To: Nancy Myers

From: Ryan Collins

Date: April 29, 2022
Subject: APLED 121-Instructions Report

How To Size Hydraulic Fluid Lines

Having properly sized fluid lines is critical in hydraulic systems. Having improperly sized fluid lines can at
best be an inefficient use of money, and at worst cause catastrophic damage to the hydraulic system.
When fluid lines are sized too small it creates resistance between the pump and the fluid lines. Under
these conditions it’s difficult for the pump to move oil throughout the systems. This can lead to
excessive heat and turbulence causing system damage to the system and fluid degradation. Its critical to
have properly seized fluid lines and with the steps below you’ll easily be able to properly size tubing.

Tools and materials needed:

 Pen and paper

 Calculator
 Fluid line sizing templet (pipe, tubing, or hose)
 Lightning Reference Handbook

Always solve to the 3rd decimal! Failure to do so can lead to

fluid lines being under or oversized.

Steps to Size Tubing

1. Gather the needed Materials to begin Sizing.

2. Identify what type of fluid line is being sized. There are 3 main types of fluid lines, with
each having their own maximum velocity. See the line types and velocities below.

Fluid Line Type Max Velocity in Gallons

per minute (GPM)
Suction Line 4 GMP
Pressure Line 15 GPM
Return Line 10 GPM
3. Fill in info in the first 4 boxes. Those being line type, max velocity, max GPM, and max
PSI. If you don’t have these pieces of information, you’re not ready to begin sizing fluid
lines.
GPM × 0.3208
4. Solve for the theoretical aera. To do this use the equation .
Max Velocity
 5. Convert the theoretical aera into a theoretical diameter. To do this use the equation
Theoretical Aera2 × 0.7854 .
6. Turn to page 124 and 125 in the Lightning Reference Handbook.
7. Determine the safety factor for the fluid lines. (Each safety factory has its own sizing
table)
8. Looking at the nominal tube OD (Outside diameter), in. column, as highlighted with blue
arrow in the picture below, and select the closet number above your theoretical
diameter.

Third
First

Second

9. Go to the right of nominal tube OD, in. column until you find a maximum pressure that
is equal or above relief valve setting. (Showed with the red arrow above)
 10. Go to the top of the chart and locate the nominal tube wall thickness that corresponds
with the required pressure rating as seen below. (Showed with a green arrow above)
11. Calculate the actual diameter of the selected fluid line using the formula
OD−( WallThickness × 2).
12. Check if the actual diameter found in step 11 is bigger than theoretical diameter found
in step 5.

If the actual diameter is smaller than that found in

step 4, move up a line size.

13. Calculate fluid lines actual area using the equation Actual Diameter 2 ×0.7854 .
GPM × 0.3208
14. Calculate oil velocity using the formula .
Actual Aera
15. Compare the velocity found in step 14 with that seen within the chart in step 2.

If the actual velocity is higher than that in step 2, go back and

check your work for errors. The line is sized too small.

Getting properly sized fluid lines is critical to the longevity of hydraulic system. Line type and
its location influence how large the line needs to be. This makes it difficult get each line to its
ideal size. To save time and money they can be sized up but never down.