Tubes, pipes and hoses

Hydraulic tubes are seamless steel precision pipes, specially manufactured for hydraulics. The tubes have standard sizes for different pressure ranges, with standard diameters up to 100 mm. The tubes are supplied by manufacturers in lengths of 6 m, cleaned, oiled and plugged. The tubes are interconnected by different types of flanges (especially for the larger sizes and pressures), welding cones/nipples (with o-ring seal), several types of flare connection and by cut-rings. In larger sizes, hydraulic pipes are used. Direct joining of tubes by welding is not acceptable since the interior cannot be inspected. Hydraulic pipe is used in case standard hydraulic tubes are not available. Generally these are used for low pressure. They can be connected by threaded connections, but usually by welds. Because of the larger diameters the pipe can usually be inspected internally after welding. Black pipe is nongalvanized and suitable for welding. Hydraulic hose is graded by pressure, temperature, and fluid compatibility. Hoses are used when pipes or tubes can not be used, usually to provide flexibility for machine operation or maintenance. The hose is built up with rubber and steel layers. A rubber interior is surrounded by multiple layers of woven wire and rubber. The exterior is designed for abrasion resistance. The bend radius of hydraulic hose is carefully designed into the machine, since hose failures can be deadly, and violating the hose's minimum bend radius will cause failure. Hydraulic hoses generally have steel fittings swaged on the ends. The weakest part of the high pressure hose is the connection of the hose to the fitting. Another disadvantage of hoses is the shorter life of rubber which requires periodic replacement, usually at five to seven year intervals. Tubes and pipes for hydraulic applications are internally oiled before the system is commissioned. Usually steel piping is painted outside. Where flare and other couplings are used, the paint is removed under the nut, and is a location where corrosion can begin. For this reason, in marine applications most piping is stainless steel.

Basic calculations
Hydraulic power is defined as flow times pressure. The hydraulic power supplied by a pump: Power = (P x Q) 600 where power is in kilowatts [kW], P pressure in bars, and Q is the flow in liters per minute. For example, a pump delivers 180 lit/min and the pressure equals 250 bar, therefore the power of the pump is 75 kW.

When calculating the power input to the pump, the total pump efficiency total must be included. This efficiency is the product of volumetric efficiency, vol and the hydromechanical efficiency, hm. Power input = Power output total. The average for axial piston pumps, total = 0.87. In the example the power source, for example a diesel engine or an electric motor, must be capable of delivering at least 75 0.87 = 86 [kW]. The hydraulic motors and cylinders that the pump supplies with hydraulic power also have efficiencies and the total system efficiency (without including the pressure drop in the hydraulic pipes and valves) will end up at approx. 0.75. Cylinders normally have a total efficiency around 0.95 while hydraulic axial piston motors 0.87, the same as the pump. In general the power loss in a hydraulic energy transmission is thus around 25% or more at ideal viscosity range 25-35 [cSt]. Calculation of the required max. power output for the diesel engine, rough estimation: (1) Check the max. powerpoint, i.e. the point where pressure times flow reach the max. value. (2) Ediesel = (PmaxQtot). Qtot = calculate with the theoretical pump flow for the consumers not including leakages at max. power point. Pmax = actual pump pressure at max. power point. Note: is the total efficiency = (output mechanical power input mechanical power). For rough estimations, = 0.75. Add 10-20% (depends on the application) to this power value. (3) Calculate the required pumpdisplacement from required max. sum of flow for the consumers in worst case and the diesel engine rpm in this point. The max. flow can differ from the flow used for calculation of the diesel engine power. Pump volumetric efficiency average, piston pumps: vol= 0.93. Pumpdisplacement Vpump= Qtot ndiesel 0.93. (4) Calculation of prel. cooler capacity: Heat dissipation from hydraulic oil tanks, valves, pipes and hydraulic components is less than a few percent in standard mobile equipment and the cooler capacity must include some margins. Minimum cooler capacity, Ecooler = 0.25Ediesel At least 25% of the input power must be dissipated by the cooler when peak power is utilized for long periods. In normal case however, the peak power is used for only short periods, thus the actual cooler capacity required might be considerably less. The oil volume in the hydraulic tank is also acting as a heat accumulator when peak power is used. The system efficiency is very much dependent on the type of hydraulic work tool equipment, the hydraulic pumps and motors used and power input to the hydraulics may vary a lot. Each circuit must be evaluated and the load cycle estimated. New or modified systems must always be tested in practical work, covering all possible

load cycles. An easy way of measuring the actual average power loss in the system is to equip the machine with a test cooler and measure the oil temperature at cooler inlet, oil temperature at cooler outlet and the oil flow through the cooler, when the machine is in normal operating mode. From these figures the test cooler power dissipation can be calculated and this is equal to the power loss when temperatures are stabilized. From this test the actual required cooler can be calculated to reach specified oil temperature in the oil tank. One problem can be to assemble the measuring equipment inline, especially the oil flow meter.

Established in the year 1969 Largest Integrated manufacturer of Fluid Transmission Products (FTPs)

Eight dedicated manufacturing / assembly plants Multi location manufacturing facilities having diversified product portfolio

Expected to cross Group Turnover of US $ 155 Million (Rs. 700 Crores) by FY 2010-11

3000 employees ISO / TS 16949:2009 & ISO 14001:2004 certified company Strategic and Technical Alliances with Major International Players in the Industry Global Presence and Scale Major supplier to most leading OEMs worldwide Overseas Warehousing Capability and Facility High level of quality and commitment to continuous improvement

1969

Incorporated as a partnership firm for manufacturing low pressure fuel hose assemblies and in the year 1998 got converted into Limited Company Established Plant I

1970

Initiated supplies to all the major domestic automotive players - Mahindra &Mahindra, Tata Motors, Kirloskar, FIAT and Ambassador Started manufacturing Rubber Hoses in-house

1980

Initiated supplies to international players setting up operations in India - Maruti, DCM, Toyota, Swaraj Mazda, Allwyn Nissan JCB, etc Included Tubular Assemblies in its portfolio of products

1990

Started supplies to most of the new multinationals entering the Indian automotive market - NewHolland, Ford, FIAT, John-Deere, JCB, Mitsubishi and General Motors Started manufacturing Hi-Pressure Hose Assemblies

Got QS-9000 accreditation for all plants Established a dedicated Rubber Hose manufacturing unit and a IIIrd Plant to manufacture High Pressure Tubes

2000

Approved global supplier to International Truck, Cummins, Caterpillar, JCB, John Deere and other OEM manufacturers overseas Established IInd Plant for Tubular assemblies, a dedicated unit for Hydraulic Assemblies and added Nylon Extrusion in its portfolio

domestic
ENGINE

Bosch Caterpillar Cummins Delphi TVS Kirloskar Suzuki Powertrain Tata Cummins

AUTOMOTIVE

AMW Ashok Leyland Bajaj Auto FIAT General Motors Hero Honda Hyundai Mahindra and Mahindra Maruti Suzuki Nissan Piaggio Swaraj Mazda

TATA Motors Toyota

OFF HIGHWAY AND FARM EQUIPMENT

Radiator & Heater Hoses Produced from EPDM Terpolymers to withstand Temperatures up to 150C. The Reinforcement can very depending on temperature and pressure requirements. The Reinforcement can be RAYON, POLYESTER or ARAMID. Commonly used in Radiator and Engine applications. Fuel & Vacuum Hoses Multilayer Hoses with an Impermeable Inner Layer of Fluoroelastomer with layers of EPICHLOROHYDRIN, subsequently Braided with PET / Aramid covered with a Heat, Ozone resistant layer. These are normaly low diameter hoses that withstand Max Pressure of 60 MPa. Silicone Hoses Suitable for cooling systems, charge air systems and induction systems. With its temperature range stability, flexibility, longevity, thermal, and electrical insulation properties, silicon polymers are a modern miracle of engineering material [Link]

from premium quality raw material, silicone hoses are used for high performance applications such as turbochargers. These hoses can withstand wide temperatures ranging from -40C to 200C.
Co-Extruded Hoses Co-Extruded Hoses can encounter demanding conditions such as high temperature and weathering . These hoses have optimum strength to ensure long service life without any maintenance. Mainly used for return and drain applications since it has no reinforcement Branch Hoses Assembly and Branch Hoses are used to connect multiple hoses with a common connector such as in engines to supply oil, fuel, gas or coolant. These are manufactured from premium quality raw material that provides ability to withstand wide temperature range from -40C to 140C.

High Pressure Hydraulic Hose Our premium product hydraulic hoses are specifically designed for supplying hydraulic fluid to hydraulic components, valves, actuators etc. They are oil resistant and synthetic rubber reinforced with one/two plies braided high tensile steel wire covered with oil, weather and abrasion resistant synthetic rubber. The compact structure of these hoses ensures their easy usage and low maintenance. All the Hi-Pressure hoses are available in various size specifications and at the affordable prices to our clients and these are used for various applications like excavators, railways, cranes & other various applications. Hydraulic hoses are crimped on the state of the art imported hose crimping machine besides meeting the required testing facilities norms for hydraulic hose assemblies. Power Steering Hose We hold expertise in providing an extensive range of hydraulic power steering hoses that are manufactured using quality material. With high tensile steel or rayon wire-over braid, these hoses are available in extruded as well as corrugated form. Our range of Hydraulic Power Steering Hoses is appreciated for its flexibility, strength & reliability and temperature resistance. Synthetic, Oil resistant rubber tube with High Tensile wire braids or textile braid called R1 or R3 Hoses along with the Hydraulic fittings constitutes the Total Power steering Hose assembly. They have abrasion & weather resistance outer cover and used for the flow of Fuel, hydraulic oil etc.

Teflon Hose Teflon Hose find its application where pressure and temperature requirements exclude rubber hoses and demand more robust designs. Teflon Hose assemblies have an excellent vibration, absorbance and flexibility at high pressure. Suitable for operating temperatures of -60C to 260C, these hoses are available in the size range of 6mm bore to 75mm bore and in long lengths. The inside core of these hoses are offered in P.T.F.E. TEFLON and reinforcement with one braid in stainless steel type 304.

Brake Hose Hydraulic Brake Hoses are widely used in automobile industry. These withstand and effectively operate in the temperature range of -40 to 100C. We offer a wide range of Brake Hose Assemblies that is manufactured using graded raw material. Since they are flexible, they absorb the shocks emanating from engines and equipments operating in dynamic conditions. We use SAE J1401 & DOT approved Brake hoses and carry IS 7079 certifications from BIS

Nylon Tube Nylon tubes are fast replacing steel tubes due to their low weight, easier manufacturability and cleaner internal diameters. They are recommended for Fuel lines, Air Brake System and Oil Circulations. These tubes have capability to resist various fuels like petrol, diesel, almost all chemicals & corrosion. . The material nylon is characterized by a combination of high strength, toughness and abrasion resistance an is ranked as an engineering plastic due its unique mechanical, thermal frictional and chemical properties.

Export coustomers
ENGINE
Caterpillar - USA Cummins - USA, Mexico, Brazil, U.K, Japan, & China FIAT Powertrain - Brazil John Deere - USA & France Navistar - USA, Canada, & Mexico

AUTOMOTIVE
General Motors - USA, U.K, Spain, Germany, Poland, Australia, Korea, & Thailand Piaggio - Italy Triumph Motorcycles - U.K & Thailand

OFF HIGHWAY AND FARM EQUIPMENT