MODULE – 7.

9
PIPES & HOSES

 Bending & Belling/Flaring Aircraft Pipes

 Inspection & Testing of Aircraft Pipes & Hoses
 Installation & Clamping of Pipes

B07 Part 5, Chapter 4

 1
Hand or power operated bending
machines
Circular formers in various
diameters, grooved around their
circumference to fit a particular
diameter pipe
Rolling a similarly grooved guide
round the former
Semi-circular grooves fit exactly the
outside
Pipe diameter of the pipe and
Bending
prevent the pipe being distorted -
2
Pipe Bending
3
 Spring is inserted into the pipe or
around the pipe to prevent
distortion
 Material - heat treatment may be
required
 Normal operation - room
Pipe Bending
temperature -
4
5
Pipe must seat on the coned face an
adaptor nipple or externally coned adaptor
Pipe is joined to the coned face by means
of a collar and union nut
High fluid pressure
Flaring tools examined regularly for the
damage
Scoring will cause leaks
Flaring – Belling -

Pipe Flaring or Belling

6
Two sizes:
The small tool for expanding the ends of
pipes 3/16 inch to ½ inch outside
diameter
The large tool for pipes from ⅝ inch to
1½ inch outside diameter -

AGS Flaring Tools

7
Pairs of half bushes to cover the range of
pipe sizes
The cones on AGS unions and adapters
have an included angle of 32
American AN couplings have a 74
included angle
◦ Special tools are required -

AGS Flaring Tools

8
Check material specification
Check heat treatment
Pipe bent to shape before flaring
Ends of the pipe - square, smooth & clean
Burrs - cracks when flared -

Flaring Operation
9
Cutting a Pipe
10
 Fit union nut and collar on to pipe
 Correct half bushes fitted into flaring tool
 End of the pipe - level with the face of the bushes
 Half bushes - dimensionally accurate
 No gap between the bushes - fitted to the pipe
◦ Diametrically opposed flash lines - on the pipe flare
◦ Cause the pipe to fail
 Expanding cone - screwed in to expand the end of
pipe
 Expanding cone - rotated and fed inwards
 Limit imposed by the shape of the half bushes -

Flaring Operation
11
12
https://www.youtube.com/watch?v=L293
sC2CiK0
https
://www.youtube.com/watch?v=Eo95bjm7
WFM
https://
www.youtube.com/watch?v=RyG2Slbaz2Y
https://
www.youtube.com/watch?v=VGwIrh33CpI
https://
www.youtube.com/watch?v=Eq1dPuPoL2
M

 1
3
Completed Flaring is inspected for:
 Splits or cracks
 Thinning
 Eccentricity
 Other visible faults

Flaring Operation
14
Check each coupling is connected to a
steel coned adaptor test fitting and
tightened
The flare should pass through the thread
of the union nut with not more than 1/64
in clearance
With the collar as far as it will go towards
the flared end of the pipe, the projection
of the pipe beyond the collar face must be
measured
Tolerances given in a table are
permissible
Flaring -
Operation
15
Tolerance Table
Tube Outside diameter
Projection Tolerance
(inches)

3
/16 in to 1/4 in 0 to 0.010 in 0 – 0.254 mm

5
/16 in to 3/8 in /64 in to 1/32 in 0.39 – 0.79 mm
1

7
/16 in to 11/2 in 1
/32 to 1/16 in 0.39 – 1.58 mm

16
UNDER NO CIRCUMSTANCES
Expanding cone be used with stainless
steel
Pick-up and damage to the flare may
occur
Special flaring tools are used with
stainless steel -

Stainless Steel
17
ANY QUESTIONS ?

18
 EASA
MODULE 07
MAINTENANCE
PRACTICES

7.9 – Maintenance & Inspection of

Rigid Pipes
B07 Part 5, Chapter 5 19
  Damage – pipe, end fittings & protective
treatment
 Corrosion – externally and internally
 Scores, Dents, Flattening, Kinks & Chafing
 Carry out bore test and pressure test if
necessary
 Correct forming of flared ends and positioning of
the olive or nipple
 Blown through with clean dry air or the system
fluid
Pre-Installation Checks
 Any inhibitor MUST be removed
 Ends MUST be blanked with proper blanking
caps - 20
As required by the Maintenance Schedule
Test equipment should be clean and
serviceable
Relevant safety precautions
◦ Important - high pressure as test medium -

Testing Rigid Pipes

21
Test rig and the system fluid
◦ Paraffin may be specified
Pressure increased to 1.5 times the
maximum working pressure of the pipe
Pressure should be maintained long
enough to make sure that no leaks occur -

Pressure Test
22
Steel ball - diameter of 80% of the
pipe diameter
Passed through the pipe in both directions
If not practicable a flow test may be
specified -

Bore Test
23
 Supporting clamps
◦ Connections made finger tight
 Clamps fit correctly, be free of sharp edges and
correct size
 Routing of the pipe checked
 Couplings tightened - specified torque
◦ Clamps – tightened
 Bonding wires - connections attached
 Multiple pipe clamps
◦ Red fibre, aluminium alloy, moulded rubber, nylon or
other material
 Packing between pipes and clamps must be as
specified
◦ Cork sheet, tinned copper or stainless steel gauze or
Installation
various types of tape
 Individual pipes - supported using rubber lined ‘P’
clips - 24
25
Standard, brazed, flared or Flareless
couplings
Union nuts turn freely
Loose parts such as nipples, non-metallic
glands - correctly positioned
Ends must align correctly
Never forced into position
◦ Drawn into position by union nuts -

Connecting
26
Two spanners - used when tightening or
disconnecting a pipes
Coupling nuts - torque loaded
Thread lubricant specified must not enter
the pipe bore -

Connecting
27
During pipe installation the minimum
clearances are as follows:
From fixed structure 6mm
(0.25in)
From control rods & rigid moving
parts 18mm (0.75in)
From control cables 25mm
(1.00in)

Clearances
28
Leak Tests
Low Pressure
High Pressure
Maximum system pressure
System is operated and checked for leaks
Fluid Leaks – Seen
Gas Leaks – Heard
◦ Acid free soapy water
Oxygen pipes - special leak testing
solution
All leak testing solutions MUST be washed
Test After
off after use -Installation
29
Sometimes cured by tightening
Dismantled and investigated.
ALWAYS wipe up any leakage from the
structure
During pressure tests pipes must be
inspected for flexing, distortion or
displacement
Flow tests are sometimes specified
Functional check of the system
FINALLY – Locked in the appropriate
matter -
Leak Tests
30
 Bonding Test
 < 0.05 Ohm

Test After Installation

31
Maintenance Manual
 Exposed positions - Corrosion or accidental
damage
◦ Corrosion may be blended out within specified
limits and then re-protected - Otherwise the
pipe is renewed
 Undercarriage wheel bays - damaged by stones,
mud or pieces of rubber thrown from the tyres
 Careless work practices
 Chafing
 High pressure pipes - oval section at sharp bends
which may crack
 Leaks are indicated by the presence of liquid or
Maintenance Inspection
an accumulation of dirt
 Leakage from a gas system may be indicated by
loss of system pressure - 32
Tubular fitting - swaged over a pipe joint
Gap between the pipe ends can be up to
8mm (0.3in)
Easier when replacing a damaged portion -

Swage Fittings Repairs

33
A hydraulically operated swaging tool.
Pair of dies - cover the range of diameters
A ratchet pipe cutter.
A de-burring tool
Marking gauges
GO/NO GO gauges -

Swage Fittings Repairs

34
Hydraulic Swaging Tools
Hydraulic Swaging Tools
Hydraulic Swaging Tools
Hydraulic Swaging Tool
Battery / Electric
Swaging Tool
Typical Hydraulic Swaging
Tool Checks
Topping-up Procedures
Hydraulic Swaging Tool
44
 Normally removed to allow the ends of the pipe
to be flared or flareless couplings to be fitted
 Usually applied to straight sections of pipe
 Additional coupling could cause vibration -
fatigue failure of the pipe
 Only be used when approved by the Maintenance
Manual
 Ensure that the final length of pipe is correct
 Ensure couplings do not foul parts of the
structure
 Thoroughly cleaned afterwards
 Pressure tested before re-installation
 New section of pipe may be inserted, using two
new union bodies and connections -

Standard Coupling Repairs

45
46
47
ANY QUESTIONS ?

48
 EASA
MODULE 07
MAINTENANCE
PRACTICES

7.9 – Maintenance & Inspection of

Flexible Pipes
B07 Part 5, Chapter 6
49
Two types of flexible hose:
Hoses with detachable end fittings.
Hoses supplied by a manufacturer which
are complete -

Flexible Hoses
50
Save the cost of renewing a complete
assembly when only the hose portion is
unserviceable
End fitting - two or more components
Socket - over the hose
Tapered nipple or insert
Tapered nipple is screwed into the bore of
the hose it expands the hose and clamps
it firmly against the socket
Compression Seal -

Reusable End Fittings

51
52
Assembly of Reusable
End Fittings
Hose - exactly the same specification as
the original
Cut hose at right angles - correct length
Clean - remove small particles of rubber
Screw socket on to the hose - left hand
thread
Screw nipple in to the socket - right hand
thread
Finally pressure test, bore test and bonding
test - 53
Life - Make sure that the hose is not life
expired.
Examining - Examine the hose for
obvious leaks from the end fittings and
particularly where the hose joins the end
fittings
Blisters - Puncture the blister, if fluid
emerges, reject the hose, if not, pressure
test and if it leaks under test reject the
hose.
Ageing Cracks - They consist of very
small short cracks. If the cracks join in a
continuous line or the braiding is showing,
Inspection
reject the hoseof - used hose
54
Security - Make sure the hose end
fittings are locked properly.
Corrosion - Examine the end fittings for
corrosion, light corrosion can be removed,
otherwise reject the hose.
Twisting - Any twist will seen by the line
running the length of the hose. If a hose
has a permanent twist, pressure test and
if no leaks are visible, consider it
serviceable.
Cut Covers - Examine closely for cuts. If
any cuts penetrate to the braiding, reject
the hose -

Inspection of used hose

55
 Chafing - If braiding is showing, reject the hose.
If slight chafing is present, the hose should be
moved but do not tape it up
 Kinks - Reject the hose
 Overheating - Appears as scaling, crazing or
discolouration of the surface. Hose with outer
wire braid may have an acceptable overall golden
brown colour. Patches of discolouration caused
by overheating are not acceptable
 Contamination - Shows as swelling,
sponginess, hardening or disintegration of the
surface, which is not acceptable. Reject the hose
-

Inspection of used hose

56
Maintenance Manual
Tests that may be carried out on a hose
are:
Pressure test
Bore test
Bonding test -

Testing of Hoses
57
Flexible hoses are pressure tested to 1½
times the maximum working pressure
Normal system fluid or paraffin, which is
safer for testing petrol hoses
Air and oxygen hoses are tested with
water then dried out with a warm air blast
A further test is carried out with clean dry
air at maximum system pressure only
While the hose is under test flex it 15 -

Pressure Test
58
Ensure the hose will deliver the designed
amount of fluid
Bore - checked by : -
Visually
Ball test
Flow test -

Bore Test
59
Bore Test

 VISUALLY

 View from each end in turn, this

method is only suitable for short
straight hoses

60
BALL TEST
Pass a steel ball through the hose from each end in
turn.
The diameter of the ball must be at least 90% of
the internal diameter of the end fitting
If the ball does not pass through the hose freely,
the pipe is unserviceable
On small bore straight hoses a steel rod may be
Bore Testof a ball -
used instead

61
FLOW TEST
The flow test consists of passing a fluid through a
hose from each end in turn and timing the flow
rate
The figure obtained is then compared with the
flow rate figure given in the Manufacturer’s
Manual -

Bore Test
62
Hoses are tested for bonding before fitting
The resistance should not exceed 0.05
ohms
Or 0.025 ohms per foot length
Which ever is the greater -

Bonding Test
63
Bonding is only possible when hoses have
metal in their structure
All installed hoses should be tested
between the end couplings and the
components to which they are connected
The resistance should not exceed
0.05 ohms.

Bonding Test
64
Damage
Corrosion of end fittings
Cleanliness, carry out ball test
Flush with system fluid
Verify the part number
Date of manufacture
Date of last test
Pressure test -

Pre-Installation Check
65
No contact with parts of the aircraft or engine
Allow for hose flexing
Correct routing
Do not exceed manufacturer’s minimum
bend radius limits
Straight hoses must be 3% longer than
the maximum distance between the
fittings
Lubricant does not enter the hose
DO NOT USE OIL OR GREASE WITH
OXYGEN -

Installation
66
Not twisted - support the hose while
tightening
Approved hose support guide and clips at
the correct intervals
Packing between hose and clips
Carry out system function and leak test
Aircraft fuel system - flow test
Bonding test
Wire lock assembly end fittings -

Installation
67
68
 THE END

ANY QUESTIONS ?
69