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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