Hose Safety and Reliability in Mining - Power & Motion

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.

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Longwall mining is an underground mining operation in which a large panel or block of coal spanning up to 1,500 ft 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 machinery. Hydraulic-powered roof supports, also called shields, protect the working area of the mine by extending as a shearer cuts back and forth along the coal face. Once it is cut by the shearer, coal falls onto a large chain conveyor for transport to 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 for 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.

High Performance for Mining

Because of the rigid safety and performance requirements for mining equipment, Parker Hannifin and other major hose manufacturers offer products designed specifically for mining applications. Parker’s GlobalCore 187 hose is a 1,000 psi (7 MPa) constant-working-pressure hose specifically engineered for the mining industry. ISO requires impulse testing at 133% maximum working pressure and 100°C for 200,000 cycles for standard and compact type hoses. GlobalCore 187 hose exceeds these requirements and can be used as a high-pressure return line or where other hoses may be overkill or requires a lower bending force.

Parker’s GlobalCore 187 hose meets or exceeds ISO requirements and is the only 1,000-psi constant-working-pressure hydraulic hose offered in sizes −8 through −48 (½- through 3-in. ID).

Constant-working-pressure hoses contradict traditional hydraulic hoses, in which pressure rating decreases as the inside diameter increases. For instance, if the maximum pressure requirement 1,000 psi, you could specify 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. 

The unified GlobalCore series of ISO hoses as the first family of 1,000 psi-rated constant-working-pressure hydraulic hose sizes from −8 through −48 (½- though 3-in. ID), and with half the minimum bend radius specified by SAE and ISO . This feature reduces overall hose assembly length, promotes 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 sharp bending of hoses.

Wide Selection for Safety

Although today’s hydraulic hose performs better than ever, a lack of maintenance, equipment abuse, or unforeseen circumstances can lead to failure of any hydraulic hose. 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 ft/sec. According to research, more than 10% of mine safety incidents in the United States involve fluid power systems, with 1% of those resulting in serious injury or death.

When connections have been properly prepared and crimped, a hose should not come loose from its end fitting. Additional safety can be provided by specifying a hose whip restraint, which limits movement if a hose should be pulled away from its end fitting.

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

Boosting Profit by Reducing Downtime

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.

Several manufacturers offer hydraulic hose crimping equipment that makes factory-quality hose assemblies quickly, easily, and cost-effectively. Parker's Parkrimp family of crimping machines crimp fittings to the proper diameter every time. These crimpers are simple to operate and built to provide years of dependable service. 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. Adding an asset tag, such as Parker’s PTS label, can save users 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 user $15 in direct productivity losses. For users with multiple, untimely failures per month, this can add up to considerable savings. Many users 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, asset tags can be invaluable in helping to ensure maximum machine or vehicle uptime.

Kyri McDonough is marketing services manager at Parker Hannifin’s Hose Products Div., Wickliffe, Ohio. For more information, click here www.parker.com/hpd. This article is based on material appearing in Parker’s Motion & Technology Blogs.

Mining Efficiency Unleashed: Maximizing Hydraulic Hose for Increased Productivity

In today’s demanding mining industry, efficiency is the key to success. To maximize productivity and ensure smooth operations, every component of the mining equipment needs to perform at its best, including hydraulic hoses. Engineered to withstand high pressure and extreme conditions, these hoses play a crucial role in powering heavy machinery.

In this article, we will delve into the world of hydraulic hoses and explore how maximizing their performance can unleash mining efficiency like never before. From selecting the right hose materials to proper installation and maintenance techniques, we will uncover the secrets to optimizing hydraulic hose performance and enhancing productivity on mining sites.

With our in-depth expertise in the mining industry, we understand the challenges faced by mining companies and the need for cost-effective solutions that deliver superior results. That’s why we dive into the technical details, sharing insights and best practices that will help you make informed decisions to maximize your mining efficiency.

Join us as we unveil the untapped potential of hydraulic hoses, and discover how their optimal performance can revolutionize your mining operations for increased productivity and profitability. Don’t miss out on this opportunity to take your mining efficiency to the next level.

Importance of maximizing hydraulic hose performance

Hydraulic hoses are the lifelines of mining operations. They transport hydraulic fluid, which is essential for powering the machinery that drives the mining process. When hydraulic hoses are not performing optimally, it can lead to downtime, reduced productivity, and increased maintenance costs. Therefore, maximizing hydraulic hose performance is crucial for mining companies to stay competitive and profitable.

Efficient hydraulic hoses enable smooth and reliable operation of mining equipment, allowing for faster and more productive cycles. By ensuring proper hose performance, mining companies can minimize downtime, reduce the risk of equipment failure, and increase overall productivity. In addition, optimizing hydraulic hose performance can also enhance safety on mining sites, as faulty hoses can lead to accidents and injuries.

Common challenges in hydraulic hose performance

Despite their importance, hydraulic hoses often face various challenges that can hinder their performance. One common challenge is abrasion, where the hoses are subject to constant rubbing against equipment or other surfaces. This can lead to wear and tear, resulting in leaks and reduced efficiency. Another challenge is high pressure, which can cause hoses to burst if they are not designed to withstand the specific operating conditions.

Extreme temperatures, chemicals, and UV exposure are other factors that can impact hydraulic hose performance. These environmental factors can cause the hoses to degrade over time, leading to reduced flexibility, loss of sealing capability, and increased risk of failure. Additionally, improper installation and maintenance practices can also contribute to poor hydraulic hose performance.

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Factors affecting hydraulic hose efficiency

To maximize hydraulic hose performance, it is essential to understand the factors that affect their efficiency. One crucial factor is the material used in the construction of the hose. Different materials have varying levels of resistance to abrasion, chemicals, and temperature extremes. Selecting the right material for specific mining applications is vital to ensuring optimal hose performance.

Another factor is the hose’s design and construction. Factors such as the number of reinforcement layers, thickness of the wall, and the type of fittings used can significantly impact the hose’s ability to withstand pressure and external forces. Additionally, proper sizing and routing of hoses can minimize pressure drops and ensure efficient fluid flow.

Tips for selecting the right hydraulic hose for mining applications

Selecting the right hydraulic hose for mining applications is crucial for maximizing performance and durability. Here are some tips to help you make informed decisions:

1. Understand the operational requirements:
Consider factors such as temperature range, pressure rating, and compatibility with hydraulic fluids and mining materials. Consult with hose manufacturers or industry experts to determine the most suitable hose specifications for your mining operations.

2. Choose high-quality materials:
Opt for hoses made from durable materials that offer excellent resistance to abrasion, chemicals, and extreme temperatures. Reinforcement layers should be robust enough to withstand the specific operating conditions.

3. Consider specialized hoses:
Depending on the mining application, specialized hoses such as flame-resistant or static-dissipative hoses may be required to meet safety regulations or prevent potential hazards.

4. Assess the flexibility and bend radius:
Ensure the hose has the necessary flexibility and bend radius to accommodate the equipment’s movement without compromising performance or causing damage.

5. Evaluate the warranty and lifespan:
Check the manufacturer’s warranty and expected lifespan of the hose. Investing in high-quality hoses with longer lifespans can save costs in the long run.

Proper installation and maintenance of hydraulic hoses

Proper installation and maintenance practices are essential to maximize hydraulic hose performance and prolong their lifespan. Here are some best practices to follow:

1. Follow manufacturer guidelines:
Adhere to the installation and maintenance guidelines provided by the hose manufacturer. These guidelines often include recommended torque values, assembly procedures, and inspection intervals.

2. Inspect hoses regularly:
Perform visual inspections of hoses to check for signs of wear, damage, or leaks. Inspect fittings, clamps, and connectors for tightness and proper alignment. Replace any damaged or worn-out components promptly.

3. Clean hoses before installation:
Ensure the hose and the surrounding area are clean and free from dust, debris, or contaminants that can cause premature wear or clogging.

4. Avoid excessive bending or twisting:
Minimize sharp bends and twists in the hose’s routing to prevent kinks, which can restrict fluid flow and lead to premature failure.

5. Train operators and maintenance personnel:
Educate employees on proper handling, storage, and maintenance practices to prevent accidental damage or misuse of hydraulic hoses.

Benefits of proactive hydraulic hose management

Implementing proactive hydraulic hose management practices can bring numerous benefits to mining operations. Some of the key advantages include:

1. Improved equipment reliability:
Regular inspections and maintenance can help identify potential issues before they escalate into major problems, reducing the risk of unexpected equipment failures and costly downtime.

2. Enhanced safety:
Well-maintained hoses reduce the likelihood of accidents caused by hose failures, such as leaks, bursts, or fires. This promotes a safer working environment for mining personnel.

3. Cost savings:
Optimizing hydraulic hose performance can result in cost savings by minimizing downtime, reducing the frequency of hose replacements, and preventing expensive equipment repairs.

4. Increased productivity:
Reliable hydraulic hoses enable uninterrupted operation of mining equipment, allowing for higher productivity and more efficient mining cycles.

As the mining industry continues to evolve, maximizing hydraulic hose performance will remain a critical factor in driving efficiency and productivity. By selecting the right hose materials, following proper installation and maintenance practices, and leveraging advanced monitoring technologies, mining companies can unlock the untapped potential of hydraulic hoses.

Efficient hydraulic hoses not only enhance productivity and profitability but also contribute to a safer working environment for mining personnel. By investing in proactive hydraulic hose management, mining companies can stay ahead of the competition, reduce operational costs, and achieve sustainable growth.

Join us in embracing the future of hydraulic hose efficiency in mining operations and unlock the true potential of your mining site. Let us help you revolutionize your mining efficiency and drive your business towards increased productivity and profitability.

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