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015 - Hydraulic Hose Assemblies PDF
015 - Hydraulic Hose Assemblies PDF
Annex (Tables 1 - 8)
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 2 / 10
Testing and replacement of hydraulic hose assemblies
2 Test for proper assembly and safe 3.3 Recommended test periods
function (formerly called: initial The employer has to specify the periods for
test) required tests, according to 3 BetrSichV within
The test for proper assembly and safe function the scope of their risk assessment and the
is intended to evaluate criteria related to the determination of measures for the safe provision
assembly and which can only be evaluated on and use of work equipment.
the completely assembled machine. Besides the The time intervals between recurrent tests have
testing of safeguards, e.g. emergency stop, the to be chosen in such a way that deviations from
installed hydraulic hose assemblies have to be the proper state of work equipment can be
checked as well. identified in time to prevent incidents.
Some test criteria can be evaluated by visual The provisions stated in the rules and regulations
inspection in the Off-state condition. Other of accident insurers with regard to tests and test
criteria require a functional test with power on. periods have to be regarded as definite
Attention has to be drawn to the machinery description of the requirements of the
movements and the related risks. Betriebssicherheitsverordnung and should be
A survey of the recommended test scope for a taken as a basic source of information for
visual inspection (for the hydraulic hoses) is specifying test periods.
given in Table 1 (see annex). The test periods of machinery or their safety
A survey concerning the recommended test relevant components, such as hydraulic hose
scope for functional testing (concerning the assemblies, can be influenced by the criteria
hydraulic hose assemblies) is given in Table 2. listed in Table 5. Those criteria should also be
considered for checking or verifying the test
periods, given in the BG-rules which have been
3 Test for safe provision and use proven up to now (to prolong or reduce the
(formerly called: recurrent test) periods as far as this is necessary).
Since hydraulic hose assemblies are exposed to With reservation of company-specific or
influences causing damage, they have to be machinery related determinations of test periods
checked at regular intervals for safe provision by the user of the work equipment and with the
and use. reservation of specific provisions by the machine
However, testing shall also be carried out as manufacturer or the manufacturer of the hoses or
extraordinary testing after accidents, modifi- hose assemblies, the test periods summarized in
cations (rebuilding) at the machine, remounting Table 6 are recommended for the testing of
at a different location without modification of the hydraulic hose assemblies.
old machine, after longer periods of non-use and
after maintenance measures as a result of Notes:
damages (collision, natural phenomena). It is possible that the user may specify the same
test periods according to the Betriebssicher-
All tests are intended, to detect and eliminate heitsverordnung as he did before the Betriebs-
damages at hydraulic hose assemblies as soon sicherheitsverordnung came into effect, e.g, to
as possible. have the hydraulic hose assembly tested prior to
the initial setting into operation and afterwards at
3.1 Recommended test scope least once a year or according to the defined
Table 3 provides a detailed survey with regard to provisions given by the manufacturer in the
the recommended extent of test scope for the operating instructions of the machine (e.g. 1x/
safe provision and use. (concerning hydraulic 2x/ 4x per year) with regard to their safe
hose assemblies, see Table 3). operational state.
Depending on the location of use or the
3.2 Test criteria for hydraulic hose existence and types of secondary safeguards of
assemblies the hydraulic hose assemblies and the relevant
risk assessment, different test intervals (as well
The recommended test criteria for the testing of as for replacement) can possibly be specified for
individual hydraulic hose assemblies with regard different hydraulic hose assemblies for one and
to their safety condition, can be found in Table 4. the same machine.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 3 / 10
Testing and replacement of hydraulic hose assemblies
Defective hydraulic hose assemblies shall be A maximum period of use for hydraulic hose
replaced. Defects of the safe operational state assemblies of 6 years including a storage period
which have been detected at the testing of the of max 2 years is generally recommended as a
hydraulic hose assemblies have to be eliminated reference value. (BGR 237 [3]). At the production
immediately or suitable measures have to be of the hydraulic hose assembly (of the machine
taken so that the machine cannot be used until respectively), the hose should not be older than
the hydraulic hose assembly has been replaced. 4 years.
Hydraulic hose assemblies shall neither be Deviations from the recommended maximum
repaired nor reassembled by old parts. period of use are possible if relevant test values
and empirical values are available which permit a
If several hydraulic hose assemblies are safe prolonged use beyond the maximum period
replaced at the same time, ensure that only of use. An extended period of use of the
those hydraulic hose assemblies are used which hydraulic hose assembly is even possible if there
are sufficiently dimensioned for the load to be is no risk from hydraulic fluids, the hose itself or
expected in the relevant connection (pressure-, a hazardous motion of the machine or the load,
tank-, leakage pipe, etc.) and that mixing of the caused by damage or a hose fracture.
connections is prevented.
For hoses consisting of thermoplastic or metallic
For further information concerning the selection hydraulic hose assemblies, other reference
of the new hydraulic hose assembly to be values besides those mentioned above may
installed, see chapter 3.7. apply.
Deviations from the recommended reference
NB: values for the period of use have to be included
Defective hydraulic hose assemblies in the operating instructions of the machine or
have to be replaced! plant.
risk assessment and the specified protective The hose, fitting and hose assembly have to be
measures. selected in such a way, that
- the requirements with respect to the hose
NB: assembly marking are fulfilled,
A prolongation of the replacement - the admissible stress of the components will
intervals shall not result in a hazardous not be exceeded with the operating pressures
situation which can lead to injuries to to be expected.
employees or other persons! - operating pressures are considered, the
control or the hydraulic pump have been
If it is intended to extend the duration of use of designed for, and which are indicated on the
the hydraulic hose assemblies beyond the type plates of such hydraulic plant
recommended six years, shortened testing components,
intervals are recommended for safety reasons. - the cross sections or nominal diameters
Some machinery manufacturers have specified respectively are sufficiently dimensioned so
shorter test and replacement intervals in their that there will be no inadmissible
operating instructions resulting from the hazard accumulation pressures which, for example,
analysis and the protection concept of particular obstruct the free backflow to the tank,
hydraulic hose assemblies with increased - the compatibility of hose materials and
requirements (such as e.g. particular gravity- sealing materials with the hydraulic fluid being
loaded axes) (e.g. testing every six months and used is ensured,
replacement after two years). - types of hose fittings consisting of a (turned)
The user has to take these aspects into account connecting pipe socket with cutting ring are
when specifying their replacement intervals. not used since they represent a serious risk of
Table 7 shows a summary of the most important accident (due to slipping).
factors influencing the replacement intervals. In summary, the replaced hose assembly has to
be suitable for the intended use with regard to
For further information concerning the selection
pressure, volume flow, possible pressure
of the new hydraulic hose assembly to be
impacts and resistance towards the hydraulic
installed, see chapter 3.7.
fluid being used.
Reference:
Further explanations to the relevant standards and NB:
regulations, to examples of applications and the It has to be checked whether the selected
procedure for the risk evaluation concerning the
hydraulic hose assemblies are also included in the hydraulic hose assembly is suitable for
publication [4]. the intended use.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 6 / 10
Testing and replacement of hydraulic hose assemblies
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 7 / 10
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
Annex
Table 1: Recommended test scope Visual inspection (prior to initial setting into operation or
putting back into operation)
- Is all information for use available which is required for the safe operation of the hydraulic plant (e.g.
hydraulic plan, parts list, description of the plant, drawings, operating / maintenance instructions,
hydrostore documents, safety data sheets for the hydraulic fluid being used etc.)?
- Do the hydraulic hose assemblies correspond to the hydraulic plan and to the parts list and the
description of the plant (including the hydraulic fluid being used)?
- Have safety measures been taken for the case of exceptionally high pressure impacts or pressure
increases, such as for example, pressure control valves?
- Are the individual hoses of the hydraulic hose assembly marked with the name or a short
designation of manufacturer, EN-number and type (pressure level), nominal diameter, quarter/year
of manufacture? (s. DIN EN 982, [12])
- Are hydraulic hose assemblies individually marked on the fittings with the name or a short
designation of the manufacturer, the max. admissible operating pressure, month and year of
manufacture?
- Are hydraulic hose assemblies installed in such a way, that according to DIN 20066 [7]:
The natural position does not obstruct the movement;
A torsion of the hose, a tensile load due to a line which is too short, or a bending radius which
is too low are all avoided;
The hose is led by buckling protection (if applicable at the connection element);
External mechanical influences or abrasion at the edges are avoided by sufficient distance;
Damage by running over is avoided by means of hose bridges;
Loosely installed hose assemblies are protected by hose guiding devices (such as hose
brackets and fixtures;
A thermal protection (shielding) protects from high temperatures?
- With regard to their installation location, are the hydraulic hose assemblies designed and arranged
in such a way, that they:
Cannot be mixed-up and are unambiguously and durably marked;
Are protected against any foreseeable damage, e.g. mechanical or due to environmental
influences such as cooling lubricants; and
Do not impair maintenance of the work equipment?
- Are hydraulic hose assemblies which are used in areas of high-level requirements, (e.g. holding up a
load) protected against hose break?
- Are hydraulic hose assemblies which in case of failure may generate hazards due to whiplash or
escape of hydraulic fluid provided with suitable protective measures, such as fastening, capturing
device or shielding?
- Are the hydraulic hose assemblies installed in such a way that they cannot be used as a ladder or
means for access?
- Do the hydraulic hose assemblies of the initially operated or reoperated machines already show
damages (s. Table 4)? If damages have been detected, proceed according to chapter 3.4.
- Have the installed hydraulic hose assemblies or hoses exceeded the period of storage or use,
recommended by the individual manufacturer (s. chap. 3.6)?
- Are the hydraulic hose assemblies over-lacquered (over painted)?
- Does the operating manual state testing intervals? If so, what?
Note:
The hydraulic hose assemblies being installed shall not consist of hoses which have already been used as part
of a hose assembly before! (s. DIN EN 982, no. 5.3.4.3)
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 8 / 10
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
Table 2: Recommended test scope functional testing (prior to initial setting into operation or
putting back into operation)
- Does the hydraulic control system fulfil the intended function and comply with the plant description?
- Is there an indication by acoustic signals or similar indicating extremely high pressure impact or
pressure increase for the hydraulic hose assembly for all required machine functions during the
intended machine operation?
- All parts of the hydraulic plant shall be tested with the intended maximum operating pressure which
can be reached in all intended applications:
Have measurable leakages been detected at the hydraulic hose assembly and connection
elements?
Did all hydraulic hose assemblies withstand the pressure?
Are there spots of abrasion due to hydraulic hose assemblies moving under operation
conditions?
- Is the information for use (operating instructions, hydraulic plan, parts list etc.) from the
manufacturer still complete and available?
- Do the conditions of use and environmental conditions of the machine still comply with the initial
intended use of the machine?
(This requires consideration of for example: kind of product, cycle times, number of pieces
produced, hydraulic pressures and volume / flows temperatures, hydraulic fluid(s) used, speeds/
stopping times of hazardous movements, moved/ upheld masses, loading and unloading method of
workpieces, place of installation, external influences (e.g. vibration, humidity, pollution by oil, UV-
radiation, mechanical influences, ambient temperature etc.), position of transport ways and kind of
transport means being used (hazards of damage), location and access for operation and
maintenance, arrangement and assembly of additional equipment, interaction/ link with other
machinery).
- Have the above mentioned preconditions changed, which previously formed the basis for specifying
a defined duration of use of the hydraulic hose assembly? If so, have the testing periods and
replacement intervals been considered accordingly and if necessary, been changed?
- Are the markings at the hydraulic hose assemblies still existent and legible?
- Do the hydraulic hose assemblies show any deficiencies indicated in table 4? If deficiencies are
detected, proceed according to chapter 3.4.
- Are the safety measures against whiplash hazard and/or escape of hydraulic fluid at the relevant
hydraulic hose assemblies still existent respectively installed?
- Have the periods for recurrent tests at the hydraulic hose assemblies been specified and kept? If
required, the periods have to be specified by the user and the required tests have to be carried out
or arranged for.
- Have the intervals for replacement recommended by the manufacturer respectively the maximum
duration of use specified by the user for hydraulic hose assemblies been taken into account (s.
chapter 3.5)?
- Have shortened test intervals been established, e.g. to biannually or quarterly (instead of yearly or
biannually) in case of intended prolonged duration of use of hydraulic hose assemblies?
- In case of modifications at the machine and in the hydraulic plant (control and equipment) as well as
after extensive maintenance work, in particular if this involves the new installation of hydraulic hose
assemblies, a relevant test for proper assembly and safe function, s. chapter 2 table 1 and 2 has
to be carried out.
- Have those modifications been recorded and have they been considered in the machine
documentation?
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 9 / 10
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
- Hazards which may occur when using the work equipment for all relevant operation procedures
(basis: hazard evaluation);
- Increased requirements for safety (such as holding of loads in particular gravity-loaded axes) e.g.
due to the protection concept of the machinery manufacturer and provisions for shortened periods
in the operation manual;
- Conditions of use of work equipment and hydraulic plant (e.g. particular loads, conditions with
defined overload, operating times, operation parameters, influence of the hydraulic fluid being
used);
- Environmental conditions (damaging external influences such as vibration, humidity, pollution,
mechanical influences, ozone generation by electric motors or welding transformers) and more, s.
table 3);
- Comparison, whether the actual operating conditions / conditions of use comply with those
conditions stated by the manufacturer at acquisition;
- General manufacturers information (of machinery manufacturer or the manufacturer of the
hydraulic hose assemblies) with regard to test intervals;
- Age respectively rate of wear of the work equipment or of the hydraulic hose assembly;
- Prolongation of replacement intervals;
- Kind and system by means of which the intended maintenance is carried out, in particular for safety
relevant components and wear parts;
- Experience made by the users / set-up/ maintenance personnel with the work equipment and the
hydraulic plant (with regard to failure behaviour, occurrence of defects, interruptions, increase of
such events);
- Evaluation of results from the visual and function inspection prior to the daily use of the machine;
- Any known accidents at comparable machines or hydraulic plants;
- Evaluation of test results of recurrent tests at those hydraulic hose assemblies or those being
operated under comparable conditions;
- Test results prior to commissioning.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015 edition 10/2006 page 10 / 10
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
- Statements or instructions given by the manufacturer of the hydraulic hose assemblies or the
machinery manufacturer, particularly provisions given by the manufacturer for gravity-loaded axes;
- Conditions of use and environment;
- Hazards due to hydraulic fluid, the pipe itself or a hazardous machine or load movement in case of
damage or break of the hose assembly;
- Test and empirical values of the machinery manufacturer or the user;
- Secondary protective measures against hazards in case of failure of the hose assembly, e. g.
covering, line break protection;
- Proper execution of tests with regard to the safe operational state in adequately determined time
intervals, (if necessary shortened) by a competent person.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001