The Hose Metal Handling Guide

Metal hoses are a crucial component in hydraulic systems and industrial applications, providing flexibility and resistance to extreme environments. To ensure their longevity and efficient operation, proper handling, installation, storage, and maintenance are essential. In this blog, we will explore best practices for each of these aspects, and how they can prevent premature failure of hose metal.

Why Hose Metal Are Important

Metal hoses offer significant advantages over traditional rubber or plastic hoses, including durability, flexibility, and resistance to high pressures and extreme temperatures. These hoses are used in various industries such as oil and gas, manufacturing, and even in chemical plants, making their maintenance and correct usage vital for safe and efficient operations.

Proper Installation of Hose Metal

A well-installed metal hose system ensures that your hydraulic or industrial application runs smoothly and efficiently. Here are some key installation guidelines:

1. Avoid Twisting: Never twist the hose assembly during installation, especially when aligning flanges or tightening threaded fittings. Using live swivel flanges or connectors can help prevent this issue. It’s recommended to use two wrenches during installation—one to hold the hose and prevent twisting, and the other to tighten the fitting.
2. Single-Plane Bending: Always ensure the hose bends in a single plane. If the assembly is installed in a circular arrangement, bending should only occur within one plane to avoid uneven stress.
3. Avoid Overbending and Sharp Bends: Bending the hose beyond its minimum bend radius can lead to premature failure. Always provide enough length to prevent overbending, and use 45-degree or 90-degree elbows where necessary. Bend restrictors can also be installed at joints to prevent excessive bending.
4. Support the Hose Properly: For horizontal installations of circular assemblies, provide support to the hose to prevent sagging. Heavy-duty, long hoses should be supported when lifted or suspended.
5. Axial Extension and Compression: The system should be designed to avoid excessive axial elongation or compression of the hose. Adequate pipe supports should be used to prevent overloading the hose and causing tension on the braided layer.
6. Careful Handling: When moving metal hose, be cautious to prevent wear, especially on braided corrugated hoses. Never pre-bend hoses to make them more flexible, as this can lead to damage and leakage.
7. Correct Assembly: Follow the manufacturer’s instructions for hydraulic hose assembly, including recommended hose length, fitting types, bend radii, torque specifications, and assembly tools.

Daily Maintenance and Inspection

Regular inspection and maintenance of hose metal are crucial to ensure their integrity and functionality. Here’s how you can keep your hose metal in optimal condition:

Regular Inspections:

• Visual Inspections: Perform routine inspections, particularly focusing on areas that are exposed to high pressure, bending, or friction. Look for signs of wear, degradation, or damage.
• Check for Wear and Tear: Inspect for cuts, bulges, cracks, blisters, leaks at fittings, corrosion of metal parts, and any loss of flexibility. If there’s visible damage, particularly exposing the braid, stop using the hose immediately.
• Check for Twisting or Kinks: Ensure the hose is not twisted, kinked, or flattened. Such issues can affect its performance and lifespan.
• Fittings: Ensure that fittings are secure and show no signs of slipping, cracking, or severe corrosion.

Fluid Compatibility:

Make sure that the hydraulic fluid used is compatible with the hose material to prevent internal degradation.

Pressure and Temperature Monitoring:

• Always operate within the hose’s designated pressure and temperature limits. Avoid pressure surges that exceed the hose’s maximum working pressure.
• High system temperatures can make the hose brittle and lead to cracking. Keep hoses away from heat sources such as exhaust manifolds.

Cleaning:

• Regularly flush the hose to remove any buildup, especially when transporting chemicals, slurries, or food products.
• Use cleaning methods compatible with the hose material and avoid harsh chemicals that may damage the hose.
• For chemical hoses, empty the contents and rinse with a neutralizing cleaner after use.

Protection from Extreme Conditions:

• Re-route hoses to keep them away from high-wear areas or contact with incompatible fluids.
• Consider using protective sleeves, such as polyurethane or nylon covers, to protect the hose from abrasion and environmental damage.
• For extreme temperatures, use insulation to shield the hose from heat exposure.

Timely Replacement:

Even if a hose appears to be in useable condition, visible damage or excessive wear are strong indicators that it needs to be replaced. Continuing to use a damaged hose could lead to catastrophic failures.

Static Electricity Grounding:

In some applications, hose metal can generate static electricity, leading to potential hazards. Use conductive materials or grounding methods to prevent static buildup.

Pressure Testing:

Conduct regular water pressure tests for hoses and fittings, especially in critical applications like chemicals, steam, LPG, and petroleum.

• Pressure should be increased to 1.5 times the rated working pressure and held for five minutes.

Record-Keeping:

Maintain a log of all inspections, including dates, findings, and corrective actions taken. This will help track the condition of your hoses and ensure timely maintenance.

Spare Parts Inventory:

Keep spare hydraulic hoses and fittings in stock for quick replacements when necessary.

Emergency Preparedness:

Equip your facility with a quick repair kit for immediate action in case of hose failure.

Personnel Training:

Ensure operators and maintenance staff are fully trained on the proper handling and maintenance of hose metal.

Common Metal Hose Failures and Prevention Methods

Even with proper maintenance, hoses can fail over time. Below are some common failure modes and how to avoid them:

• Outer Cover Wear: Caused by repeated friction against machine surfaces or other components. Prevention includes re-routing the hose, using protective covers, and regular inspections.
• Hose Rupture: Often results from pressure surges, excessive bending, high system temperatures, or exposure to corrosive liquids. Select hoses with appropriate pressure ratings and install pressure relief valves to prevent damage.
• Cracking: High temperatures beyond the hose’s rated limits can cause cracks. Always monitor system temperatures and select hoses that can handle the required temperature range.
• Blistering: Air or fluid contamination, high pressure, or manufacturing defects can cause blisters in the outer cover. Use compatible fluids and regularly vent the system to release trapped air.
• Braided Layer Wear: Caused by dragging components, improper lifting, or external objects damaging the braid. Ensure proper lifting and handling techniques.
• Joint Failure: Typically due to over-tightening, incompatible materials, or incorrect assembly. Always ensure that fittings are securely attached and the hose length is adequate for high-pressure applications.

Best Practices for Hose Metal Storage

Proper storage is crucial to prevent hose damage even when they are not in use. Here are some storage best practices:

• Indoor Storage: Store hoses in a dry, shaded, temperature-controlled environment away from UV light and moisture.
• Avoid Sharp Bends and Tangles: Store hoses without tight bends or twisting. Use large storage loops or dedicated hose reels to maintain the hose’s shape.
• Elevate from Ground: Store hoses off the ground to prevent contact with dirt, debris, or chemicals.
• Protect Hose Ends: Use caps or plugs to cover hose ends, keeping out dirt, moisture, and insects.
• FIFO (First In, First Out): Store hoses based on the FIFO principle to ensure older hoses are used first.

Table: Common Metal Hose Failures and Prevention

Conclusion

Maintaining hose metal is essential to ensure their longevity and safe operation in hydraulic and industrial systems. By following the correct installation, handling, storage, and maintenance practices, you can prevent premature failures and ensure smooth system operations.

If you need more information on how to handle or maintain hose metal in your specific application, contact us today! Our team of experts is ready to guide you through the best practices for ensuring the longevity and safety of your equipment.

• Need help choosing the right metal hose for your system?
• Reach out to us for expert advice and recommendations tailored to your needs!

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