66 B1 / B2 Module 6 – Materials and Hardware 6.

6 Pipes and unions Page 1

6.6 Pipes and Unions

a) Identification of, and types of rigid and flexible pipes and

their connectors used in aircraft.

b) Standard unions for aircraft hydraulic, fuel, oil, pneumatic

and air system pipes.

Module 6 – Materials and Hardware Lesson Plan

1. Aircraft plumbing components;

6.6 Pipes and Unions
2. Fluid line construction;
3. Fluid line fittings;
4. Standard unions for aircraft fluid systems.
Module 6.6- Pipes and unions Page 2

Fluid system installation Fluid lines (2)

Pipes Flexible lines
! Long distance and tubes (Hoses)
! High pressure (3000 psi)
! Different diameters
(same flow) ! Can be bent
! Adapter fittings ! Swaged
! Flexible joints ! Standard threads
(to moving parts) on hose fitting
R R
! Vibration loads ! Standard fittings
for joining
! Good seals ! Pressure-taking and
seal problem

Fluid lines (1) Flexible fluid lines

Rigid lines Semi-rigid lines Flexible

(Pipes) (Tubes)

! Not bent ! Not bent

! Not flared ! Flared or swaged
! Tapered threads ! Standard threads
cut into the wall on union fitting
! Threaded fittings ! Standard fittings
for joining and for joining and Hydraulic system pipelines
directional changes directional changes
! Weight problem ! Seal problem
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 3

Aircraft Plumbing Components

pressure they are designed to carry, hoses may have reinforcing
material wrapped around them. Various types of fittings are used
Vital systems in the aircraft such as fuel, oxygen, lubrication, to attach hoses to each other or to other components.
hydraulic, instrument, fire extinguishing, air conditioning,
heating, and water systems all require fluid lines. Fluid-line fittings are made from a variety of materials for
many different purposes. New designs, some highly specialized,
Fluid lines are made of rigid, semirigid, or flexible tubes, are being developed on a continuous basis.
depending upon the application. A tube is defined as a hollow
object, long in relation to its cross section, with a uniform wall
thickness. The cross section of a tube may be round, hexagonal,
octagonal, elliptical, or square. Tubes used for fluid lines are
usually round in cross section.

A rigid fluid line (pipe) would be one that is not normally bent
to shape or flared. Directional changes and connections are made
by the use of threaded fittings. A fitting is a device used to
connect two or more fluid lines. Rigid fluid lines will usually
have threads cut into their walls.

Semirigid fluid lines (tubes) are bent and formed to shape and
have a relatively thin wall thickness in comparison , to rigid
lines. Various types of fittings are used to make l connections
between semirigid tubes.

Because of the need for flexibility in many areas of aerospace

vehicle construction, it is often necessary to employ hose instead
of semirigid tubing for the transmission of fluids and gases
under pressure.

Flexible fluid lines (hoses) are made from rubber or synthetic

materials and are usually called hoses. Depending upon the
Module 6.6- Pipes and unions Page 4

Pipe construction Pipe/ Tube specifications

S ` odq!0. 21!odq!hmbg
! Pipe ! Tube

NC
! OD (nominal size); ! OD (nominal size);
! Wall thickness increase ! Size in 1/16-in OD
5/堡 with schedule nos. increments;
! Thick walls complete ! Thin walls (impossible to
Tapered pipe threads with tapered threads; cut threads);
! Tapered threads form a ! Flared tube ends + flared
metal-to-metal seal; tube fittings a metal-to-
metal seal;

AN Fittings with pipe threads ! A variety of materials. ! A variety of materials

Tube construction Material characteristics

Single and double flares
! Copper tubes ! Easily fabricated; annealed to keep
Nt srhc d!c h` l dsdq soft; replaced for fatigue; crack,
Ek̀ qd ne!rkddud hardness, brittleness.
26°
Ek̀ qd

! Steel tubes ! Softened for working and re-heat-

treated to restore strength; hard
enough with thinner wall so not
S !rkddud greater weight.

Flared tube ! Aluminum ! Light weight and resistance to

Maximum flare Minimum flare corrosion.
alloy tubes
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 5

Construction of Pipes and Tubes

tapered to form the metal-to-metal seal. External threads with
The pressure of the fluids in fluid lines varies from very low, 5 the taper occur on the crests. For internal threads, the taper is
to 10 pounds per square inch (psi) [34 to 69 kPa] for an reversed and affects the thread root.
instrument system, to as much as 5000 psi [34.450 kPa] for a
hydraulic system. Low-pressure fluid lines may be made of Large-scale use of pipe on aircraft is impractical because of
plastic or rubber hose. High- pressure fluid lines are made in a weight. However, many aircraft components will use pipe
variety of materials, including aluminum alloy, stainless steel, threads.
and reinforced flexible hoses.
Semirigid fluid lines are usually referred to as tubes or tubing.
The term pipe refers to a rigid fluid line that may be defined as a Tubes can be bent to shape and are often flared for connectors.
tube made in standardized combinations of outside diameter Tubes used for fluid lines are sized by the outside diameter in
(OD) and wall thickness. The various combinations of diameter inches and the wall thickness. For example, a tube may be 1/2 in
and wall thickness are specified as schedule numbers and have [12.7 mm] OD by 0.035 in [0.89 mm] wall thickness. Tube sizes
been standardized by ANSI (American National Standards (OD) increase in 1/16-in increments. Tube fittings use dash
Institute). numbers to indicate their size. A -8 fitting is sized to fit an 8/16-
or 1/2-in tube. The tube itself may be referred to as a -6 (3/8-in)
Pipe is specified by its nominal diameter( 1/4 in, 1/2 in, 1 in, etc.) or -8 (1/2-in) tube rather than by its fractional size.
and the desired schedule number. Table 1 shows how the
dimensions of a nominal size of pipe will vary in relation to the Tubes are made from aluminum alloys, CRS or titanium. Only
schedule numbers. The outside diameter of a nominal size is the the materials authorized by the manufacturer, or approved
same for each schedule number, but the wall thickness increases substitutes, may be used on a specific aircraft system.
with the schedule numbers. As the schedule number increases,
the pressure carried by the pipe can be greater. However, the Tube Connections. Because of the thin wall thickness of tubes,
fluid-carrying capability of the pipe will be reduced due to a threads usually cannot be cut in the tube. Special fittings have
smaller inner diameter. A pipe's nominal size cannot be obtained been designed to allow tubes to be connected to other tubes as
by direct measurement. well as to aircraft system components. These fittings may be
classified as flared, flareless, swaged, soldered, or brazed. Many
Pipes are joined by fittings that use threads cut in the wall of the of the fittings used for these connections are standard parts and
pipe. To provide a fluid-tight seal, the threads are tapered, unlike carry AN or MS specification numbers.
machine-screw threads. As two parts are screwed together, the
taper will cause a very tight metal-to-metal seal. Pipe threads are
Module 6.6- Pipes and unions Page 6

Flexible hoses
! Specification ! Flow capacity:
One 1/2in hose will carry
! ID (inside diameter) the same amount of fluid as
a 1/2in tube
! Wall thickness
! Braided construction
! Three MIL-H
universal standards ! MIL-H-8794-8 means
1/2" medium pressure hose
! Rubber and synthetic
materials ! Flexing requirements

! Pressure rating ! Permanent end-fitting

300 psi or lower Reusable end-fitting
300 to 1,500 psi
1,500 to 3,000 psi ! Protective sleeves: against
heat and wear

Construction of hoses
Reinforcement Cover

LP Single cotton braid Ribbed or rubber

MP Single steel braid Rough oil-resistant

cotton

HP Double or more steel Smooth cover

braid

! Small diameter hoses used for high pressure.

! Burst pressure 4 times the working pressure.
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 7

Construction of Hoses

For many years most hoses used on aircraft were made of rubber
to one of three MIL-H specifications. Synthetic materials such as Medium-Pressure Hoses. MIL-H-8794 hose is used for
Teflon and several elastomers have proven to be superior in pressures up to 1500 psi [10342 kPa], and slightly higher in
many ways to rubber hoses. certain sizes. This type of hose has a synthetic rubber tube with
one layer of braided cotton and one layer of stainless-steel braid
Flexible hose for use in aircraft systems is manufactured in four for reinforcement. A rubber-impregnated braided cotton cover
different pressure categories: low-pressure, with a maximum makes this type of hose easy to identify. Yellow markings are
operating pressure of 300 psi [2068 kPa]; medium- pressure, 300 the same as on the 5593 hose with the exception of the LP
to 1500 psi [2068 to 10342 kPa]; high-pressure, 1500 to 3000 psi symbols.
[10342 to 20 685 kPa]; and extra-high-pressure, 3000 to 6000
psi [20865 to 41 370 kPa]. These pressure ranges just given are MIL-H-8794 hose is approved for aircraft hydraulic (mineral-
general and that variations will be encountered in specific based), pneumatic, coolant, fuel, and oil systems. There are other
systems and installations. hoses that have braided cotton covers that are not compatible
with the fluids or pressure that 8794 hose is used for. Only MIL-
Hose assemblies, the hose and the installed fittings, are usually H-8794-specification hose will have yellow markings.
pressure tested at a pressure at least twice the maximum
operating pressure. The burst pressure is usually required to be Many hoses currently being manufactured for this pressure range
at least four times the maximum operating pressure. use inner tubes made of tetrafluoroethylene (TFE, or Teflon) or a
variety of new synthetic rubber materials. Teflon hose can be
Low-Pressure Hoses. The construction of a low-pressure hose used for practically all fluids that may be encountered on an
conforms to specification MIL-H-5593. The inner tube of the airplane. Teflon is nonaging, chemically inert, and physically
hose consists of synthetic rubber with a braided-cotton stable, and it can withstand relatively high temperatures.
reinforcement. The outer cover is synthetic rubber. The hose is Medium-pressure Teflon hose is produced under specification
identified by a yellow stripe and markings. A linear stripe, called MIL-H-27267. Most of the newer hoses may be identified by
a lay line , is interspersed with the symbol LP, the hose their covers, which are a stainless-steel braid. Identification of
manufacturer's code, the hose size, and the quarter/year of these hoses requires that a printed tag from the manufacturer be
manufacture. attached.

Low-pressure hose is used for instrument air or vacuum systems,

automatic pilots, and instruments where the maximum pressure
for the hose is not exceeded.
Module 6.6- Pipes and unions Page 8

Hose identification markings

! The strength of a hose is

determined by the braids
Flame and aromatic resistant hose and reinforcement;
! As a result, it is not
necessary to increase hose
Nonself-seling, aromatic and diameter and decrease hose
heat-resistant hose length when used for higher
pressure applications.

Flame, aromatic, and

oil-resistant hose

Nonself-seling, aromatic-
resistant hose Self-sealing, aromatic-
resistant hose

Hose identification markings

! Lay line- serves to show whether or not the hose has

been twisted when it was installed.

! Yellow markings (1): LP

! Yellow markings (2): OEM code, hose size and

quarter/year of manufacture;

! SKYDROL indicates the line is used with Skydrol or

any of phosphate-ester synthetic hydraulic fluid.

! HP and extra HP hoses recognized by their braid

construction.
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 9

Construction of Hoses…

High-Pressure Hoses. The construction of high-pressure MIL-

H-8788 hose has a seamless inner tube made of synthetic rubber
and is reinforced with high-tensile-strength, carbon-steel wire Size of Hoses. A hose is sized in accordance with the size of a
braid. The smaller sizes will have two layers of wire braid, and tube with similar fluid-carrying capabilities.
1 A 1/2 in hose will
2
the larger sizes (above 3/4 in [1.905-cm]) have a triple- wire- carry the same amount of fluid as a 1/2 in tube. The inner
braid reinforcement. The application of this hose, except for diameter (ID) of the hose inner tube, would therefore be
handling higher pressure, is similar to the MIL-H-8794 hose. approximately the same as the ID of a tube. The hose will use
the same dash number to indicate size as that used on a
Another high-pressure hose complies with specification MIL-H- comparable-sized tube. Thus a 1/2 in hose will be identified as
38360. This hose has a Teflon-type inner tube with reinforce- an -8 hose.
ments of stainless-steel wire and braid, the amount of reinforce-
ment depending upon the diameter of the hose. Because of the Identification of Hoses. Care must be taken in the selection of
TFE inner tubing, this hose can be used for most of the fluids hose for a particular application. Hose is selected on the basis of
employed in aircraft systems. size, pressure rating, temperature rating, and material. The
technician must be very careful that a replacement hose meets
Extra-High-Pressure Hoses. The MIL-H-8788 hose has proven the necessary requirements.
capable of handling most system pressures in the past. As new,
high-performance aircraft are developed, a need has been For rubber hose, the pertinent information must be printed on the
generated for higher pressures in the operating systems. A hose hose. The color of the printing is significant, with yellow being
developed for systems with pressures up to 6000 psi [41 370 kPa] used on general-purpose rubber hose. A color other than yellow
is called extra-high-pressure hose. identifies a hose with different properties.

This type of hose uses spiral stainless-steel wire layers Newer hoses with braided stainless-steel covers should have
cushioned with a high-temperature elastomer between layers. metal tags with the necessary identification material. If markings
The synthetic inner tube allows this hose to be used for are not legible or are missing, that hose should not be installed
practically all aircraft fluids, including phosphate esters. The on an aircraft.
usable temperature range for hose in this category will be up to
400OF [204 OC].
Module 6.6- Pipes and unions Page 10

Plumb fittings to components Difference of AN and AC type union

Union; elbow; tee; cross;
nipple; boss; plug; reducer;
adapter; universal fitting AN FEATURE AC
37° ANGLE 35°
yes RECESS no
coarser THREADS finer
AN 818 D 6 blue or COLOR gray or
black yellow
BODY
longer LENGTH shorter
Nut 6/16"
Alum.

Flared-tube fittings

Elbow; tee; cross; cap; plug

 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 11

Standard Tube Fittings to prevent fluid leakage and is installed with an AN6289
nut.]
Standard tube fittings may be classified as flared, flareless,
swaged, soldered, or brazed. Many of the fittings used for these
connections are standard parts and carry AN, AND, or MS
specification numbers. c. Pipe-to-tube (or pipe-to-AN) fittings- Many aircraft
components use internal pipe threads for connections. This
Flared fittings require a 37Oflare to be formed on the end of the requires the use of a special fitting called a pipe-to-AN
tube. The flare of the tube matches a cone on the fitting. The nipple. The fluid-tight seal is provided by pipe threads for
fitting is threaded with standard machine-screw threads. A the component and a metal-to-metal flare for the tube.
special nut and a sleeve are used to pull the flare into contact
with the cone and form a fluid-tight metal-to-metal. Small-sized Fittings are specified by AN or MS numbers that identify the
or thin-wall tubing may have a double flare. The double flare is function of the fitting.
used to provide a greater thickness of metal and thus more
strength for the seal. Flared fittings are usually made of aluminum, steel, or stainless
steel, with the fitting being the same material as the tube on which
The basic components of a flared connection are the AN818 nut, it is used. An exception is the use of steel fittings in higher
the AN819 sleeve, and one of a number of fittings with a cone to temperature areas, such as in an engine compartment.
match the tube's flare. Fittings commonly used are classified as:
Flared-Fittings Designations. Fittings are designated by an AN
a. Tube fittings- the union, the elbow, the angle, the tee, the or MS number, which indicates the function of the fitting. The
cross etc. fitting is sized by the OD of the tube it is used with. The outside
diameter of the tube is expressed in sixteenths of an inch. An
b. Universal/bulkhead fittings- It is often necessary to have AN819 fitting for a 1/4-in tube would have a designation of
fuel, oil, or other tubes pass through structural portions AN819-4, and for a 3/4 -in tube it would be AN819-12.
(bulkheads) of an aircraft. This requires a fitting with a long
body and provisions for securing the fitting to the bulkhead. Aluminum-alloy fittings are indicated by a D before the dash. The
letter C indicates the fitting is made from corrosion-resistant steel.
[The term universal applies to fittings used to connect a No letter before the dash number indicates that the material is
component with internal machine-screw threads to a tube or steel.
hose. Machine screws have straight threads and will not
provide a fluid-tight seal. A rubber O-ring gasket is required
Module 6.6- Pipes and unions Page 12

Reusable hose fitting (medium pressure)

n Clamp the hose between the socket and the
nipple with sufficient force to prevent
separation.

Rnbj ds!!!!!Mhookd!!!!!!!!Mt s

Ehsshmf !` rrdl akdc

Pipe-to-AN fitting Permanent hose fittings

Permanent hose fitting

Tapered pipe Standard union

threads threads
Fitting for extra HP hose
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 13

Standard Hose Fittings

Hose fittings are made in a variety of configurations, such as
Hose-end fittings may be of a permanent, factory-assembled straight, 45Oand 90O. They are made to mate with either flared
design, or they may be designed to be removed and reused on tube fittings (AN and MS types) and flareless fittings (MS types).
new hose. Reusable fittings consist of three parts: the socket,
the nipple, and the coupling nut. Typical fitting configurations used for hose assemblies are
shown. The fittings illustrated are designed to mate with
Each type of hose (high-, medium-, and low-pressure) will have MS33514 flareless fittings. Hose fittings designed to mate with
its own end fittings. These are not interchangeable. Reusable flared tube fittings incorporate a 37O bevel to match the cone of
fittings are easily installed in the field using common hand tools. the fitting.

The permanent-type fitting requires replacement of the entire

hose assembly, both the hose and the fittings. During assembly,
the socket is swaged circumferentially to compress the hose
between the socket wall and the nipple. The serrations inside the
socket and on the nipple grip the hose to prevent slippage. The
socket is welded to the nipple at the forward projection and is
also provided with an interlock that prevents a blow-off under
maximum pressure. The skirt of the socket is flared to allow for
the hose to bend at the fitting without creating concentrated
stress at the end of the socket.

When used for extra-high-pressure hose, the fitting is designed

with an internal locking and sealing member called a lip seal.
The inner tube of the hose is inside the lip seal, with the
reinforcing layers outside of the lip seal but inside the socket
wall. After the fitting is attached to the hose, the socket is
swaged, causing the circumferential serrations to grip both the
inner tubing and the reinforcing layers, inside and outside,
producing a blow-off -proof attachment.
Module 6.6- Pipes and unions Page 14

Swaged-on fittings Quick-disconnect fittings

! Used in areas where routine Tube disconnected;

disconnection is not required. fitting seals

Cutaway view of a ! Also used for hose couplings.

swaged tube fitting

Tube connected;
fitting opens

Permanent hose fitting

 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 15

Standard Unions for Aircraft Systems

installation takes less time, substantial weight is saved, and
In addition to the flared-type fittings, standard unions are also repairs can be made on the aircraft without removing complete
available using flareless tube connections, swaged tube fittings, sections of tubing.
soldered and brazed fittings and quick-disconnect couplings.
Soldered and Brazed Fittings. Fittings that require soldering or
Flareless Tube Connections. High-pressure fluid lines are made brazing are found on many high-pressure systems. Many
of material which is too hard to form satisfactory flares. Flareless applications that have used this process in the past are now using
fittings, made to MS standards, are designed to eliminate the need swaged fittings. Brazed or solder fittings require considerably
for a flare on the tube. A sleeve seizes and grooves the tube as the more skill to create and are difficult to make on the aircraft.
fitting is tightened, producing a fluid-tight seal.
Quick-Disconnect Couplings. Quick-disconnect couplings are
The flareless tube fitting consists of three units: a body, a sleeve, required at various points in aircraft systems. The purpose of
and a nut. The body of the fitting has a counterbored shoulder these couplings is to save time in the removal and replacement
against which the end of the tube rests. The counterbore has a of components, to prevent the loss of the fluid, and to protect the
cone angle of about 24° which, upon assembly, causes the cutting fluid from contamination. The use of these couplings also
edge of the sleeve to cut into the outside of the tube. Tightening of reduces the maintenance cost for the system involved. Typical
the nut forces the sleeve to form the metal-to-metal seal. Flareless uses are in fuel, oil, hydraulic, and pneumatic systems.
fittings are easy to identify since there is no flare cone or no space
between the threads and the end of the fitting. The coupling consists of a male and a female assembly. Each
assembly has a sealing piston (poppet) that prevents the loss of
Swaged Tube Fittings. Many aircraft use swaged fittings to join fluid when the coupling is disconnected. Three check points may
tubes in areas where routine disconnections are not required. be used to verify a positive connection. These involve sound,
Military specifications require that all tubing be permanently visual observation, and touch. A click may be heard at the time
joined, either by swaging or welding, except where it is the coupling is locked. On some couplers, indicator pins will
necessary to make disconnections. Swaged fittings are made by extend from the outer sleeve upon locking. These pins can be
Deutsch Metal Components from aluminum, stainless steel, and seen and felt by hand.
titanium and they are used with tubes of the same material. The
fittings are attached quickly and easily by means of a hydrau-
lically operated portable swaging tool. The advantages of the
swaged-type tube fittings are that the original cost is low
compared with that of standard AN or MS fittings, the
Module 6.6- Pipes and unions Page 16

Fluid line color codes Fluid line color codes

Marked with 1-inch

Red /Four point star Orange/Parallel diagonal Yellow/Vertical rectangle tape and decals
Fuel Compressed gas Lubricant

Warning symbol
Skull & cross bones

Green/rectangle Blue/Horizontal wave Gray/triangle Maroon/diamond Metal tag

Breathing Oxygen Coolant De-icing Fire protection

Fluid line color codes

Green; gray/Crest moon Orange; blue/crosses Maroon; gray/

Clouded irregular circle
Rocket Oxidizer Pneumatic
Air conditioning

Blue; yellow/dots Orange; gray/zigzag Maroon; orange/lightning

Hydraulic Instrument air Electrical conduit
 66 B1 / B2 Module 6 – Materials and Hardware 6.6 Pipes and unions Page 17

Color Codes for Aircraft Systems Water injection lines

Color codes for aircraft plumbing lines are established by a. Triple color bands of red, gray, and red; and
AND10375. These codings replace the plain color system used b. Black chevrons against a white background.
before August 1949. Because of the fading of the colors and the
fact that the color perception of some persons is not sufficiently Pneumatic lines
acute, the plain colors were found subject to mis-interpretation
under severe conditions. For this reason, new color coding was a. Dual color bands of orange and blue; and
established with black-and-white symbols. b. Black diamonds against a white background.

A unique code is used for every system of the aircraft, where

a. Code bands are colored;

b. Symbols are black against a white background.

Typical examples are:

Fuel lines

a. A single red color band; and

b. Black (4-pointed) stars against a white background.

Hydraulic lines

a. Dual color bands of blue and yellow; and

b. Black circles against a white background.

Oxygen lines

a. Single color bands of green; and

b. Black rectangles against a white background.