5 Essential Steps To Maintaining Industrial & Hydraulic Hoses
Whether stainless steel or Teflon hoses, all industrial and hydraulic hose systems need preventative maintenance to ensure their long service life. Consistent maintenance efforts in conjunction with adhering to a hose’s standard operating procedures can keep managers and operators aware of the condition of each hose in active use, greatly reducing the risk of a failure and potentially causing safety issues or, worse yet, unplanned downtime. Below, we cover five steps that are indispensable to any preventative hose maintenance plan.
1. Visually inspect hoses and their fittings
Visual inspections are a simple yet vital step in preventative maintenance since periodic checks are the most direct way of identifying signs of damage, disrepair, or unusual performance problems. It is recommended to compile a list of indicators that signal when a hose assembly requires replacement so your workers can get ahead of problems before they occur. These indicators should include:
- Leaking in the hose or around the fittings
- Fittings slippage or displacement
- Soft, loose, or degraded covers
- Damaged covers, including abrasions, cuts, cracks, and blisters (if the damage exposes the reinforcement, immediate replacement is necessary)
- Damage to the hose body, such as charred surfaces, cracks, and unusual stiffness or hardness
- Damage to the fittings, such as cracks and corrosion
- Twists, kinks, and crushed or flattened portions in the hose
Keep in mind that industrial hoses should never be reused or repaired since any damage or deterioration experienced will have already compromised their structural integrity. Thus, no amount of servicing can restore its performance to its original capacity.
2. Implement lifecycle tracking
Each hose (and its fittings) has an expected service life. Organisations can ask the manufacturer or supplier for a clear idea of how long their hoses should last for their unique applications and the recommended interval for inspections and tune-ups. Also, consider tailoring your maintenance schedule to the hose assembly’s individual components to achieve a more efficient maintenance process.
At each stage of a hose’s lifespan, look for signs of damage and deterioration and see if they match the wear and tear expected at that phase of the part’s service life. Most importantly, document the part’s condition as having accurate records allows for monitoring any increases in damage and tracking trends in performance.
Last but not least, consider applying a permanent tag or marking on each hose assembly for quick identification when performing inspections and replacements.
3. Conduct functionality tests
Periodically test all hose assemblies in the facility by operating them at their maximum rated working pressure to check for leaks and other problems.
During testing, ensure any system surges are also below the maximum permissible pressure and keep personnel at a safe distance in case of a malfunction. And as a reminder, never perform inspections – particularly those requiring direct physical contact – with a hose under pressure due to the risk of fluid injections, which can cause severe injury.
4. Establish a consistent replacement schedule
The components of a hose assembly will eventually break down over time, even with optimal system operations and good preventative maintenance. For instance, the elastomeric seals will eventually turn brittle or start to harden due to constant exposure to heat and pressure as well as age. Replacing these parts whenever the hose is removed is key to keeping the overall system in good condition and preventing unscheduled downtimes for troubleshooting and repairs.
5. Keep spares readily available
As with other equipment in the facility, having spare hoses on hand ensures you are not forced to temporarily shut down your machinery and face delays should a hose assembly unexpectedly go down. An analytics system using the data from preventative maintenance routines allows organisations to determine the right quantities of components to store on-site for emergency replacements. Pair this with an in-house inventory, and it becomes easier to order replacements in advance.
Conclusion
When it comes to preventative hose maintenance, visual inspections, routine replacement schedules, data logs of active parts, and a steady inventory of spare hose components are all essential elements in your maintenance plan. By following these steps, organisations can ensure the long-term optimisation and cost-effectiveness of their systems as a whole.
