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Crane Resistoflex Standard Specification for Quality Control Testing
and Documentation
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1.1
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Qualifications Tests: Hoses lined with Teflon® PTFE shall be
capable of passing qualification tests designed to demonstrate the hose's
ability to withstand severe operating conditions. Once a hose design has
passed qualification testing, re-testing is not required. If the manufacturer
changes the hose design, however, the new design must be re-tested. The hose
manufacturer shall make hose qualification test reports available upon requests.
Qualification testing is as follows:
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1.1.1
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Burst Testing: Subject hose to destructive burst test to
determine allowable operating pressure and proof test pressure.
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1.)
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Install hose on test stand designed to allow internal pressurization of hose
with hydraulic fluid.
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2.)
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Introduce hydraulic fluid into hose, purge all air.
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3.)
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Pressurize at an approximate rate of 100 psi/sec. until hose fails.
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4.)
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Record burst pressure.
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5.)
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Allowable operating pressure is defined as 25% of burst pressure for a
4:1 safety factor.
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6.)
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For Chlorine Transfer Hose, allowable operating pressure is 20% of burst
pressure for a 5:1 safety factor.
Note: Allowable operating pressure is also known as "rated
working pressure" and "working pressure."
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1.1.2
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Steam-Cold Water Cycling: Subject representative PTFE-lined hose samples
to steam-cold water cycling to determine the ability of the lined hoses to
withstand rapid temperature changes. Procedure is as follows:
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1.)
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Install hose on closed-loop test stand and circulate saturated steam at 125
±5 psig (50 psig for TRC hose) until the skin temperature varies no
more than ±2.5°F for 10 minutes. Temperature shall be measured by
a thermocouple attached to the crimp collar.
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2.)
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Close off the steam and immediately circulate water at a maximum temperature of
77°F until the skin temperature reaches 122°F.
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3.)
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Vent and introduce air to purge the test hose for a minimum of one minute to
completely drain hose of water.
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4.)
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Repeat steps 1-3 for a total of 100 cycles.
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5.)
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During the 100 cycles, leakage is cause for rejection.
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1.1.3
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Impulse Testing: Subject hose assemblies to rapid and frequent pressure
cycling to determine hose assembly's ability to withstand long-term pressure
cycling. (Note: impulse testing is not required for TR or TMH)
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1.)
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Install hose on test stand designed to internally pressurize hose with
hydraulic fluid.
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2.)
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Pressurize hose to 125% of rated working pressure, return to ambient pressure,
return to 125% of rated working pressure. This is defined as one cycle.
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3.)
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Continue cycling at a rate of approximately 70 cycles/min. until 50,000 cycles
have been completed. (100,000 cycles for TRC)
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4.)
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During the test, any leakage is cause for rejection.
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1.1.4
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Vacuum Testing: Subject representative hose assemblies to vacuum
conditions to determine rated vacuum for hose at a given temperature.
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1.)
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Seal assembly ends modified fittings that have been modified to draw a vacuum
in the hose interior. Place assembly in an oven and heat until the desired
temperature is reached.
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2.)
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Reach the desired vacuum level and hold for 48 hrs.
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3.)
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At the end of the 48 hrs. turn off the oven and allow the hose to cool to
ambient temperature while still under the same vacuum level.
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4.)
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Turn off the vacuum and observe the hose for buckling or collapse of the liner. Any buckling or collapse of the liner shall be cause for rejection.
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5.)
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If no collapse of buckling has occurred, the vacuum and temperature shall
be considered acceptable.
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1.2
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Proof Tests for Customer Orders: 100% of finished hose assemblies shall
be proof tested at 1.5 times rated working pressure.
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1.2.1
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Factory-made hose assemblies shall be proof tested hydrostatically and
pneumatically as required (submerged in water) at 1.5 times rated working
pressure. Chlorine Transfer Hose is proof tested at 2 times rated working
pressure. TR and TMH are not pneumatically tested.
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1.2.2
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Hose assemblies made at an Authorized Fabricating Distributor location shall
be hydrostatically or pneumatically proof tested. (TR and TMH are fabricated
at the factory, only)
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2.0 Quality Documentation
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2.1
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Manufacturer's design, engineering, manufacturing, sales, and service shall
be certified to ISO 9001.
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3.1
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Description: Rubber covered, smooth-bore PTFE liner.
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3.2
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Materials of construction
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3.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed and unpigmented. Standard liner
is non-conductive. Optional conductive liner shall be available. Conductive
liner shall be capable of conducting 12mA at 1000V.
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3.2.2
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Rubber Carcass: The rubber carcass shall be EPDM rubber combined with
multiple plies of reinforcement. This construction shall be additionally
reinforced with a high-tensile wire to resist crush or collapse. The rubber
carcass shall be able to maintain its mechanical properties throughout the
rated range of operating pressures and temperatures of the hose assembly.
Standard carcass color shall be blue, with optional white available.
Manufacturer's name shall be printed on the layline.
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3.2.3
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End Fittings: End fittings shall be available as pipe fittings,
flanges, cam-lock, compression, and sanitary. Flare-through liner shall
be available for flanges and tri-clamp sanitary fittings. End fittings
material shall be carbon steel, alloy, or plastic.
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3.3.1
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Size availability: TRC hoses shall be available in 1/2" through 2" NPS.
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4.1
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Description: Stainless steel braided, smooth-bore PTFE liner.
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4.2
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Materials of construction
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4.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed and unpigmented. Standard liner
is non-conductive. Optional conductive liner shall be available. Conductive
liner shall be capable of conducting 12mA at 1000V.
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4.2.2
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Braid: Braid shall be stainless steel type 304.
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4.2.3
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End Fittings: End fittings shall be available as pipe fittings,
flanges, cam-lock, compression, and sanitary. Flare-through liner shall
be available for flanges and tri-clamp sanitary, and cam-lock style fittings.
End fittings material shall be carbon steel, alloy, or plastic.
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4.3.1
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Size availablity: SB hoses shall be available in 1/2" through 1-1/2" NPS.
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5.1
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Description: Stainless steel braided, convoluted-bore PTFE liner.
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5.2
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Materials of construction
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5.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed and unpigmented. Standard liner
is non-conductive. Optional conductive liner shall be available. Conductive
liner shall be capable of conducting 12mA at 1000V.
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5.2.2
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Braid: Braid shall be stainless steel type 316. Polyolefin shrink
sleeve shall be available.
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5.2.3
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End Fittings: End fittings shall be available as pipe fittings,
flanges, camp-lock, compression, and sanitary. End fitting material shall
be carbon steel, alloy, or plastic.
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5.2.4
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Optional Construction: Type CBF is same construction as above with
flare-through liner. Type CPB is same construction as above, except braid
material is polypropylene. Type CPBF is same construction as above with
flare-through liner, except braid material is polypropylene.
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5.3.1
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Size availability: CB hoses shall be available in 1/2" through 4" NPS.
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6.0 Chlorine Transfer Hose (CTH)
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6.1
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Description: Hastelloy braided, convoluted-bore PTFE liner.
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6.2
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Materials of construction
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6.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed. Standard liner is conductive.
Conductive liner shall be capable of conducting 12mA at 1000V.
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6.2.2
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Braid: Braid shall be Hastelloy C-276.
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6.2.3
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Chafe guard: The braided hose shall be wrapped with a spiral wound
chafe guard of high-density polyethylene (HDPE). The chafe guard shall be
retained at the ends by stainless rings.
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6.2.4
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End Fittings: Standard end fittings are male NPTF. End fittings and
collars shall be monel. End fittings shall also be available as flanges,
Hiltap Critical Service Couplings, and CGA 820.
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6.3
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Additional Safety Factors: The proof test pressure of the CTH is 2
times the working pressure.
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6.4
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Dimensional Data
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6.4.1
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Size availability: CTH hoses shall be available in 1/2", 1", and 1-1/2"
NPS.
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7.1
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Description: Stainless braid over a stainless convoluted hose lined
with smooth-bore PTFE.
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7.2
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Materials of construction
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7.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed and unpigmented. Standard liner
is non-conductive. Liner shall be drawn into the hose assembly and relaxed in
a timed temperature cycle (Thermalok method).
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7.2.2
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Stainless steel convoluted hose: Stainless steel convoluted hose shall
be type 316.
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7.2.3
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Braid: Braid shall be stainless steel type 304 or 316.
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7.2.4
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End Fittings: TMH end fittings shall be lap-joint rotating flanges
with flare-through liner. Flanges shall be available in carbon steel and
alloys. The leak proof and emissionless High Integrity Flange shall be
available as an option. Stub-ends shall be stainless steel type 316.
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7.3.1
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Size availability: TMH hoses shall be available in 1" through 8" NPS.
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8.1
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Description: Rubber-covered hose lined with smooth-bore PTFE.
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8.2
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Materials of construction
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8.2.1
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Liner: The liner shall be extruded tubing made from Teflon®
PTFE resin. The resin shall be unreprocessed and unpigmented. Standard liner
is non-conductive. Liner shall be drawn into the hose assembly and relaxed in
a timed temperature cycle (Thermalok method).
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8.2.2
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Rubber Carcass: The rubber carcass shall be neoprene rubber combined
with plies of fabric, and reinforced with a high-tensile wire to resist crush
or collapse. The rubber carcass shall be able to maintain its mechanical
properties throughout the rated range of operating pressures and temperatures
of the hose assembly. Hose ends shall be beaded to achieve a sealing surface
over which the PTFE liner can be flared. Standard carcass color shall be black.
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8.2.3
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End Fittings: TR hose end fittings shall be rotating split flanges.
The hose ends shall be pre-molded and reinforced per a proprietary process.
Protective PTFE lined auxiliary flanges shall be available.
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8.3.1
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Size availability: TR hoses shall be available in 1" through 4" NPS.
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