How to Avoid an Industrial Hose Failure

Industrial hoses serve a number of critical functions in processing and production facilities. Examples include conveying materials through the workspace, and facilitating refrigeration or sanitation operations. The normal wear and tear they experience during use in these and other applications gradually weaken their structural integrity, eventually leading to cracks, splits, and other damage that can affect the performance of other equipment or the quality of the products and processes. Improper selection, assembly, installation, or use hastens the loss of structural integrity in hoses, significantly reducing their service life. In all cases, these “failed” hoses require replacement before safe operations of the equipment can resume.

In the following article, we delve into some of the most common failure modes for industrial hoses, outlining their characteristics, causes, and solutions.

Common Causes of Industrial Hose Failure and Their Solutions

There are several reasons an industrial hose may fail, ranging from using the wrong component for the application to employing the right component in the wrong conditions. Below, we outline some of the most common ways industrial hoses fail, their causes, and their solutions.

The Fitting Is Blowing off of the Hose

Cause: If the fitting is separating from the hose, the likely cause is improper assembly or choice of proper components.   The hose may not have been fully inserted into the fitting or clamp location and/or not crimped to the manufacturer’s recommendations.

Solution: Once the fitting has blown off the hose, it is necessary to replace the entire hose assembly as damage to the adjacent hose may have occurred. When constructing the new unit, ensure the hose is inserted and attached properly.

The Connection Point Between the Fitting and Hose Is Leaking

Cause: If the connection area between the fitting and hose is leaking, the fitting may have blown off partially or it may have cut into the hose’s tube.  This issue may be attributed to either too much or too little crimping during the assembly stage.

Solution: When the fitting to hose interface is leaking, the best solution is replacing the entire hose assembly. When constructing the new unit, check for compatibility between the fitting and hose and review the instructions for proper assembly as recommended by the manufacturer.

The Hose Is Leaking and Bubbling

Cause: If the hose is leaking or bubbling in the hose near the fitting, there are two main causes. The inner tube may have been damaged during the assembly stage; the fitting’s attachment is improperly applied.   It is also possible for moisture to be allowed enter the hose and corrode the reinforcement wires.

Solution: The solution to this problem is replacing the hose assembly using proper assembly techniques.

The Hose Is Hard, Brittle, and Cracked

Cause: If the hose is hard, brittle, and cracked at room temperature, it was likely exposed to temperatures above its maximum rating. The combination of high heat and oxygen led to the hardening of the cover and inner tube.  Once cracked the reinforcement is exposed and can fail from environmental exposure.  Likewise, if the tube is cracked from heat, the working fluid in the hose can migrate into the reinforcement leading in turn to the hose failing to contain the fluid and pressures for which the hose is being used.

Solution: When replacing the hose assembly, evaluate the operating and environmental conditions to which the previous unit was exposed. If the problem was high ambient heat, install heat guards or shielding. If the problem was high fluid temperature, employ a hose assembly with a higher temperature rating or integrate a heat exchange to lower the fluid temperature.

The Hose Is Cracked but Soft and Flexible

Cause: If the hose is cracked—but soft and flexible—at room temperature, it was likely exposed to temperatures below its minimum rating.

Solution: When replacing the tube assembly, evaluate the operating and environmental conditions to which the previous unit was exposed. Employ a hose assembly that accommodates lower temperatures or integrate thermal equipment to achieve higher ambient and/or fluid temperatures.

The Hose Has Burst

Cause: If the hose has burst, it may have reached the end of its service life. However, if there is evidence of tearing or deterioration on the hose cover, it may have been exposed to excessive chafing, corrosion, or rubbing.

Solution: In the former situation, the solution is to replace the hose assembly. In the latter situation, a new hose assembly is also necessary. However, it is important to consider integrating protective hose sleeves and guards or rerouting the hose to eliminate contact between the hose and other components.

The Hose Cover Is Damaged

Cause: If the cover of the hose is damaged, there was likely not enough lubrication during the assembly stage, which led to the unintentional twisting of the hose while being restrained to attach the fitting.

Solution: When replacing the hose assembly, re-route it (with clamps, if necessary) and use the layline as a guide.  It is important to only install hoses in a single plane of reference.  Hoses installed in multiple planes can twist and lead to premature failure primarily due to excessive loading on the reinforcement.

The Inner Tube Is Deteriorated

Cause: If the inner tube shows signs of excessive deterioration, such as swelling, delamination, or blistering, the material flowing through hose may not be compatible with the inner tube.

Solution: When replacing the hose assembly, either change out the hose material for one compatible with the current process fluid or the process fluid for one compatible with the current hose material.

Contact the Industrial Hose Experts at Jason Industrial Today

The above list is not all-inclusive. For more information on the common causes of industrial hose failure and how to solve them, turn to the experts at Jason Industrial (a Megadyne company).

At Jason Industrial, we offer an extensive range of industrial hose products and related services. To learn more about our offerings, contact us or request a quote today.

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2020 Hydraulic Hose Product Guide Updates


Jason Industrial released a Hydraulic Hose line in 2018 after decades of being a leading source of industrial hose. Since our initial launch, we listened to customer feedback and expanded our product line to better serve market needs. Our updated Hydraulic Hose Product Guide contains the additions made to our product line along with answers to commonly asked customer questions. The product guide is available for download here.

 

Key Updates Include

 

  1. New products, which can be found throughout the catalog with the “New Product” symbol, including:
    • Hose with the Dreamshield™ cover, a special rubber cover compound that is 6 to 8 times more abrasion resistant than the current standard cover:
      – Series 5012 – SAE 100R1AT, 1SN DIN EN853 – Wrapped MSHA Cover 1-Wire Braid Hose, Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5022 – SAE 100R2AT, 2SN DIN EN 853 – Wrapped MSHA Cover 2-Wire Braid Hose, Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5122 – SAE100R12, DIN EN 856 R12 – MSHA Cover 4-Spiral Hose – Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5132 – SAE 100R13, DIN EN 856 R13 – MSHA Cover – 4 or 6-Spiral Hose 5,000 PSI Constant Pressure, Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5152 – SAE 100R15, DIN EN 856 R15 – MSHA Cover – 4 or 6-Spiral Hose 6,000 PSI Constant Pressure, Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5162 – SAE 100R16, – MSHA Cover – 2-Wire Braid Hose 47 Dreamshield™ Extra Abrasion Resistant Cover
      – Series 5172 – SAE 100R17 – 3,000 PSI Constant Pressure, 1 or 2-Wire Braid Hose Dreamshield™ Extra Abrasion Resistant MSHA Cover
      – Series 5192 – SAE 100R19 – 4,000 PSI Constant Pressure – MSHA Wrapped Cover Dreamshield™ Extra Abrasion Resistant Cover – 2-Wire Braid Hose
    • JIC340 – General Production Hose Crimper with InfoCrimp™ Controller
    • Polyethylene Armor Guard used to protect hose assemblies from external mechanical damage
  2. Some existing couplings were replaced by new couplings. Use table below to find coupling to use for discontinued part.
Discontinued Part Number Replacement Part Number
1252 1248
1254 1249
1256 1250
4052 4048
4054 4049
4056 4050
4075-4516 4075-4216
1270-1604 1270-1404
  1. Coupling 1271-3612 was discontinued
  2. MyCrimp App instructions – Download our app to ensure you always have the latest safety information for using the correct hose, coupling and crimp specifications.
    Download for iOS – https://apps.apple.com/us/app/mycrimp-jason-industrial/id1250484050
    Download for Android – https://play.google.com/store/apps/details?id=com.customcrimp.jasonindustrial&hl=en_US
  3. Easier to read “How to Read Hose & Coupling Part Numbers” graphic –
  4. Updated “SAE Hose Working Pressures” chart
  5. Updated Chemical Resistance Chart
  6. Color coded pages
    • Gray – General information
    • Green – 1 and 2-wire braided hose and matching 12/JB12 couplings
    • Purple – 100R12 Series hose and matching 40/JB40 couplings
    • Yellow – 4 and 6-spiral hose and matching 60/JB60 couplings
    • Blue – Oil Return and Transportation (Air Brake) hose and field attachable (reusable) couplings
    • Red – Crimping equipment and accessories
  7. Pictures and drawings included for all couplings

For any questions about our updated Hydraulic Hose Product Guide, please contact us.

 

California Proposition 65: Compliance and the Jason Industrial Portfolio of Products

Effective August 30, 2018, Proposition 65, also known as the Safe Drinking Water and Toxic Enforcement Act of 1986, will be expanded to include almost 1,000 chemicals known to cause cancer or reproductive toxicity. As a result, the previous generic warning enacted in 1986 will need to be replaced with a warning that identifies specific chemical ingredients used in the manufacture of products shipped to California.

Full implementation of the Prop 65 amendment means that violators will face sanctions for failing to comply with the requirements set forth. Jason Industrial is making sure that we will be fully compliant with Prop 65 before the deadline. To further explain this law and its purpose, we will explore the history of Prop 65, why there is a demand for more specific warning labels on product packaging, and the steps we are taking to achieve full compliance with the law.

History of Proposition 65

When it was enacted and approved by a majority of California voters in 1986, Proposition 65 – or the Safe Drinking Water and Toxic Enforcement Act of 1986 – sought to keep harmful and carcinogenic chemicals out of California’s drinking water, and to warn residents if water they used for drinking and cooking had been potentially contaminated. The list of harmful chemicals has grown significantly since that time—there are now more than 1,000 chemicals on the list.

Previously, only generic warning labels on products containing these chemicals had been required. In 2016, the law was amended to require all businesses to add more specific warning labels on the full range of products now covered by the law.

Jason Industrial’s Compliance

Jason Industrial is currently taking all required steps to be fully compliant with Prop 65 before the deadline. As a first step, we have identified all products that need packaging with the required new labels under the amended Prop 65.

These products are shipped from our branches, whether to California or from other U.S. customer locations that may ship to California will have the proper warning label attached. Additionally, we will label the outside of shipping boxes noting Megadyne Americas compliance with Proposition 65 beginning August 30th, 2018. Customers receiving products that include chemicals noted on the revised proposition must ensure they carry the warning labels to their customers.

To ensure that we do not miss anything, we will send instructions and labels to all Jason Industrial shipping points so that products which may contain these chemicals can be pinpointed.

Learn More

Jason Industrial by Megadyne is dedicated to the health and safety of our customers. Additional information can be found on California’s Proposition 65 website. To download the full Proposition 65 chemical list, visit the California Office of Environmental Health Hazard Assessment’s website. If you have questions or concerns, please contact us to learn more about our compliance with Proposition 65.