Bioflex Ultra Hose

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Hose Construction

Bioflex Ultra Hose Design Options

Bioflex Ultra Hose Grades are made up by combining the Design Options, which are defined by 2 letters as shown below, and fully described in the linked sections.

For example, “Bioflex Ultra AS, PB, SG” defines a hose with an Antistatic PTFE liner (AS) and a Polypropylene braid (PB) and an outer Safegard (SG) spiral HDPE protection sleeve.

PTFE Liner Tube Options - GP (Natural PTFE) and AS (Antistatic PTFE)
Braid Options - TO (Tube Only, No Braid), SS (316 SS Wire), and PB (Polypropylene)
Rubber Cover Options - RC (Blue EPDM), BK (Black EPDM) and SI (Silicone Rubber)
External Protection Options - SR (Scuff Rings), SG (Safegard Spiral) and PC (SS Wire Coil)

Bioflex Ultra in Comparison with Convoluted PTFE Hose

• Hygienic Cleanability - much better, due to no internal convolutions
• Flow Rates - more than 2 x higher
• Pressure Ratings - more than 1.5 x higher
• Self Draining - Excellent self draining with PTFE lined fittings
• Non-Whistling - no whistling noise with gasses

Bioflex Ultra in Comparison with Conventional Smoothbore FEP, PFA or PTFE Lined Rubber Hose

• No Adhesives - No toxic adhesives used in the Bioflex Ultra construction, eliminating the possibilities of Process Fluid contamination in service
• Flexibility - Much better flexibility
• Internal Shape Control - No distortions in bore when flexed

Bioflex Ultra in Comparison with Silicone Rubber Hose

• Hygienic Cleanability - much better, due to the non-stick PTFE Liner
• Chemical Resistance - considerably improved, particularly to strong oxidising acids and bases
• Temperature & Pressure Ratings - much higher temperature and pressure capability
• Steam Resistance - permanently resistant to steam sterilising (unlike silicone hose, which has a limited life)

Bioflex Ultra GP, SS with a PTFE Lined Sanitary Triclover Fitting

Note: Rubber covered hose is marked in accordance with EN 16643

Properties

Temperature vs Pressure

Due to its extremely strong construction, Bioflex Ultra has outstanding resistance to temperature and pressure, much higher than that of conventional convoluted PTFE lined hose.

Maximum Working Pressure (MWP) Variation with Temperature:

MWP for SS grade hose, also for RC, BK and SI grades are as given in the graph, BUT only within the temperature range for the particular grade of hose, as given below:

Min/Max Operating Temperatures:

• Bioflex Ultra GP or AS SS -73˚C to +260˚C
• Bioflex Ultra GP or AS SS,RC & SS, BK -40˚C to +150˚C
• Bioflex Ultra GP or AS SS, SI -73˚C to +204˚C
• Bioflex Ultra GP or AS PB - MWPs for PB are as given in the graph up to 80˚C, then reduced by 50% between 80˚C and 100˚C (the maximum for PB).

Temperature vs Vacuum

All sizes and grades of Bioflex Ultra hose are usable at vacuum to -0.9bar up to 200˚C (100˚C for TO grades). Above this, the vacuum resistance should be reduced 2% for every degree above 200˚C (100˚C for TO grades).

Temperature & Maximum Working Pressure Graph for Bioflex Ultra

Flow Rates

In practice, flow rates will vary with hose flexing, fluid viscosity, end fitting design and other parameters, but Bioflex Ultra hose flow rates are always around 2 times better than convoluted PTFE hose, when comparing hose assemblies with PTFE lined (non bore-restricted) end fittings.

Bioflex Ultra Hose - Flow Rate Calculation

If it is required to determine the flow rate of a particular hose assembly, or if it is required to determine the pressure required to generate a certain flow rate, then this can sometimes be approximately calculated by the Bioflex Ultra supplier.

It should be noted that calculations can only be made for fluids with a viscosity equal to water, and for hose assemblies with PTFE lined end fittings (no bore restrictions at the ends of the hose).

The following information should be given to the supplier

To calculate the Flow Rate in Cubic Meters per Hour:

• Pressure in Bars at the Entry into the Hose Assembly - subtracted from - Pressure in Bars at the Exit from the Hose Assembly (to calculate Pressure Drop over the Hose Length).
• The hose configuration (roughly straight, or 33% Bends, or 66% Bends, or 100% Tightly Coiled)

OR To Calculate the Pressure Drop in bars over the length of the Hose Assembly:

• Required Flow Rate in Cubic Meters per Hour
• The hose configuration (roughly straight, or 33% Bends, or 66% Bends, or 100% Tightly Coiled)

Bioflex Ultra Size, Grades, Bend Radii & Dimensions

*The 7/8”, 13/8” and 17/8” hose sizes are only suitable for use with PTFE lined sanitary clamp (or triclover) end fittings and PTFE lined I-Line end fittings

Bioflex Ultra Sizes, Grades, Pressures & Weights

* The 7/8”, 13/8” and 17/8” hose sizes are only suitable for use with PTFE lined sanitary clamp (or triclover) end fittings and PTFE lined I-Line end fittings.

** The Maximum Working Pressure of a hose assembly is limited to the lowest of the MWP's of either of the two end fittings, or of the hose itself as listed above. The MWP of the hose reduces as the operating temperature increases as specified in the Graph.

Labeling & Coding

Standard Labeling

All Bioflex Ultra hose assemblies are labeled with the following information:

• Manufacturer’s Name (Aflex Hose Ltd)
• Hose Size and Grade
• EN16643 and year of standard publication
• EN16643 electrical property grade
• Max. Working Pressure and Test Pressure
• Working temperature range*
• Unique Serial Number
• Month & Year of Manufacture
• Aflex Hose Telephone Number
• CE Mark (if applicable)

*Note any restrictions on working pressure resulting from elevated temperatures.

This information is normally laser-etched on to a loose stainless steel Ring mounted on the hose.

In some cases, at the discretion of Aflex Hose, the information may be etched on to a thin stainless steel plate which is clamped to the hose, or on to the end fitting ferrule at one end. This may be necessary for example, if the customer requires additional information which may not fit on to a Ring.

Customers may specify which labeling system they require, and may request additional information on the label.

Streamline Tagging

This system is only applicable to the Silicone (SI) rubber covered grades of Bioflex Ultra that have a stainless steel (SS) braid.

A label and/or Color Code is placed around the silicone cover of the hose and then encapsulated by a transparent silicone that is formed into a thin streamlined cover.

Note: 1/2” size, Color Code only, no text.

Color Coding

This system is applicable to all grades of Bioflex Ultra hose.

A colored PTFE spiral strip is wound on to the hose.

It can be left loose, or it can be encapsulated under a transparent, heat-shrunk polyolefin sleeve.

Quality Assurance & Certification

EN ISO 9001:2008

Aflex products are all manufactured in accordance with BS EN ISO 9001: 2008 Quality Management Systems independently assessed and registered by The British Standards Institution (BSI).

EN16643

Bioflex Ultra meets the requirements of EN 16643 (SC), which include the electrical and electrostatic requirements of hose assemblies.

TS16949

Aflex Hose Ltd manufactures PTFE flexible hose for the automotive industry in accordance with TS16949 and is assessed and certified by The British Standards Institution (BSI).

ISO 14001:2015

Aflex Hose Ltd have been successfully assessed to the requirements of ISO 14001, by the British Standards Institution (BSI). By gaining this accreditation Aflex Hose Ltd are demonstrating our commitment to reducing our impact on the environment.

USP Class VI and ISO 10993-5, 6, 10 and 11 guidelines

Natural and Antistatic PTFE Hose Liners, Platinum Cured Silicone Rubber Covers (White and Clear) and EPDM Rubber Cover (Blue) have been independently tested in accordance with USP protocols and are found to conform to the requirements of USP Class VI Chapter <88>.

Natural and Antistatic PTFE Hose Liners now also meet the more stringent USP Class VI and ISO 10993-6,10 and 11 guidelines at 121˚C (250˚F) with a “no reaction” classification.

Natural and Antistatic PTFE Hose Liners and Platinum Cured Silicone Rubber Covers (White and Clear) have also been tested in accordance with USP protocols and are found to conform to the requirements of USP Class VI <87>, the L929 MEM Elution Test and are considered non-cytotoxic.

Natural and Antistatic PTFE Hose Liners have now been further tested and have passed the more stringent USP Class VI and ISO 10993- 5 guidelines at 121˚C (250˚F).

USP <661> Physicochemical Test for Plastics

Natural and Antistatic (Carbon filled) Externally Convoluted Smoothbore PTFE hose has been tested in accordance with USP Physicochemical Test for Plastics and found to meet the criteria of the following reference: USP34, NF 29, 2011. Monograph <661> Containers, Physicochemical Test-Plastics.

FDA

The Materials used to manufacture the natural PTFE Tube liner conforms to FDA 21 CFR 177.1550, and the antistatic PTFE liner conforms to FDA 21 CFR 178.3297.

3-A Sanitary Standards

Bioflex Ultra hose assemblies accredited to 3-A Sanitary Standards are identified within the product brochure.

BPSA leachables and extractables testing

Aflex Hose Natural and Antistatic PTFE Hose Liner Tube has been independently tested in accordance with BPSA recommendations, and found to be satisfactory.

Copies of the Test Report are available for specific assessments to be made.

Flame Resistant

To special order only, Aflex Hose are able to supply hose with a special rubber cover which is compliant with the requirements of BS EN 45545, DIN 5510 and NFF 16101 specifications.

Pharmaceutical Manufacturers Approvals

Most of the major pharmaceutical manufacturing companies in the world have audited and/or approved Aflex Hose as a Hose Supplier.

CE Marking (Europe only)

Aflex has been assessed by The British Standards Institution (BSI) and found to comply with the Pressure Equipment Directive 2014/68/EU (European Community) Conformity Assessment Module D1, approved to CE Mark applicable hose products, accompanied by a Hose Usage Data Sheet, and a Declaration of Conformity.

Attestations of Conformity to ATEX Directive 2014/34/EU (Potentially Explosive Atmospheres)

Available for hose assemblies for components used in Gas Zones 1 & 2 and Dust Zones 21 & 22, when applicable.

Material Certification to EN10204

Available for all the hose or hose assembly components.

Certificates of Conformity to EN ISO/IEC 17050

Are available for all products.

Fuel Hose Approval to SAE J1737

Bioflex Ultra hose samples have been tested and approved to SAE J1737 for Automotive Fuel Hose applications.

Hose Testing

Each assembly is pressure tested to 2.0 times maximum working pressure before despatch, and pressure test certificates can be supplied.

Fire Resistance to BS5173 Section 103.13 Part 6.2 and 6.

BK Grade Bioflex Ultra hose assemblies are “Fire Resistant”. If DRC-300 is added at both ends, the assemblies are upgraded to “Fire Proof”.

Food Contact

Manufactured in compliance with Regulation (EC) No 1935/2004 - on materials and articles intended to come in to contact with food, Commission regulation (EU) No 10/2011 - relating to plastic materials and articles intended to come into contact with food and Regulation (EC) No 2023/2006 - on good manufacturing practice for materials and articles intended to come in to contact with food.

Special Usage Conditions

Cleaning & Sterilising Systems - CIP, SIP and Autoclave

CIP & SIP – PTFE liner tubes are chemically resistant to all CIP, SIP and Autoclave conditions. A primary consideration is whether the cleaning and purging cycle is likely to develop an electrostatic charge on the internal surface of the liner, in which case AS (Anti-Static) grade hose is required.

AS grade hose and Electrostatic charge generating systems are fully described in the hose liner section.

CIP systems using high electrical resistivity solvents like Toluene will require AS grade hose.

Another electrostatic generation problem arises when wet steam is passed through, or when the cleaning fluids or WFI are purged out of the line using nitrogen, compressed air or another gas, because droplets of liquid or water in the gas then generate a multi-phase condition until they are cleared out, which will generate a static charge, and so will require AS grade hose.

In static generating applications where AS grade hose is not acceptable due to the black PTFE liner, alternative solutions may be available – please contact us for advice.

Autoclave

Autoclave sterilisation does not normally involve any high flow rates through the hose bore, so static generation is not a problem. Aflex hose grades GP and AS, with SS braids are fully resistant to all autoclave conditions throughout the service life of the hose.

The rubber covered grades EPDM, (RC and BK) and Silicone Rubber (RC, SI) are able to withstand at least 300 x 30 minute autoclave cycles at relatively high autoclave temperatures (up to 135°C, 275°F). Please note that in robust applications covers may become more susceptible to tearing after extended autoclave cycles. Contact us for more specific information.

PTFE Hose-Use with Alkali Metals, Halogens and certain Halogens containing Chemicals

PTFE hose liners react chemically with Fluorine, Chlorine Trifluoride and molten Alkali Metals and so no hose grades are suitable for use with these chemicals.

When PTFE lined hose is used to carry Chlorine or Bromine, either as gasses or fluids, trace quantities can diffuse into and through the PTFE liner wall thickness. These will then combine with atmospheric moisture to corrode any SS, PB or RC outside the liner tube. It has been found that Corroflon SP, HB or KYB hose is best suited for these applications - Please consult the Corroflon brochure.

Depending upon the internal pressures and temperatures, some other gasses and fluids with a high halogen content may also be transmitted in trace quantities through the wall of the PTFE tube, including Hydrogen Fluoride, Hydrogen Chloride, Carbonyl Chloride (Phosgene), Carbon Tetrachloride and others. Please contact us for a suitable hose grade recommendation.

Other “Penetrating” Fluids and Gases

Sulphur Trioxide, Methyl Methacrylate, Caprolactam and Glacial Acetic Acid are some other chemicals which do not react chemically with the PTFE, but which can be absorbed and transmitted through the PTFE liner tube wall - please contact us for the optimum solution with these chemicals.

Generally, however, as a hydrophobic (non-wetting) material, PTFE is very resistant to the absorption of chemicals. In some cases, PTFE has superior resistance to diffusion, for example to the diffusion of automotive fuels, in comparison with all other plastics and rubbers.

Gas/Fluid Cycling

There are some applications where fluids then gasses are passed through the hose, in a cyclic sequence.

This is normally associated with changes in temperature and/or pressure. For complex reasons these conditions are extremely damaging to the hose liner, whatever material it is made from.

For example, hoses are sometimes used to pass steam, water, steam etc into rubber moulding presses, in order to heat the mould, then rapidly cool it before reheating in the next cycle. Hoses of all types fail rapidly in such an application and PTFE lined hoses are no exception.

Please contact us for further information if these conditions apply.

Connecting Assemblies for Use in Applications

The lengths of hose assemblies and their configuration in use when connected into the application must always be in accordance with the Hose Configuration information at the end of this product literature.

When being connected for use in applications, the end fittings on hose assemblies must be connected to correct mating parts in the correct way, using the correct tools, spanners, clamps, nuts and bolts etc. The connections must be sufficiently tightened to ensure that the joint is leak free but not be over tightened as this can damage the sealing surfaces, especially with PTFE lined and flared end fittings.

In applications involving the transfer through the hose of expensive or dangerous fluids or gases, the hoses and connections must be pressure tested in situ before being put in to service. This should be done with some harmless media to 2.0 times the maximum working pressure of the hose assembly, as stated in the product literature.

If in doubt please contact us for advice.

Special Applications

Aflex Hose PTFE lined hose products are not rated as suitable for use in the following, special applications:

• All Radioactive Applications involving high energy radiation, including Gamma radiation (degrades PTFE)
• All Medical Implantation Applications.
• All Aerospace Applications, except by special prior agreement, confirmed in writing.

Silicone-Free Application requirements

Some applications, particularly paint manufacturing plants, and other specialized applications require that hoses do not include any silicone containing materials in their manufacture, or sometimes that hoses are guaranteed to be 100% Silicone Free. Customers or Distributors must specifically identify and define any such requirements in writing on all enquiries/orders.

Configure for Bend Radius

Hose Configuration Requirements

Hose Assemblies are usually connected at both ends in service. They may then either remain in a fixed, or static configuration or in a flexing, or dynamic configuration.

Whether static or dynamic, the First Rule concerning the configuration of the hose is that the bend radius of the hose must never be less than the Minimum Bend Radius (MBR) for the hose as listed in the relevant hose brochure.

The most common situation when this is likely to occur is when the hose is flexed at the end fitting, with stress being applied to the hose at an angle to the axis of the end fitting. Typically, this happens either because the length of the hose is too short, or because the weight of the hose plus contents creates a stress at an angle to the end fitting.

The Second Rule, therefore, if possible, is to design the configuration to ensure that any flexing in the hose takes place away from the end fittings.

Configure for Abrasion & Torque

The Third Rule is that the hose configuration should always be designed, and supported where necessary, to avoid any possibility of external abrasion.

In some cases, the length, configuration and angle of the hose can be designed to avoid abrasion. In others, static or moving support frames or support wheels are required.

The Fourth Rule is that the hose must not be subjected to torque, either during connection, or as a result of the flexing cycle.

Torque (twist) in the hose can be applied during connection if the hose is accidentally twisted, or if the second end being connected is a screwed connection, and the hose is subjected to torque during final tightening.

In a flexing application, if any flexing cycle of the hose occurs in 3 dimensions instead of 2, then torque will also occur:

EN16643 Hose Assembly Electrical Property Grades

The hose assembly electrical property grades and electrical resistance limits are defined within EN 16643 and tested in accordance with BS EN ISO 8031. Aflex Hose electrically conductive (EC) assemblies are defined in EN 16643 as electrically bonded and given the symbol M. M-grade assemblies exhibit a maximum electrical resistance of 100Ω between end fittings. Aflex Hose anti-static (AS) PTFE liners and rubber covers are termed static dissipative within EN 16643 and given the symbol Ω followed by letters that specify either the liner, cover or both; L=liner, C=cover, CL= cover & liner. Ω-grade covers or liners exhibit an electrical resistance of 103-108Ω.

The table below identifies each EN 16643 electrical grade for a hose assembly along with a brief description and example assembly configuration.

How to Order

The quantity, hose size, liner, braid, cover, protection system, length and fittings must be selected and specified in full.

EITHER by a full, written description. The hose grade can be specified by the code initials e.g. “Bioflex Ultra AS, SS, RC, DRC-300” defines an antistatic PTFE lined hose with an EPDM rubber cover over a SS braid, with a double rubber cover at both ends. The quantity, length and fittings can then be written in - e.g. “4 off x 1” bore Bioflex Ultra, AS, SS, RC, DRC-300 hose x 3.00 meters long. Both ends non-lined ANSI 150# S/S Flanges”.

OR by Part Numbers. Example from above “4 off Part No. 16-BFXU/AS-RC-00-3.00m-12-12, with DRC 300 at both ends”.

Any special requirements relating to the hose construction, or information required on Tags, or Certificates, or special testing of requirements, must be specified in full on the enquiry or purchase order.

Selecting the Hose Grade

There are two types of PTFE liner available, natural (GP) and antistatic (AS) and two types of braid; Grade 316 stainless steel (SS) and polypropylene (PB). Rubber covering and other external protection systems are also available.

A hose grade is specified by using the abbreviations given. For example, Bioflex Ultra AS,PB would describe a hose with an antistatic PTFE liner and a polypropylene braid. Selecting the End Fittings

Bioflex Ultra is available with a range of ‘standard’ end fittings, normally supplied hygienically PTFE lined and flared.

Stainless Steel End Fitting Materials

• Non-Lined Spigots - are made from Grade 316L SS
• PTFE Lined Spigots - are made from Grade 316L or Grade 316C SS
• Cam and Groove Female Fittings - are made from Grade 316C SS (Body) and 316L SS (Spigot)
• Swivelling Nuts and Flanges - are made from Grade 304 SS
• Ferrules - most ferrules are made from Grade 304 SS, except some are made from Grade 316L SS - contact us if necessary.

The equivalent specification for the different Grades of Stainless Steel are listed below:

Specification Equivalents List

To special order, end fitting components can be made in nonstandard grades of SS such as 1.4435, or other materials such as Hastelloy or Monel.

Conditions of Sale

Bioflex Ultra hose and hose assemblies are only supplied on the basis that the customer has read and accepted the Conditions of Sale. Customers own Conditions of Sale (or equivalent) are not accepted unless an acceptance, signed by a Director of Aflex Hose is supplied.

Selecting the Hose Length

Bioflex Ultra hose assemblies are made up to the specific lengths required. The hose length is taken as the length from the sealing face at one end of the hose to the same at the other end. The length tolerance is normally +2% / -0%. Closer tolerances are available to special order. (see also Length Calculation)

Bioflex Ultra Hose Assembly Length Limitations*

*Listed minimum lengths are for the Bioflex Ultra Hose only, and DO NOT INCLUDE THE LENGTHS OF THE FITTINGS AT EACH END. These must be found from the end fitting pages and added to calculate the minimum length of the hose assembly.**Longer lengths may be available to special order.

If required, Bioflex Ultra Assembly can be defined by an individual Part Number, made up of 7 entries as below:

1) 

2)

3)

*Note - If one of the rubber end protection systems is required, for one or both ends, please define the requirement in writing in addition to Part Number.

4)

5)

6 & 7

Notes

For Flange only: Add ‘/ZP’ for Carbon Steel Zinc Plated, or add ‘/EC’ for Epoxy coated

Elbows:

For all types of Elbow fittings add ‘/90°’ for 90° elbows

Triclamps: 

For ‘Hot Formed’ PTFE Lined Triclamps add ‘/HF’

Additional Requirements:

Any additional requirements which are not included in the Part Number must be written out in full in the Order, including any special labeling or color coding.

- When purchasing Triclovers/Sanitary Fittings please specify the surface finish required

Example:

A ³/₄” bore Bioflex Ultra GP, RC Hose Assembly with an Antistatic PTFE Liner and an outer
Safegard Sleeve with:

End (1) - a ³/₄” ANSI 150# Swivel Flange, PTFE Lined

End (2) - a Cam and Groove Swiveling Female, PTFE Lined

and a Length of - 4ft 6 inches

Hose Assembly Part No. = 12 - BFXU/AS - RC - SG - 54in - 12L - 16L

Entry No. 1 2 3 4 5 6 7

Length Calculation

Calculating the Hose Length

The formula for calculating the bent section of the hose length around a radius is derived from the basic formula that the circumference of a circle = 2πR, where R = the radius of the circle, and π = a constant, = 3.142.

So, if the hose goes around a 90˚ bend, which is 1/4 of a full circumference, and the radius of the bend is R, then the length of the hose around the bend is = 1/4 x 2πR. Or half way round, in a U-shape, = 1/2 x 2πR.

Note: In calculating the length of a hose assembly, the (non-flexible) length of the end fittings must be added in, also the length of any straight sections of hose, as in the following example:

Example:

To calculate the length for a 2” bore size hose with flange end fittings, to be fitted in a 90˚ configuration with one leg 400mm long, the other 600mm long.

Length of Bent Section (yellow) = 1/4 x 2πR (334) = 1/4 x 2 x 3.142 x 334 = 525mm

Length of top, Straight Section, including the top end fitting length = 600 - 334 = 266mm

Length of bottom end fitting = 66mm

Total length of Hose Assembly = 525 + 266 + 66 = 857mm

Things to consider

1. A hose will normally take the longest radius available to it to go around a corner, not the MBR! Also - always remember to include the non-flexible end fitting lengths.
2. In dynamic applications, remember to always calculate the lengths for the most extended configuration during the flexing cycle, not the least extended.
3. If the configuration is simply too complex for calculation, then obtain a length of flexible tubing of some kind, mark on paper, or a wall, or floor, or both where the connection points will be relative to each other, scaled down if necessary, then manually run the flexible tubing between them with full radii round bends. Measure the extended length, then scale up if necessary to determine the approximate length of the hose.

If in doubt, contact us.