost and assembly line productivity. In this blog, we will explore the major types of DOT air brake fittings used by truck and trailer OEMs and how they compare on price, performance, ease of assembly and customization as well as new technology trends.

The U.S. Department of Transportation (DOT) standards have been in place for over 50 years and they specify how air brake hose and tubing, assemblies and end fittings used on trucks and trailers are expected to perform. The official requirements for DOT-certified air brake fittings are published in Title 49 of the Code of Federal Regulations, Section 571.106. 

These regulations were developed to reduce injuries and fatalities that could occur as a result of brake system failure. DOT-certification is required for the air brake hoses and tubing used to control the air brakes, and for the end fittings directly connected to those hoses and tubing. There are certain applications for fittings and tubing outside of the air brake system on heavy trucks, including air horns, air-ride seats, axles and others. Fittings and tubing used for these applications do not need to be DOT–rated. However, most OEMs choose to avoid the mistake of applying a simple industrial fitting into an area of use requiring DOT conformance. They will standardize on DOT conforming parts, adsorbing the higher cost to ensure safety.

For best practices on choosing DOT air brake tube fittings download the complete guide.

Air brake tubing, tube fittings and plastic air brake tubing assemblies must be able to meet the following code requirements:

• Construction
• Tensile strength
• Boiling water conditioning and tensile strength
• Thermal conditioning and tensile strength
• Vibration resistance
• End fitting retention
• Thermal conditioning and end fitting retention
• End fitting serviceability
• End fitting corrosion resistance

There are several key factors truck and trailer OEMs should consider when choosing DOT conforming air brake fittings:

• Fitting performance
• Price
• Assembly time
• Customization
   

An industry staple for decades, brass compression fittings are trusted for their dependable, versatile application and comparatively low price point. While they are priced competitively, installation tends to be more labor-intensive than other types of fittings. Once installed though, they are considered excellent in terms of forming joint connections and offering superior sealing performance.  

Brass compression fittings withstand high heat. As such, they are often chosen for environments near air compressors and in engine compartments.  

Customization lends itself well to brass compression fittings. Brass can be manufactured into various shapes with relative speed, however, its physical properties can add some manufacturing complexity.

Introduced in the 1990s, brass push-to-connect fittings offer reductions in fitting time assembly and complexity. They maintain the performance profile of brass compression fittings, yet allow for relatively foolproof assembly with no additional tools other than a tool cutter.

The biggest benefit to brass push-to-connect fittings is the assembly time savings. Installation time can be reduced by as much as 90%. Compounding this savings over time and installations can represent an enormous cost improvement for the user. In addition, the brass push-to-connect fittings can be color-coded. This helps to identify where the fittings are to be installed, saving more time and reducing installation errors. 

Although the unit cost is higher for a brass push-to-connect fitting than a compression fitting, the labor savings more than makes up the difference.    

Brass push-to-connect fittings offer similar customization attributes to compression fittings. But the advances in simplicity, fool-proof design and color coding, make them an exceptional choice, adding value to truck OEMs.

Manufactured with a polymer body and brass screw threads, composite push-to-connect fittings offer all the labor saving features of brass push-to-connect fittings. However, due to the polymer, the material is lighter in weight and lower in cost than brass. The 43% weight reduction, when considered in aggregate on board a truck where 100 or more DOT fittings may exist, can be a substantially positive design factor. Customization is also enhanced as the polymer is formed using versatile injection molding processes. This allows for freedom in creating uniquely shaped bodies for specific applications.

In recent years, engine temperatures have increased, due to design enhancements that offer other positive benefits. This has pushed the upper-temperature limits of some DOT push-to-connect fittings and tubing. When maximum operating temperatures are close to, or surpassed, the probability of problems occurring, such as leaks and premature hardening of elastomeric seals, increases. 

This challenge can be met in several ways. Some manufacturers have opted for brass compression fittings in high heat areas. Others have chosen to modify the seal used in push-to-connect fittings. They have increased the thickness of the elastomeric seal, thereby offsetting the accelerated setting activated by heat. Still, others have designed completely new DOT-rated push-to-connect fittings, with a higher maximum temperature specification.  

Two main types of thread patterns are typically used on air brake tube fittings: American National Standard Taper Pipe Threads (NPTF) and Straight Thread O-ring (STO).  

While NPTF threads are far more common, STO fittings are found to be more reliable connections where they are employed. This is largely due to the sealing being completed by an elastomer O-ring as compared to the metal-to-metal sealing in an NPTF fitting. In NPTF fittings, voids in the connection remain, increasing the chance of leaks. 

An STO fitting does present an increased cost to truck OEMs. They may require some customization of the fittings or their respective components. The added reliability of the STO fitting will need to be weighed against the increased cost by the truck OEM.

Truck OEMs want to avoid performance issues with air brake assemblies at all costs because these may lead to accidents, complaints, investigations, warranty claims and recalls – with significant financial implications and public repercussions. Careful consideration should be given to selecting the right type of DOT fitting to optimize brake system performance while at the same time keeping costs in check.

To learn more about what to consider when choosing DOT air brake tube fittings, download Parker’s guide “The Truck and Trailer OEM’s Guide to Air Brake Tube Fittings”.

This blog was contributed by the Fluid and Gas Handling Technology Team, Parker Hose Products Division.

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Over the past 6-1/2” years the water blast industry has witnessed significant positive progress in many areas of operation, most notably the area of safety. In September 2011, WJTA established a color coding scheme using system operating pressures through its Recommended Practices for the Use of High-Pressure Water Jetting Equipment. Manufactures throughout the water blast industry responded to meet this recommendation, with UHP hose manufacturers moving away from their traditional hose jacket colors to ones that complied with the recommended color scheme.

OEM pump manufacturers ensured each component from the UHP pump to the “shotgun” was compliant with WJTA recommendations. Since then, OEM’s have also made tremendous advancements in the process of heat exchanger cleaning. Automated equipment now allows the operator to work at safer distances from high- pressure lines while improving productivity and reducing worker fatigue.

To learn more, download our white paper Why Safety Concerns Are Changing the Water Blast Hose Market.

Major water blast contractors also embraced increased safety for operators by examining every area of their operation and looking for ways to eliminate risk while raising productivity and lowering operational costs. Overcoming these challenges, in many cases, required taking a second look at some of the most traditional water blast practices. For example, one tradition has been the use of a PVC cover on UHP hose assemblies. The objective was to lower operational costs by protecting the UHP hose from abrasion. The PVC cover served its purpose by protecting the underlying UHP hose and reducing the occurrences of abrasion damage. The lengthened service life of PVC covered assemblies justified the modest cost increase for the PVC and became an accepted practice in the water blast market.

While the PVC cover solution has remained unchallenged for decades, the increased focus on safety has exposed the weaknesses of this approach. With the proper inspection of every component of the assembly being paramount to safety, foremost, is the inability to thoroughly inspect the entire assembly before use: 

• The PVC cover obscures the underlying high-pressure hose.

• Over time, as the PVC begins to discolor from exposure to UV rays, the ability to visibly inspect a PVC covered assembly decreases further. 

• As dirt and debris from the application find their way into the PVC cover, it becomes nearly impossible to inspect the UHP hose inside.

Secondly, a PVC cover adds weight to the assembly, increasing the amount of effort or force required to drag the assembly across a surface. A common issue with PVC cover is that water builds up between it and the hose, further adding to the weight. The heavier load requires more effort during the cleaning operation, moving hoses as the work progresses, and loading assemblies back on to service trucks upon job completion. This increased effort contributes to operator fatigue and muscle strains possibly leading to other injuries and job- related mistakes.

In many cases, weight is also the destructive force causing the PVC cover to detach from the retaining collar, commonly referred to as PVC cover pull out. Even without additional weight, PVC pull-out can occur by merely dragging the assemblies while holding the cover. The other alternative is pulling the assembly by the PVC collar. By applying the load to the collar, the force transfers into the fitting. While crimped fittings can sustain some level of external force, experts do not recommend it. The fact is, there is no good way to drag a covered hose.

Another potential hazard associated with a PVC covered hose assembly is operator confusion regarding the true purpose of the cover. It is not uncommon for operators to mistake the PVC cover for a burst containment shield. This misunderstanding could result in an operator using a PVC covered assembly when the application requires a safety shroud or burst shield, thus increasing the chance of injury for the operator and bystanders.

With the realization that PVC covers protect from abrasion but at the cost of operator safety, the challenge is to provide an abrasion resistant hose that:

•  solves the problems of the inability to inspect the underlying hose;

•  prevents water ingression and reduces weight to eliminate fatigue;

•  eliminates PVC pull out; and,

•  stops confusion regarding the burst shield.

Safety is important at Parker. Our hose engineers have developed a solution to these challenges by extruding a highly abrasion resistant secondary jacket directly onto the primary UHP hose. The extrusion of a secondary jacket on water blast hoses, referred to as TOUGHJACKET™, addresses every area in which a PVC cover falls short while adding a few more benefits. 

“Abrasiontesting of the TOUGHJACKET material to ISO 6945 showed the proprietary polyurethane jacket achieves abrasion levels at least 100 times greater than PVC.”
— George Molinar, senior engineer Parker Hannifin

The TOUGHJACKET hoses also have a WJTA compliant outer jacket color, with the underlying primary hose having a contrasting color. This contrast in the hose jacket colors serves as an early warning indicator of an abrasion problem to the operator and safety inspector, prompting the operator to correct the abrasion issue or potentially remove the assembly from service.  And since the secondary jacket is extruded on to the UHP hose, it is impossible for water to ingress into the assembly, eliminating all weight gain caused by trapped liquids. Ultimately, it allows operators to fully inspect all components of the hose assembly.

To learn more about how safety concerns are changing the water blast market, download our white paper Why Safety Concerns Are Changing the Water Blast Hose Market.

Article contributed by Paul Walker, business development manager for Ultra-High Pressure Thermoplastic Hose at Parflex, Parker Hannifin.

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The European standard EN 45545 was introduced in 2013 with a transitional period until 2016 and raises the level of requirements to the previous national standards, which have now been withdrawn.

The standard affects manufacturers of rail vehicles in all different categories including high-speed trains, regional trains, city-trams, industrial rail transportation and truck maintenance vehicles. But what does this all mean for design engineers of rail vehicles?

Download the rail hose selection guide here

The EN 45545 aims to protect passengers and staff against onboard fire incidents on railway vehicles. Part two of the European standard (EN 45545-2) defines tighter requirements for the fire behavior of materials and components including flooring, seats and cables on railway vehicles.

This part also specifies the test methods, test conditions and reaction to fire performance requirements.  Concerning the burning behavior of hydraulic hose materials, the EN 45545-2 contains specific requirements for oxygen index, smoke density and smoke toxicity. Products are classified according to 26 requirement sets (R1-R26) depending on where the materials are used. Each requirement has a corresponding series of test performance criteria. The requirement sets defined for hose materials is R22 (inside the vehicle) and R23 (outside the vehicle) and as well three hazard levels (HL1, HL2, HL3). HL1 contains the lowest requirements and HL3 the highest. The classification depends on how many kilometers the rail vehicles are in a tunnel and whether they are automatic, two-stores or if sleepers are on board.

Several tests are used to measure how the product compares to the product requirement sets. EN 45545-4 contains normative references to the EN 50553, which is furthermore important for hose assemblies installed within hydraulic/pneumatic circuits essential for the running capability of the vehicle. Hose assemblies selected for such important applications must pass a flame test according to ISO15540 (min. 800 °C for at least 15 minutes).

New trains built from March 2016 onward must be in line with the new standard. It is no secret, that the rail rolling stock industry is among the world’s most demanding in terms of the pressures placed on components and systems used, particularly considering the extremes of vibration and temperature that are present in typical operating environments.

As we are now in the age of higher speed trains, longer tunnels and the need for greater survivability, the European Union was looking for an alternative either to the prior valid different national safety standards or to the classic hose assembly flame test in accordance with EN 15540 and all of this combined with the demand to ensure compliance with ever lower pollutant emission limits. Design engineers have to deal with a variety of pneumatic, hydraulic and further applications which require different hose characteristics and this means a range of different hose types and all of these hose products must be EN 45545 approved. These challenging requirements can be a burden for a design engineer.

The first step is to determine which product requirements apply (R1-R26). Secondly, determine the fire hazard level (HL1-HL3) and finally, identify a suitable material that meets the above ratings and the technical requirements for the application. It is Ideal to select a partner and products that meet all requirements set and that have been tested and approved according to the EN 45545-2 requirements.

Working with a certified and well-experienced partner can ease the selection of the right components. Parker has developed a complete range of rail hoses (RH) for rail applications from low to high pressure and was the first hose European manufacturer to develop a new rubber compound to meet the required standards of EN 45545 in terms of fire retardancy, smoke behavior and toxicity. On top of that, the Parker RH hose range delivers additional advantages such as a better bend radius to support easier design and routing and assembly cost savings. All hoses can be supplied for many rolling stock applications:

• Hydraulics (brake system, hydrostatic): 441RH, 477RH 421RH, 477RH, 372RH, 797RH
• Pneumatics (brake system, suspension, auxiliary systems): 801RH, 681DB, 421RH, 441RH
• Cooling systems (water cooling, air conditioning): 801RH, 681DB, 441RH, 421RH, 441RH
• Fluid Conveying (diesel fuel, water for sanitary facilities and heating (water): 801RH, 681DB,  421RH    

International companies with substantial expertise, such as Parker, have a global presence for the leading players of the rail industry and can offer the right hose for each rail application and on top, you can choose the way of product supply which best answers your individual manufacturing philosophy. The delivery options include complete hose assemblies, hose/tube assemblies, single hoses and fittings and hose crimpers and tooling for the Parkrimp No-Skive self-assembling.  

The Parker Rail Hose range focuses on the safety of people and property and for many years has been supporting all relevant applications within different types of railway trains and vehicles. A comprehensive cheat sheet that details all you need to know about a successful rail hose selection has been developed.

For more information, download the brochure "The Rail Hose Range for European Rail Transportation'"

This blog was contributed to by Conny Stöhr, marketing services manager, Hose Products Division Europe.

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In today’s medical device industry, there is strong demand for smaller, sleeker designs and speed to the market with the newest breakthrough products. Engineers designing respiratory equipment, such as ventilators and anesthesia machines, are challenged by a host of critical factors. Users demand top performance and compliance with evolving regulatory standards. Medical device original equipment manufacturers (OEMs) must address these challenges by producing equipment that meets design specifications and performance expectations while also controlling costs. To do this, resources need to be identified to help meet these needs and expedite the design process.  

A direct acting proportional valve, integral to the design of an inspiratory flow system, provides precision control for the flow of gas. Specialized proportional valves are available for application in ventilators and anesthesia machines and provide accurate and safe delivery of precise gases to patients.  

In this blog, we will focus on proportional valves and the key factors OEM design engineers should consider when selecting them to meet ventilator and anesthesia machine design requirements, including:

• Installation and component functions.
• Application considerations and requirements.
• New proportional valve technologies.

Choose the right proportional valve for your application needs, download the guide, "Selecting a High Flow Proportional Valve for Ventilators & Anesthesia Machines".

There can be on the order of a dozen components in an inspiratory flow system. Proportional valves are often located in the middle of the system and provide flow control of the gases employed and prevent over-pressure in lines. Other components may include: inlet filters, pressure transducers, auto zero or calibration valve switches, check valves, pressure regulators, mass flow sensors, relief valves, oxygen sensors and fittings and tubing. The various components can be categorized as safety elements and control elements. Proportional valves are considered control elements.  

The following application and design specifications should be considered when selecting a proportional valve:

Air source: Most ICU/Operating room and general ward ventilators use hospital plumbed air which can be prone to significant pressure variations. A proportional valve will balance the variation of pressure. Depending on the application, using a high-pressure proportional valve can eliminate the need for a pressure-reducing regulator.

Safety: When a pressure reducing regulator is installed for safety purposes, then a proportional valve is necessary to maintain consistent flow rates.

Device size: Trends are towards smaller systems.  Employing a proportional valve with pressure regulation can reduce the number of pressure management components needed, thus reducing system size.

Gas compatibility: Careful selection of proportional valves with compatible elastomers is important, particularly in anesthesia applications. 

Life and reliability: Documented life testing across varied temperatures and conditions is important to the prevention of premature aging of valves. 

Compliance: It is important to select a valve that meets the most recent directives and regulations pertaining to the manufacturing of medical device products and components such a RoHS and REACH. 

Mounting style: Proportional valves have several mounting options.  The most common are manifold and cartridge.  Selection should be based on the best fit for the designed system. 

Customization: If customization is a requirement, choosing a supplier that offers flexible design capabilities such as lead wires, calibration and mounting options is ideal.

The specifics of the installation location, physical size constraints, type of gases being used, the extent of use anticipated and operating conditions are variable and should be reviewed on a case-by-case basis.  Once a clear picture has been drawn, the following considerations should be evaluated, specific to the proportional valve selection:

• Flow and pressure requirements
• Media compatibility
• System voltage
• Current control
• Mount size, weight and orientation
• Control capability
• Power profile
• Calibration

Parker Precision Fluidics has recently expanded its line of proportional valves for respiratory equipment such as ventilators and anesthesia machines as well as other life science applications. The VSO® MAX HP line consists of two models that offer a combination of flow performance, operating pressure range, controllability and power efficiency.

Features include:

• High valve-to-valve consistency.
• Reduced power consumption profiles and lower heat generation. 
• Cleaned for oxygen service.
• Reach and RoHS compliant. 
   

When specifying proportional valves for medical equipment such as ventilators and anesthesia machines, it's important to consider component functions, application requirements and system specifications to ensure the valve you choose optimizes the performance and design of the device while keeping costs in check.

For additional information on choosing proportional valves for ventilators and anesthesia machines, download the guide "Selecting a High Flow Proportional Valve for Ventilators & Anesthesia Machines".

This blog was contributed by Sam Ruback, marketing development manager, Parker Precision Fluidics Division.

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From OEM component suppliers to heavy-duty truck manufacturers, there are advantages of using cartridges in transportation applications. 

Cartridges are used across many markets including industrial, pneumatic, filtration, semiconductor, life science, automation, and heavy-duty trucking. In all of these markets, manufacturers and end users alike recognize the benefits of a compact sealing design that improves system reliability. Originally developed for thermoplastic materials, specialty cartridges have been manufactured and tested for a variety of materials to bring the sealing technology to a wide array of applications. 

Many of our OEM manufacturers that supply to the transportation market have found great success in utilizing Parker’s Prestomatic SAE Encapsulated Cartridges in their systems. Let’s take a closer look at how manufacturers can improve system reliability and automate their processes.

For best practices on choosing DOT air brake tube fittings download the complete guide.

Basically, any component that uses compressed air on the truck could potentially utilize a cartridge. In-cab controls, air horns, air ride seats, airbags, brake valves and leveling valves are all great examples. A cartridge connection is typically taking the place of a threaded port.

Cartridges are very compact and provide great advantages when working in tight spaces. It is not always easy to get a wrench in tight spaces and pipe fittings are known to leak when not installed properly. A cartridge eliminates this worry with assembly simply by pushing the tubing into the cartridge. The compact design of the one-piece cartridge enables automation of the manufacturing process and improves system reliability. The cartridge becomes an integral part of the overall component, eliminating threaded connections and the possibility of spiral leakage along the mating threads.

This affords the component manufacturer the ability to produce a highly reliable product that allows end users and truck manufacturers to speed up their assembly time. Cartridges also often provide the opportunity to reduce overall weight, which is always of importance to the trucking industry.

In short, this technological advancement to the industry brings consistent reliability and a number of benefits to the end user truck manufacturer. As mentioned before, ease of assembly ranks high on the list of benefits. In addition, when a cartridge is used in a port, there is no need for the truck manufacturer to buy fittings for the ports. It is a quick and easy push-to-connect assembly that saves time and money in the assembly process. Easy assembly equates to fewer errors and therefore a more leak-free solution. In fact, with the low profile solution that a cartridge offers, more design freedom for future changes and improvements are possible; not to mention the ability to color code the connections to ensure proper plumbing of the system.

Now that we understand the benefits of using a cartridge in place of a threaded port, let’s take a quick look at the actual features of the Prestomatic SAE Encapsulated Cartridges. 

• The SAE encapsulated cartridge meets performance requirements of FMVSS 571.106 and SAE J2494-3 and the proposed dimensional standards of SAE J2494-4 in 6061-T6 aluminum.

• The push-in connection is self-centering in the cavity and no thread is needed to insert the fitting into its cavity.

• The seal is pre-assembled, greased and protected.

• The cartridges are protected against contamination from manufacture to installation and the packaging is designed for the automation assembly process.  

Watch our latest video to see the benefits of using a cartridge versus a tapered thread fitting: 

Parker’s Fluid System Connectors Division offers the widest range of brass fittings for the transportation market and SAE encapsulated cartridges are just a glimpse into the vast offering we provide. From extruded, forged, plated, and composite materials, we make connections to bring increased efficiencies and higher productivity. Our vast offering of NTA, Transmission, Vibra-Lok, Prestomatic, PTC, Air Brake Hose Ends and PMH, and Pipe fittings can fit the needs of the heavy truck market with superior quality.

For more information about our Prestomatic SAE Encapsulated Cartridges or the rest of our vast offering of transportation fittings, please contact Parker Fluid System Connectors Division at (269) 694-9411. 
 

Article contributed by Samantha Smith, marketing services manager, Fluid System Connectors Division.
 

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Composite DOT-certified push-to-connect fittings are manufactured with a polymer body and brass screw threads and holding mechanisms. They utilize a collet to grip tubing, plus an elastomeric sealing mechanism to complete the tube end seal, allowing for a relatively foolproof assembly with no additional tools other than a tube cutter.

Like their brass counterpart, Prestomatic (PMT), composite PTC fittings do not rust or corrode. The internal push-to-connect sealing mechanism affords a strong and dependable seal robust enough to meet all DOT parameters and to withstand high and low-temperature extremes.

Composite fittings are particularly notable for their lightweight and durable construction, which features the same sharp biting edge as Parker’s Prestomatic fittings. What’s more, the weight benefits provided by composite push-to-connect fittings over brass fittings are significant enough to affect fuel efficiency and payload potential.  

Composite push-to-connect fittings weigh about 43% less than brass push-to-connect fittings. With approximately 60 to 100 DOT tube fittings used per truck, that equates to a weight savings of about seven to nine pounds per vehicle! When you consider that some fleets number in the thousands, the potential benefits of composite push-to-connect fittings are substantial and can be passed along to end users.

One major benefit of PTC technology is the time savings in assembly. Attached to tubing with a simple push, these fittings may reduce assembly time by as much as 90 percent over compression style fittings, averaging four seconds per connection. That means an assembler who used to assemble 90 compression fittings in one hour may be able to assemble as many as 900 connections with push-to-connect fittings. This also means one worker can potentially complete in one hour, the same number of fitting connections it would have taken 10 workers to complete.
 

Considering an hourly wage of about $25, the labor cost to assemble each compression fitting connection is around $0.27, compared with just under $0.03 for each push-to-connect connection. At that rate, by switching from compression fittings to push-to-connect fittings, a manufacturer could potentially reduce its assembly labor costs from $250 per hour to less than $50. The financial benefits are compounded when you consider that with faster assembly processes, OEMs may also be able to produce more vehicles per hour with push-to-connect fittings.

Since push-to-connect fittings don’t require manual assembly or counting turns of the wrench, truck and trailer OEMs may be able to increase the consistency of the quality of their assemblies. Another time-saving benefit of push-to-connect fittings is that they can be supplied with color coding on the tube ends of the fittings, helping to specify which sections of the air brake system the fittings are to be installed. This not only adds further time savings by categorizing fitting connections but also helps to prevent installation errors and rework.

They also add greater customization potential for truck OEMs, since they allow for the creation of uniquely shaped bodies produced by injection molding processes. With longer lead times and upfront tooling costs required, custom-made composite fittings make sense when higher quantities of the custom fittings are required. However, with proper mold design, suppliers may be able to offer jump-sized versions of a part at a fraction of the cost and lead time required for the original component.

Although the unit cost of composite push-to-connect fittings is higher than that of compression fittings, most truck OEMs find the significant labor savings and weight reduction of this product more than make up for higher unit costs. And, when installed properly, DOT-rated push-to-connect fittings are just as reliable as compression style fittings in virtually all applications.

Article contributed by Samantha Smith, marketing services manager, Fluid System Connectors Division.

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Traditionally, DOT-rated compression and push-to-connect fittings use American National Standard Taper Pipe Threads, referred to as NPTF pipe threads. NPTF or pipe fittings feature tapered threads providing the mechanical strength needed to hold the joint together, plus the metal-to-metal sealing formed when the tapered threads are tightened against tapered port threads. This thread type requires the use of a thread sealant to seal any spiral leak paths or voids that may remain between the tapered threads on the fitting and threads on the port.

The far more common industry standard for the connection ports installed on air brake system components such as air tanks and brake valves, the choice of pipe thread fittings often arises as a matter of necessity, with the fitting thread dictated by the corresponding ports on components. As another benefit, pipe threads don’t require an additional sealing mechanism, besides thread sealant, and they tend to be the lower cost of the two major types.

The main disadvantage with pipe threads, however, is that voids in the connection still can remain. Pipe threads are prone to leakage, especially since there is no other sealing mechanism besides the tapered threads themselves. In air brake systems, pipe thread leakage has been noted at one area in particular-- port connections on air tanks, a known source of warranty claims. Studies of these leaks have shown it may be the way these ports are manufactured that leads to a poor seal.

The process requires female threads to be machined into steel spuds that are welded into the air tank. The ensuing welding process can cause the spuds to warp, which results in a poor fit. In addition, certain NPTF threads can be difficult to position. For instance, an elbow pipe thread fitting may need to be loosened to orient, creating a potential leak path. 

Leakage issues like this are less of a concern with the other main fitting thread type, the straight-thread O-ring (STO). Fittings of this design have straight threads providing only the mechanical connection, but not the airtight seal. Meanwhile, the seal is handled by an elastomer O-ring seal or gasket that mates up against a defined portion of the equipment. In this way, the O-ring compensates for any variation in the surface of the port.

A less common option for ports installed on air brake components, STO fittings may not be specified in systems with the frequency of pipe threads. However, they have proven to offer more reliable connections where they’re used. For example, warped air tank spuds have less impact when STO fittings are used. One OEM found that most of their warranty claims for air leakage disappeared when they switched from air tanks with pipe thread ports to tanks with STO ports. 

However, the added reliability of STO fittings also comes at an increased cost to truck OEMs. In many cases switching to STO fittings may require some customization of the fittings or their respective components. These are costs and benefits for OEMs to weigh as part of their overall business plans.

Article contributed by Samantha Smith, marketing services manager, Fluid System Connectors Division

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Diesel and biodiesel engine manufacturers are moving toward electroless nickel plated connectors as part of their fuel system specification. We’ll tell you why.

The transportation and mobile markets always keep performance at the forefront of their specifications, standards and recommendations for truck, bus and other heavy truck applications. As a leading supplier to this market, Parker is committed to responding to the needs of changing requirements.

An increased use of various diesel and biodiesel fuels in heavy-duty fuel systems creates the need to continually assess the compatibility of system materials and the fuels themselves. It has been known for quite some time that B100 (pure) biodiesel fuel can degrade some hoses, gaskets, seal elastomers, glues, plastics, rubber compounds, polypropylene, etc. and the list continues to grow as testing advances. PTFE, Fluorocarbon and Nylon have been known to perform well with B100 biodiesel. B20 biodiesel blends of 20 percent or less have fewer effects on these materials, but great caution in material selection is always important.

Recently, it has been noted through further testing that the oxidation process of diesel and biodiesel may be accelerated when using materials such as bronze, tin, lead and zinc. This can create insoluble fuel gels or salts, which can cause blockage in fuel system lines. Heavy-duty manufacturers are responding by eliminating these materials (commonly used throughout the truck for many different applications) as a part of the fuel system.

Brass is comprised of approximately 60 percent copper, 38 percent zinc and 2 percent lead, all materials that are noted to accelerate corrosion with diesel and biodiesel fuels. Copper acts as a catalyst, accelerating the aging of diesel fuel, which creates organic acids. This acid, in turn, corrodes the copper, releasing copper ions that become absorbed in the fuel stream and damage downstream components.

The zinc in brass is also cause for concern due to the fact that diesel fuel, when in contact with zinc or zinc compounds, will become contaminated with low levels of zinc, which can form zinc salts. These salts will tend to form insoluble gels in the fuel and can plug fuel filters, narrow orifices, fuel injector nozzle holes and other small diameter passages within the fuel system.

Parker's Fluid System Connectors Division has responded to the changing diesel and biodiesel fuel system needs. In order to improve performance in the fuel lines, manufacturers must switch to a material that does not oxidize in fuel systems. Stainless steel is an option, but an expensive one. In turn, Parker has electroless nickel (ENI) plated to the fuel wetted surface (the area of the fitting that comes in contact with the fuel) of their brass fuel fittings to accommodate the increasing need for improved performance in the fuel systems.

This provides a very cost effective solution to the problem. While only electroless nickel plating the components in contact with the fuel, the non-fuel wetted components of the fitting can remain brass. The electroless nickel plating prevents corrosion and wear, provides robust chemical compatibility and is approved by all current suppliers that have changed their specifications to accommodate the new requirements. In fact, Parker has the capability to add an electroless nickel plated coating to any brass component that we manufacture.

For more information about our vast offering of DOT transportation fittings, please visit our website  or contact Parker Fluid System Connectors Division at (269) 694-9411.

Article contributed by Samantha Smith, marketing services manager, Fluid System Connectors Division.

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Blowout prevention systems (BOP systems) are one of the most important pieces of equipment used in exploration and deep drilling applications. These large systems are vital to safety in both on- and off-shore operations, working to restrict or shut down pipes in the event of a blowout. 
 

In the Oil and Gas industry, blowout preventers are critical to the safety of crew, rig and environment, as well as monitoring and maintaining well integrity. BOP systems are intended to provide a fail-safety to the systems that include them in drilling operations. This fail-safety means that BOP systems must be dependable, strong and in perfect working condition. The dangers of deep drilling and exploration leave little room for mistake, and safety equipment such as blowout preventers is vital, and sometimes life-saving.

BOP fluid in hydraulic lines provides the muscle needed for the blowout preventer's powerful rams to seal a well shut during drilling or in an emergency. This prevents pressurized hydrocarbons from escaping into the environment. The BOP Stack is equipped with hydraulically-powered rams that prevent the escape of high-pressure gas if a gas pocket is encountered while drilling. Therefore, the hydraulic hoses act as control lines that operate (open/close) the rams. Blow-out prevention is a major safety and environmental issue and therefore there are extremely stringent requirements regulated by the American Petroleum Institute for BOP systems.

A blowout in the world of oil and gas drilling is the uncontrolled release of crude oil and/or natural gas following the failure of pressure control systems. Before pressure control equipment was made available in the 1920s, the uncontrolled release of oil and gas from wells during drilling operations was common. The phenomenon was referred to as an oil gusher or a wild well. While gushers were iconic to oil exploration and served as symbols of newfound riches, they were dangerous and wasteful. An accidental spark in the event of a blowout leads to catastrophic oil or gas fires. Modern wells now have BOP systems, which are intended to prevent such damage and danger. 

Parker's high-performance BOP hoses are designed for hydraulic use and certified to withstand fire, high heat and pressures in safety critical applications. All Parker Fire Armor BOP Hose Assemblies are tested and approved by Lloyd’s Register (LR), ensuring compliance with American Petroleum Industry API 16D guidelines to meet and exceed OD/1000/499 flame testing at 1300°F for five minutes. 

Parker's range of BOP hoses are used for hydraulic connections between the well control equipment and the control system in BOP systems. Combining Parker’s trusted ParLock multi-spiral hose range with Interlock connection and optional stainless steel armor, these high-performance hoses are designed provide protection from external shock and withstand the pressures of BOP applications.

Parker offers a full range of hose sizes from -6 to -32 and a working pressure range of 3000 to 5000 psi:

The FA21 BOP Hydraulic Hose is made for general applications where flame resistance is required. The braided construction offers a constant working pressure of 3000 psi and a ½ SAE bend radius. The specially formulated cover is designed to withstand the flame test requirements outlined by API specification 16D. 

The FA35 BOP Hydraulic Hose uses a spiral construction that offers a constant working pressure of 5000 psi. The red synthetic rubber cover offers flame resistance.

Parker’s FA35 BOP hose can be combined with the optional metal armor cover to provide added protection against external damage in harsh environments. The armor is available in 304 stainless steel. 

BOP systems depend upon reliable, strong equipment for safety of operations and assurance that the system will effectively contain and stop damage in the event of a blowout. Parker's Certified BOP Assembler Program guarantees customers convenience, speed and the expertise of a local distributor with the quality, accuracy and traceability of a factory-made hose assembly. In the world of exploration and deep drilling, waiting for replacement parts means risking the safety of workers and possible environmental damage. To ensure the best speed to market, Parker-qualified distributors undergo workshop audits, the Parker Certificated BOP Hose Assembler Program and re-certification and auditing, which means minimal risk and maximum efficiency, keeping applications running and the job done safely and on time. 

Certified experts are trained by Parker to put together BOP hose assemblies which must then be tested and pass the assembly burst test. Certified assemblers then receive assigned designation. Only Parker-certified distributors are qualified to complete BOP hose assemblies. By certifying individual assemblers rather than locations, Parker ensures superior quality parts and proper assembly from local oil and gas distributors. All Parker-qualified distributors undergo re-certification and audits annually to ensure the reliable and safe products every time. 
 

Customers can expect convenient, on-hand inventory from local warehouse and assembly facilities, with an unmatched preventative maintenance plan that removes the burden of inspection and repair schedules and ensures safe and properly working equipment using the Parker Tracking System (PTS). A powerful, comprehensive and easy-to-use system, PTS provides fast, simple and accurate delivery of parts and services. Frequent equipment inspections and change outs are vital to safety in BOP systems. PTS provides assurance that Parker's BOP hose assemblies always provide superior quality, safety, and reliability in even the most severe conditions.

Balancing the need to control costs, while expanding exploration into ever harsher environments, requires a supplier who can address these challenges and bring innovation and quality through products and services that meet your needs. With more than five decades of experience serving the oil and gas market globally, Parker’s Hose Products Division has become a valued partner and technology leader for today’s oil and gas companies.
 

Article contributed by Kyri McDonough, marketing services manager at Hose Products Division, Parker Hannifin.

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Hydraulic Hose User Safety

Any of us who have driven a vehicle knows from experience certain mechanical issues produce symptoms that can be detected by our senses of touch and hearing. Vibrations felt in the steering wheel and noise from the floorboard can be indicators of out-of-balance tires. Warped brake rotors may trigger shaking through the brake pedal. Through abnormal levels of vibration, one can determine a mechanical device is declining. 

The same holds true for machines and industrial equipment. Many components of a machine are rotating and each one is generating its own distinctive pattern and level of vibration that creates a smooth flow of energy. But, when the flow is interrupted, excessive noise and shaking signal a problem or deterioration in the machinery. The reactionary move would be to service the equipment immediately. By being proactive though and pinpointing issues before they arise, you’re maintaining a machine’s integrity while getting the most out of your investment.

No two vibrations are the same. Each level and frequency are unique that even the human touch cannot distinguish. This is where a vibration analysis can provide the imperative sensitivity, especially for any rotating machinery, to evaluate the condition of equipment and avoid failures. Vibration analysis looks for anomalies and monitors changes from the established vibration signature of a system. This is achieved through recordkeeping of a machine’s vibration history and over time predict problems before serious issues arise.

A critical component of vibration analysis involves sensors. These machine-mounted devices are necessary to gather complete data to assess and monitor machine health quickly and accurately. That means obtaining a full-spectrum vibration signature in three axes (horizontal, vertical and axial) on both ends of the motor and driven equipment through an accelerometer, which measures low to very high frequencies. They are used for low to medium frequency measurements and are used for vibration monitoring and balancing operations on rotating machinery.

Sensors are used to quantify the magnitude of vibration known as vibration amplitude. In other words, it reports how smooth or rough the machine is running. A vibrations’ magnitude is expressed as:

• Displacement - total distance traveled by the vibrating part from one extreme limit of travel to the other extreme limit of travel.

• Velocity - the speed of the vibrating mass changes continuously.

• Acceleration - the value representing the maximum rate that velocity is changing. 

Vibration analysis and monitoring can be used to discover and diagnose a wide range of problems related to rotating equipment. This includes unbalance, misalignment, sleeve-bearing problems and resonance issues. However, determining the presence of these problems is not a simple and easily performed procedure. Collecting and evaluating vibration signature analysis can be complex and cumbersome.

Parker values the importance of vibration analysis to ensure the longevity of industrial machinery. They’ve introduced a simple, yet highly effective way to measure vibration through their new SensoNODE Vibration Sensors. These easy-to-use devices can be attached to any type of equipment to monitor vibrations in even the most difficult-to-reach locations. They help identify the specific cause and location of a problem, reducing maintenance costs and equipment downtime. 

With simplicity in mind, the SensoNODE Vibration Sensor provides two measurements of vibration: Root Mean Square Amplitude (RMS) and Peak. This allows the user to receive an indication of when a machine is starting to experience degradation and proceed with immediate maintenance actions. For example, data of the overall vibration may indicate an alignment of the shaft or balance of the motor system of a particular piece of equipment needs a slight adjustment. These are simple fixes that can be applied without compromising the machinery.

Data is compiled in a clear and concise way that can be interpreted and compared to the output of vibrations with International Standard ISO: 10816 charts to know what is an acceptable rate of vibration. A user can look at the measurement coming off of the sensor and read across the chart to get an exact number. This is an indication as to whether machinery is operating in an area where damage is likely to occur or things are running perfectly.

A small shake or rattle can indicate big problems. Vibration analysis can be an essential tool for predicting equipment failure and increasing machine efficiency. There are a variety of methods and ways to measure vibration. With SensoNODE vibration sensors, a user has access to data that’s straightforward and an early indicator of developing failures or problems with rotating machinery. This allows you to take immediate action and ensure operations are running smoothly.

See demonstrations of the SensoNODE Vibration Sensor at Sensors Expo, booth 1109, June 26 – 28, McEnery Convention Center, San Jose, CA.

Learn more about the SensoNODE Vibration Sensor.

This post was contributed by David Shannon, business unit manager, Parker Hannifin.

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The safest, highest quality hydraulic hose assemblies are made with hoses, fittings and crimping equipment from the same manufacturer. Components from different manufacturers should not be used when making hose assemblies (apart from rare instances when both manufacturers have approved the exception). Installing fittings from different manufacturers can cause coupling retention to be adversely affected. For instance, mixing and matching components can lead to hoses bursting, couplings leaking and blown-off ends maiming or even killing workers. Thread or flange ends must also be properly matched to their mating components to create leak-proof connections. In addition to the dangers involved, mixing and matching brand names will void the manufacturer’s warranty and could also exclude manufacturers from liability should someone get injured from a failed hose assembly.

It is important to remember that an individual is solely responsible for the hose assemblies he or she fabricates. Mixing and matching components can potentially expose that person and their employer to liability claims if an assembly fails. The following advisory from Parker addresses common causes, misconceptions, consequences and costs of incompatible hydraulic hose assemblies.
 

Generic, look-alike and/or "knock-off" hoses and fittings have become more prevalent in the marketplace in recent years. Be certain to correctly identify components before introducing them into a hydraulic system. Laylines on hoses and stampings on fittings designate, among other things, manufacturer, type, size, working pressure and age. Never use a hose or fitting of unknown capability or origin.
 

Correction: While manufacturers’ fittings may look similar, they likely have not been approved for use on a different manufacturer’s hose. Parker, for instance, subjects its fittings to a substantial number of testing and qualification procedures prior to approving them for use on a particular hose. It is important to note that SAE and NAHAD also indicate that it is extremely important that the specific instructions of the hose and coupling manufacturers be followed. The intermixing of hose and couplings from different manufacturers is not typically acceptable. Couplings are engineered to only work with approved hoses and vice-versa. Do not use hose/coupling combinations that are not approved by the manufacturer. If the hose and coupling are supplied by different manufacturers, then both must approve of their use together. In no instance should the information printed in this section supersede a manufacturer's instructions.
 

Correction: Only use specific hose and fitting combinations that have been tested together as an assembly in accordance with the industry specification. The fitting, unless qualified by its manufacturer (then also by the hose manufacturer) for use with a particular hose, should not be used.
 

Correction: A manufacturer’s formal crimp specifications rarely, if ever, support different manufacturers’ hose, fitting and crimper combinations. Only crimp hoses and fittings with equipment approved by the manufacturer of the hose and fitting.  Please reference Parker Crimpsource for Parker’s crimp specifications as well as compatible hose and fitting combinations. 
 

To mix and match components is to increase the risk of hose failure – a dangerous situation regardless of setting or application. Possible consequences of hose failure resulting from the use of incompatible components include:

- Fittings thrown off at high speed
- High velocity fluid discharge 
- Fluid injection injury
- Violently "whipping" hose
- Sparking or explosion from sprayed flammable fluids
- Suddenly moving/falling objects otherwise held static by fluid pressure

Hose failure is also expensive for those who sell assemblies or rely on them to get the job done. The high cost of hose failure can include:

- Assembly replacement
- Downtime
- Subsequent machine and/or system damage
- Warranty claims
- Customer dissatisfaction
- Worker lost-time/compensation
- Medical bills/increased insurance premiums
- Contamination control/clean-up
- EPA penalties/fees
- OSHA infractions

Parker’s recommendations are consistent with SAE standard J1273: Industry Consensus on Best Practices for Using Hydraulic Hose. The complete technical paper, which includes SAE-recommended practices for hose assembly fabrication, can be purchased from www.SAE.org.

Article contributed by Kyri McDonough, marketing services manager at Hose Products Division, Parker Hannifin.

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No matter what type of port or tube ends your fittings have, it's important to know and use the proper assembly and installation steps. Today we are talking about tapered thread ports, which include NPT/NPTF, BSPT, and metric taper. The tapered threads on these port ends serve two functions: to hold the fitting in place while under pressure, and to serve as the primary seal. Therefore, proper fitting assembly and installation is key to ensuring leak-free tapered thread port connections in your system. 

Watch the video to learn the proper process for assembly and installation of tapered thread ports, or follow the steps outlined below. 

Step 1: Inspect the components.
To ensure a proper connection, the male and female port threads must be free of burrs, nicks, scratches, or foreign material.

Step 2: Apply the appropriate sealant to the male pipe threads. 
This sealant can also act as a lubricant which is especially important with stainless steel threads because of the potential for galling. To avoid system contamination, leave the first one or two threads from the end of the fitting free of sealants. If you chose to use PTFE tape, be sure to wrap it correctly - 1-1/2 to 2 turns in a clockwise direction when viewed from the tapered thread end.  NOTE: Be sure to chose a sealant based on the application. Pre-applied sealants are often preferred because of the convenience. 

Step 3: Finger tight. 
Once the sealant is in place, screw the connector into the port until finger tight.

Step 4: Wrench tighten.
Wrench tighten the connector to the appropriate turns that are recommended in the Assembly and Installation section of the Parker Catalog 4300. Normally the total number of tapered threads engaged should be between 3-1/2 and 6. Under or over tightening may result if you deviate from this range.  NOTE: If you have a shaped fitting, make sure that it is properly aligned. Remember, never back off tapered thread connections to achieve alignment, as this could potentially cause a leak.

By following these steps, your tapered thread port connections should be leak-free. To help you ensure that all of your hydraulic fitting connections are installed leak-free, Parker Tube Fittings Division has created a series of tube and port end assembly and installation videos for the most common hydraulic fitting connections, which will be shared on TFDtechConnect.com over the next couple of months. You can also find detailed assembly and installation information for port end threads and tube fittings in the Assembly/Installation section of our Catalog 4300. 

Did you find this post helpful? Subscribe to TFD techConnect posts by email. TFD techConnect is a technically-focused monthly blog written by engineers for engineers specifically around motion and control engineering challenges.

Contributed by Burleigh Bailey, senior product engineer at Parker Tube Fittings Division

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