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Line of Sight Testing of Hydraulic Hoses with Pinhole Failures | Diamondback Sleeve

It’s no secret that hydraulics and pressurized systems, when operated in extreme or unsafe conditions can present real dangers to the operators, equipment, and anyone else around the machine. Even the most seasoned equipment operators will warn of the potential safety hazards (like pin-hole leaks) associated with their pressurized hydraulic hoses.

To prevent, or lessen the risk of serious injury, some industries have began implementing safety measures that are required of the equipment manufacturers and operators. 

When working with any type of earth moving equipment, line-of-sight safety is a big concern, especially if you’re operating in confined, or limited spaces where an operator or other workers may not be able to get out of the way in a safe manner. 

Seeing this need, Python created their advanced Diamondback sleeve series which provides next-level line-of-sight operator protection.

But what truly is line of sight protection? And how do can you weed out the imposters?

Line of Sight Testing of Hydraulic Hoses with Pinhole Failures | Diamondback Sleeve

Whether the equipment is operating on a farm, in a mine, or at a construction site, ensuring operator and passerby safety is of paramount importance when hydraulic equipment is present and in operation. 

Pinhole leaks, or failure of a pressurized hose in any way, may cause severe injury, or potentially even death if left untreated.

To test the Diamonback sleeve’s durability and strength against pinhole leaks, a series of tests were run that simulated different levels of protection, from a bare line with no protection, to the Ultimate Diamondback Pro sleeve.

When a hydraulic hose with a pinhole leak is pressurized, the small orifice creates a violent flow of fluid. If strong enough, this flow is able to inject itself into human skin. The oil will spread inside the body and can lead to amputations or death if serious enough. This test was performed to determine if the protective sleeves are able to meet the qualifications (from the ISO standard 3457:2003) to be deemed a hose guard.

International Standard 3457:2003 states “Hoses containing fluid at pressures exceeding 725 psi or temperatures above 140°F which are located within 3.28 ft of the operator in the normal operating position and whose direct spray in case of failure can reach the operator shall be guarded. Hose guards, including flexible hose coverings, shall be sufficiently sturdy to stop, disperse, or divert the fluid stream, in case of hose failure, from direct contact with the operator.” 

The tests, shown in the video below, were completed using a series of highly-pressurized hydraulic lines (tested above 4,000 PSI), some of which had no sleeves, some had competitive sleeves, and some had the Diamondback pro. The test was completed using an uncooked bratwurst to simulate the impact a pinhole leak can have on an operator’s hand or limb. 

All sleeves were clamped and sized properly to achieve the best results for the protection of the operator.

Throughout the tests, we proved that the diamondback sleeve provides a next-level line of sight protection compared to our competitor sleeves. And we also proved not all flexible hose covers qualify as hose guards, and that installation is just as important.

Diamondback proved to be sufficiently sturdy to stop, disperse, or divert the oil stream when installed with clamps on the ends during a pinhole failure.

Beyond line-of-sight protection, the Diamondback sleeves are also tested for colorfastness to light through the Zenon Arc testing. During this test, we rated 5.0 when exposes to 224 KJ (KiloJules) compared to 4.5 of the leading competitive sample.  

The Diamondback sleeve is also tested to meet:

Additional specifications include:

  • Meets abrasion standards (ISO 6945 and ATSM D6770) tested to over 1 million cycles
  • Ultra tight construction reduces oil spillage
  • Pinhole protection tested to 4,000 PSI. Burst tested to 12,000 PSI.
  • Meets operator “Line of Sight” specifications EN982 norm 833 EN414, ISO 3457-2003
  • Excellent UV, chemical and abrasion protection
  • MSHA approved #IC-289/01
  • Cut to length, 50% less bulky than Cordura

Have questions on how to integrate our Diamondback sleeve or want to know more about the tests? Contact us today with any questions.  

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