Heavy Duty Chemical Composite Hose 20 Bar

The heavy duty chemical composite hose is the large-bore build for transfer work that a standard hose cannot hold. It covers 100 mm to 200 mm bore (4 in to 8 in), a working pressure of 2.0 MPa (20 bar) with an 8.0 MPa (80 bar) burst, and a service window of -30°C to +80°C, in 15 m lengths with 20 m available. A low-permeability ECTFE fluoropolymer liner sits inside a reinforced thermoplastic carcass, clamped between an inner and an outer helix. It is specified for ship-to-ship and ship-to-shore oil transfer where waves, motion and pressure swings arrive together.

Product Overview

The heavy duty chemical composite hose is a non-vulcanised, multi-layer thermoplastic hose in the large-bore, high-pressure corner of the composite family. It sits in the same construction class as the standard chemical build, but carries a thicker wall, a fluoropolymer liner and heavier helices, and that is what allows 20 bar at 200 mm bore. Specify it when a 10 bar hose would run at its ceiling for most of its life. The sheet measures pressure in megapascals: 2.0 MPa working, 8.0 MPa burst.

In one sentence, the hose is an ECTFE fluoropolymer liner, a reinforced fabric carcass, an inner and an outer helix and a coated fabric cover, compressed together rather than bonded.

Three numbers frame the product: 20 bar working pressure, 100 mm to 200 mm bore, and a +80°C ceiling. Bend radius runs from 500 mm at 100 mm to 900 mm at 200 mm, so the hose still follows a loading arm.

Four advantages matter to a terminal engineer. The wall holds 20 bar continuously in large bore. The ECTFE liner keeps permeation low on aromatic and chlorinated cargoes that would migrate through a polypropylene film. The twin helix keeps the bore open under suction as well as pressure. And 7.6 kg/m at 100 mm keeps a two person lift practical.

Main users are oil and chemical terminals, ship and barge operators, tank cleaning stations and refinery loading gantries. Equipment includes marine loading arms, ship manifolds, reducers, vapor return lines and dockside pump sets, plus any duty where ship side and shore side pressures differ widely.

The problem it solves is the 10 bar hose that fails early. A hose rated at 10 bar spends its life near its limit when a terminal pumps at 8 to 9 bar, and valve-closure surge takes the rest. A 20 bar build in the same bore moves the working point to the middle of the range, which is where a hose lasts.

Quality is controlled at the points that decide large-bore life: helix forming, liner splicing and crimping. Every assembly is proof tested before dispatch, marked with its batch, and shipped with test records. HENGHUA holds ISO 9001 and ISO 18752, plus CE, CCS, ABS, DNV, MSHA and California Proposition 65 listings.

Product Advantages of the Heavy Duty Chemical Composite Hose

• 20 bar in large bore: 2.0 MPa working pressure with an 8.0 MPa burst, published on the sheet.
• Low-permeation ECTFE liner: holds aromatic, chlorinated and oxygenated cargoes that weep through PP film.
• Suction and discharge duty: the inner helix resists collapse, so one hose covers both directions.
• Thick wall for abrasion: deck dragging and jetty contact wear the cover, not the carcass.
• Three build variants: SG-SS, PTFE-SG and PTFE-SS match helix and liner to the cargo and the budget.
• Handling weight kept down: 7.6 kg/m at 100 mm, so a two-person lift stays practical.

Applicable users: oil and chemical terminal operators, ship and barge crews, tank cleaning stations, refinery loading gantries, marine hose distributors and EPC contractors specifying ship-to-shore transfer.

Detailed Technical Specifications

• Temperature: -30°C to +80°C. The ceiling is set by the ECTFE liner and the fabric carcass, so confirm the cargo temperature before ordering.
• Working pressure: 2.0 MPa, or 20 bar, at every bore in the range.
• Burst pressure: 8.0 MPa, or 80 bar, at every bore in the range.
• Safety factor: the sheet states 5:1, while the 80 bar burst is four times the 20 bar rating. We quote both numbers in writing so the buyer can apply the rule its own specification uses.
• Length: 15 m standard, 20 m maximum. Longer assemblies are built as two lengths with a tested joint rather than one continuous hose.
• End fittings: crimped ferrules with fixed or floating flanges, cam and groove couplings, tank couplings and NPT male threads, in carbon steel or stainless.

Structure and Materials

• Inner helix: a steel spiral that keeps the bore round under suction and stops the hose flattening when a pump pulls vacuum at the end of a discharge.
• Liner: low-permeability ECTFE fluoropolymer, the chemical barrier between cargo and carcass.
• Carcass: multiple plies of woven fabric and thermoplastic film that carry the axial load and hold the pressure.
• Capa: an abrasion-resistant coated fabric that takes deck contact, sunlight and salt.
• Outer helix: a second steel spiral that carries hoop load and shields the carcass from impact.
• Build variants: SG-SS uses a galvanised inner helix with a stainless outer; PTFE-SG and PTFE-SS pair a PTFE inner helix with galvanised or stainless outer wire for wet and salt-heavy locations.

Why the composite build holds up

Load in a pressurised hose arrives in two directions, and the construction splits them. Hoop stress tries to burst the wall outward, and the outer helix resists it as a continuous steel spring, so the fabric plies only stabilise the liner instead of carrying the whole load. Axial stress tries to pull the ends apart, and the woven plies take that in tension, which is how one wall thickness stays both flexible and strong.

The liner does a different job. It is a thermoplastic film stack, not a cured rubber tube, so it does not swell and soften when a solvent passes through. ECTFE is chosen for low permeation: it slows small molecules, which keeps the carcass dry and stops the cover blistering after months of aromatic service.

The helices also explain the vacuum behaviour. A rubber suction hose needs a heavy embedded wire to stop collapse, and that wire makes it stiff. A composite hose puts the wire on the inside face of the bore, where it supports the wall directly and leaves the rest free to bend. The result is a 200 mm hose with a 900 mm bend radius that still holds full vacuum.

Safety factor and margin

Two numbers govern safe use: working pressure and burst pressure. The sheet publishes 20 bar, 80 bar and a 5:1 design factor. Read together, they say the burst figure is four times the rating while the design intent is five. That gap is why we ask for the medium and the surge conditions rather than the line pressure alone: 20 bar against an 80 bar burst is generous for steady pumping and tight for a line that sees water hammer.

Proof testing is the practical check. Every assembly is held at test pressure long enough to expose a liner fault or a bad crimp, and released only when it holds. Ask for the certificate with the batch number and keep it with the hose record, because that is the document an incident review will ask for. A terminal that cannot produce it is relying on the supplier’s memory.

Chemical Compatibility and Media Guide

Three rules for reading the chart. Temperature derates every rating, because a film that resists a solvent at 20°C can soften at 70°C. Concentration matters more than the chemical name, since 30% and 98% sulphuric acid behave like two products. Contact time decides the outcome: a line flushed after each transfer sees far less attack than one that stands full for a week. Send the cargo list for a written answer and the full compatibility chart as a PDF.

Applications and Industries

• Ship-to-shore oil transfer: marine loading arms and manifolds at crude, product and chemical berths.
• Ship-to-ship transfer: barge and tanker pairs working in open water with relative motion at the connection.
• Refinery and terminal gantries: high-pressure loading of distillate and aromatic cargoes into road and rail cars.
• Chemical plants: bulk receipt and dispatch of solvents and acids where a 10 bar hose would run at its limit.
• Tank cleaning stations: suction duty with slops and wash water at large bore.
• Dockside pump sets: discharge lines where the pump curve peaks above the rating of a standard composite hose.

Selection Guide for Heavy Duty Chemical Composite Hose

Size, flow and pressure drop

Pick the bore from the pump curve, not from the connection on the ship. A 100 mm hose moves about four times the volume of a 50 mm hose at the same velocity, and each step up cuts friction loss sharply. Where a 200 mm line is available at the berth, use it and take the lower velocity, because slower flow reduces static generation and surge.

End fittings and hose assembly

The fitting decides whether the hose survives its first season. Common ends here are fixed flange, floating flange, cam and groove, tank coupling and NPT male, in carbon steel or stainless. A floating flange takes bolt-hole misalignment at the manifold without twisting the hose, which is why it is usual at a ship connection. All assemblies are crimped in house, with the ferrule matched to the cover thickness.

Pre-built assemblies beat field assembly in large bore. A 200 mm hose crimped at the factory arrives with a tested joint; one assembled on the jetty depends on the tooling and the operator that day. Buy the finished hose assembly, with flanges fitted and proof tested, not a bare length and a box of fittings.

How it compares

Against a rubber hose the difference is structural rather than cosmetic. A rubber suction hose of the same bore carries an embedded wire carcass and weighs considerably more per metre, so it needs mechanical handling and resists being repositioned by hand. The composite build reaches the same pressure with a lighter wall and a tighter bend radius.

What drives the price

Four items set the cost per metre: bore, liner polymer, helix material and end fittings. ECTFE liner stock costs more than polypropylene, which is why this build sits above a standard chemical hose. Stainless helices cost more than hot-dip galvanised, and a PTFE-covered inner helix more again. Fittings are quoted per pair and can rival the hose cost on short assemblies, because a 200 mm stainless flange is a machined part.

Common selection mistakes

• Buying on working pressure alone and ignoring the surge at valve closure.
• Sizing the bore to the ship connection instead of to the pump curve.
• Specifying galvanised helices for a permanent salt-water deck.
• Reusing old flanges on a new 20 bar assembly without checking the bolt pattern and gasket face.

Installation, Operation and Maintenance

Installation

Support the hose along its length rather than hanging it from the two ends, and keep the bend radius above 500 mm at 100 mm bore and 900 mm at 200 mm. Do not bend closer than one hose diameter from the ferrule. Leave a slack loop at the ship connection so relative motion is absorbed by the loop, not the crimp.

Inspection and retirement

Check the cover for cuts, blisters and exposed helix before every transfer. Run a hand along the hose under light pressure and look for soft spots, which signal liner damage rather than cover wear. Retire on evidence: a bulge, a leak at the ferrule, a kink that does not recover, or a failed proof test. Review chemical service at six years, earlier where the hose is dragged or runs above 60°C.

Cleaning, storage and service life

Drain and flush after each cargo, and confirm the flushing medium suits the liner before you use it. Store coiled, off the ground, out of direct sun, with the ends capped. Never store a wet hose with residual cargo inside: the liner is resistant, not immune, and a standing heel of acid does more damage in a month than a year of flow. Terminal duty typically runs five to eight years.

Quality Assurance and Test Data

Production runs through incoming material inspection, helix forming, liner splicing, carcass build, cover application, crimping and proof testing. Wire diameter, film lot and fabric strength are checked on receipt. Helix forming is measured against the drawing, because an out-of-round spiral shows up later as a kink. Crimping uses calibrated tooling with ferrule depth recorded per assembly.

Testing covers the points a buyer cannot see. Every assembly is pressure tested before dispatch. Burst testing is done on samples from each production lot. Electrical continuity is measured end to end when a conductive build is ordered. Dimensional checks confirm bore, outside diameter and bend radius against the specification.

Traceability is by batch and by assembly. Each hose carries a batch number and its test record is retrievable, which is what an auditor asks for after an incident. Packaging is film plus a plywood case for LCL, and bubble wrap on a reel for FCL, so a 200 mm hose arrives round.

Standards and Certifications

Company certifications: ISO 9001 and ISO 18752 quality systems, plus CE, CCS, ABS, DNV, MSHA, GOST-R, MA and California Proposition 65 compliance. Certificate scope and numbers are supplied with the quotation for the destination market.

Frequently Asked Questions

What is a heavy duty chemical composite hose made of?

An ECTFE fluoropolymer liner, plies of fabric and film carcass, an inner and an outer steel helix, and a coated fabric cover. The layers are compressed, not vulcanised, which separates it from a rubber hose.

What does 2.0 MPa mean in bar?

2.0 MPa is 20 bar, or roughly 290 psi. The published burst pressure is 8.0 MPa, which is 80 bar.

Is the safety factor 4:1 or 5:1?

The sheet publishes a 5:1 design factor alongside 20 bar working and 80 bar burst, and 80 bar is four times the rating. We quote both figures in writing so your specification review can apply whichever rule it uses.

Can it handle vacuum as well as pressure?

Yes. The inner helix supports the wall directly, so the hose holds suction without collapsing. State the vacuum level and the bore and we confirm the rating in writing.

What is the temperature limit?

-30°C to +80°C. Cargo above +80°C needs a different liner, and we will tell you honestly if a request falls outside the range rather than book the order.

Which cargoes need the PTFE variant?

Dichloromethane, trichloroethylene, hot aromatics and strong oxidisers sit at the edge of the ECTFE liner. The PTFE-SG and PTFE-SS builds widen the margin; we confirm against the concentration and temperature you send.

How is it different from the 10 bar chemical composite hose?

Wall thickness, liner polymer and pressure class. The 10 bar build covers in-plant and tank truck work; this one is for large-bore ship-to-shore transfer where the working point sits near the top of a standard chemical composite hose rating.

How fast can you deliver a first batch?

Standard bores ship against confirmation of the assembly drawing, and a standard-specification bulk run takes about seven days. Custom lengths, stainless helices and special flanges extend the schedule, and sampling on a new drawing is quoted at 48 hours.

How do I get a quote and the datasheet?

Send the medium, concentration, temperature, working pressure, bore, length, end connection, quantity and destination port through the contact form. You will receive a quotation with a drawing, the proof test basis and the specification as a PDF.

Why Source Composite Hose from HENGHUA

HENGHUA manufactures composite hose in an 18,000 m2 facility with eight high-speed lines and an annual output of 25 million metres for customers in more than 70 countries. Helix forming, liner splicing and crimping are all in house, which matters for large bore: those three operations decide whether a 200 mm hose leaves the factory round, sealed and straight at the ferrule.

The quality system runs to ISO 9001 and ISO 18752, with CE, CCS, ABS, DNV, MSHA, GOST-R and MA listings. Certificate packs ship with the quotation for the market you export to, not assembled after the fact. Every assembly carries a batch number, so a terminal audit is answered with a document, not a conversation.

As a manufacturer and exporter we build to drawing, not to a catalogue page. OEM and ODM work covers private-label covers, custom flange patterns, non-standard lengths and rope covers, with sampling in 48 hours and about seven days for a standard bulk run. Distributors get a factory price basis and a consistent specification between shipments.

Technical support is part of the order. Send the cargo list and we return a liner recommendation with the chart; send a failed hose and we assess it against the batch record. Sales engineers answer specification questions directly rather than through a distributor.

Solicitar um orçamento

Send your medium, concentration, temperature, working pressure, bore, length, end connection, quantity and destination port through the contact form. Our sales engineers confirm the liner and pressure class for your duty, then return a drawing, a quotation, the proof test basis and the specification as a PDF. Ask for the certification pack or a trial sample. If you are replacing a 10 bar hose that keeps failing, tell us the pump curve and the surge conditions, and we size the heavy duty chemical composite hose for the working point.