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Line-of-Sight Hydraulic Hose Testing of Pinhole Failures

Line-of-Sight Hydraulic Hose Testing of Pinhole Failures

It is widely known that hydraulics and pressurized systems can pose significant risks to operators, equipment, and bystanders when operated in extreme or unsafe conditions. Even experienced equipment operators acknowledge the potential safety hazards, such as pinhole leaks, that are associated with pressurized hydraulic hoses.

To prevent or lessen the risk of serious injury, some industries have begun 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 when working in tight, restricted spaces where an operator or other workers may have limited room to maneuver safely.

Recognizing the importance of operator safety, we created our advanced Diamondback sleeve series which provides unparalleled line-of-sight operator protection.

But what is line-of-sight protection? And how do you weed out the imposters? In this article, we will discuss:

  1. The Dangers of Pinhole Leaks
  2. The Hose Durability Test
  3. The Diamondback Pro for Unmatched Protection

The Dangers of Pinhole Leaks

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.

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.

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

Diamondback Abrasion Sleeve

The Hose Durability Test

To run the hose durability test and compare the effectiveness of each hose guard, we used International Standard 3457:2003, which 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 tests 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 testing, the Diamondback sleeve provided unmatched line-of-sight protection compared to competitor sleeves. The competitor's hose covers are flexible, but not properly guarding. In comparison, Diamondback is sufficiently sturdy to stop, disperse, or divert the oil stream when installed with clamps on the ends during a pinhole failure. With the Diamondback Pro, there is complete operator protection.



The Diamondback Pro for Unmatched Protection

Beyond line-of-sight protection, 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. 

dbk flat blog-2

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

Ready to Level Up?

The Diamondback Pro hydraulic hose sleeve has it all. With unmatched pinhole leak and burst protection, you can be confident operators are safe and equipment is ready to run. Here at Python, we've got you covered no matter the application. Contact us to learn more.

Python - Diamondback PRO CTA