Gates Inspection-And-Preventive-Maintenance-For-Industrial-Hose PDF
Gates Inspection-And-Preventive-Maintenance-For-Industrial-Hose PDF
Gates Inspection-And-Preventive-Maintenance-For-Industrial-Hose PDF
table of contents
What is Preventive Maintenance? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Benefits of a Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Components of a Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Definition of an Industrial Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
• Three Basic Elements of a Hose
Proper Hose Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
• STAMPED
Proper Coupling Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Static Electricity Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hose Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Hose Maintenance Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Hose Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hose Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
RMA Hydrostatic Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specialty Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
• Acid/Chemical Hose
• Air Hose
• LPG Hose
• Petroleum Hose
• Steam Hose
• RMA Standards for Steam Hose Testing
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 THE G ATES S AF ETY G U I DE 3
Caution!
1. Hose should not be used in “out-of-sight” applications where the hose is buried, encased or
submerged. Use rigid pipe in these applications.
2. Hose has a finite service life and is not meant to be used in permanent applications.
4 THE G ATES S AF ETY G U I DE 5
M - Material
• Chemical name(s) and state(s) – liquid, solid or gas
Being • Food, pharmaceuticals, cosmetics
Conveyed: • Dry or powder
• Liquid
P- Pressure:
• What is the working pressure?
• What is the maximum surge pressure?
• Is there a vacuum?
E - End
• What type of end connections?
Requirements • See “Proper Coupling Selection” on page 6
D - Delivery
• Identify how many items and when they need to be supplied.
• Distributors
— Call customer service
• End Users — Call distributors
• Are there any special packaging or branding requirements?
6 THE G ATES S AF ETY G U I DE 7
Industrial Hose
• Quality
Products/List Prices
• Ease of handling
75 Gates GLX™
Pocket
Solid Male Female Swivel
International
Description: One piece staked ferrule design. Smooth ferrule ID Thread
designed for textile reinforced transfer hoses. Male pipe NPTF 30°
cone seat and female JIC 37° flare swivel terminations. TuffCoat
® Identification Kit:
plated steel for 400 hour red rust corrosion protection (SAE-J516 7369-4318
and ASTMB-117 salt spray conditions).
8 THE G ATES S AF ETY G U I DE 9
• The grounding of a static-eliminating or through use of: Use with a hose that has a carbon fiber static
conductor or wire reinforcement where the
static-conducting component. 1. Static conductive stock in the staple can be inserted easily against a static
tube or cover. conducting member.
Static Electricity 2. Bent wire method • Cut the hose end square to the
Grounding Importance: Use with a hose that is wire-reinforced.
desired length.
• Locate the static wire, wire braid
• Movement of some dry material through a • Locate the helix wire or the static wire.
or carbon fibers.
rubber or plastic hose can generate enough • Pull the wire out with pliers.
static electricity to be hazardous. Not only could • Place one leg of an aluminum, copper
Close-up of hose end
a static spark ignite a fire or cause an explosion, • Bend the wire into the inner surface or stainless steel staple into the wire showing wire braid in hose.
but enough charge could build-up in the hose to of the hose tube. reinforcement or carbon fiber.
cause a severe shock if contacted. • Use caution not to puncture the tube. (For acid chemical hoses use only
stainless steel staples.)
• Attach the couplings so the bent wire
and the coupling make contact. • Place the other leg of the staple inside the
(The bent wire must not extend the full tube making sure the staple straddles the
length of the stem, since it could create tube wall and is snug against the end cut.
a leak at the coupling.) • Pinch the staple with pliers to force the leg
• Place the assembly on a non-conductive against the inner surface of the tube wall.
surface and check it for electrical continuity • Clean the staple and coupling shank ends
with an ohmmeter that measures electrical with an emery cloth or steel wool.
resistance. (The maximum allowable resistance
Helix wire being bent into the inner • Attach the coupling so the staple and Placing the staple.
is 20 thousand ohms per foot of hose.)
surface of the hose tube. coupling make contact.
• Record all test data on a hose inspection
• Place the assembly on a non-conductive
card and file it with maintenance records.
surface and check it for electrical continuity
with an ohmmeter that measures electrical
resistance. (The maximum allowable
resistance is 20 thousand ohms per
foot of hose.)
• Record all test data on a hose inspection
card and file it with maintenance records.
Hose inspections
Periodic Inspections— be less expensive than replacement or repairs
Achieving hose safety and performance requires • Critical nature of application 1. Visually Inspect for Leakage 2. Hydrostatic Pressure Testing
periodic inspections of the hose and fittings
• Operating temperatures (see page 15 — RMA Hydrostatic
prior to, during and after use. Hoses that have ARNING: NEVER inspect a hose for
W Testing Procedures)
become old, worn or damaged can present a • Operating pressures leaks by running your hand over it while it WARNING: Never use flammable or
danger to personnel and to the environment. is under pressure or contains the material
• Environmental factors corrosive fluids or compressed gas.
Hoses that are not properly maintained can fail, being transferred.
It is helpful to think of hose inspection at • Test at regular intervals.
which may result in costly material spills, cleanup,
• Escaping fluid under high pressure can • Essential for hoses used in hazardous
downtime and injury. Planned inspections, two levels:
exert enough force to penetrate and cut applications such as chemical, steam,
corrective actions and hose replacements can
flesh, causing painful or severe injury. petroleum and compressed gas transfer.
• Hot materials and chemicals can cause • Always use water for pressure testing.
serious burns.
Level 1 Inspection • ALWAYS conduct close inspection of
3. Inspect Hose Tube for Hardness,
Color Change, Cracks, Blisters,
An ongoing inspection of hose on a daily basis looking for signs of: hose when pressure is released and Erosion etc.
the hose does not contain potentially
dangerous material.
1. Hose Cover Damage 4. Cover Blisters
• Cuts, cracks, abrasion, exposed • Chemical incompatibility. Level 2 inspections should be conducted, if possible, during regular
reinforcement, etc. • Permeation in the early stages of leakage. equipment shutdown or at least every three months, even if it means shutting
• The blister can break and expose the equipment down for the specific purpose of hose inspection.
2. Stiffness or Hardness of the Hose
reinforcement that can degrade from
• As a hose ages and is exposed to sunlight, contact with environmental factors.
ozone, extreme temperatures or chemicals,
it can lose some of its resiliency and 5. Kinked or Flattened Hose
become stiff and hard. When flexed, • Restricted material flow and
a stiffened hose can crack, leading to hose performance.
a catastrophic failure.
6. Leakage
3. Changes in Color
• Puddles or spilled material under
• May indicate chemical attack. the hose assembly.
• Ozone or aging effects. • Problem with coupling interface
or attachment.
• Weeping from the hose.
7. Damaged Hose Reinforcement
• Weakened hose.
12 THE G ATES S AF ETY G U I DE 13
Specialty Hose
Acid/Chemical Hose
Selecting the right chemical hose is EXTREMELY to the chemical it is being exposed to can 7. Hydrostatic Testing (see Page 15) • Visually inspect the hose for coupling
critical. The incorrect hose can lead to potentially deteriorate and lead to premature hose failure. slippage, leaks or any indications of
• Lay the hose straight on rollers in a
dangerous or fatal accidents/failures. weakness or hose failure.
• Never leave an operating transfer hose clean, dry area.
To ensure selection of the correct acid/chemical unmonitored or unattended. • When the test and inspection are complete,
• Visually inspect the outer cover for cuts,
hose follow these steps: thoroughly drain the water from the hose.
5. Always Drain the Chemicals abrasions, bulges, soft spots, coupling slippage
1. Use the Chemical Resistance Table and Hose from the Hose and any other signs of wear. 8. Fitting Inspections
Finder in the Gates Industrial Hose Catalog • After a hose passes the visual inspection,
• Always disconnect the hose when • Select the proper couplings. Metals are subject
#39496-000 to select the proper hose. The connect it to a suitable test pump and fit the
not in service. to attack by the conveyed chemicals.
table lists approximately 1,400 chemicals and open end with a quick-opening valve.
the Gates tube stocks most suitable for each • Completely drain and flush all corrosive • Check exposed surfaces of couplings, flanges
type of chemical. residues and vapors. • Fill the hose with water and bleed the air out. and nipples for cracks or excessive corrosion.
2. Use couplings that are compatible with the • Use extreme caution when flushing the • Always use water. Never pressure test • Check for coupling or nipple slippage.
application and the product being conveyed. hose with water. Some chemicals, such as with compressed gases, corrosive
liquids or solvents. • Retire any hose assembly that does not pass
concentrated acid, may react with water
3. Contact your Gates representative or distributor the inspection.
and splatter. • Always use the recommended safety
to help you select the correct hose, or contact
the Gates Product Application group in Denver • Always dispose of the waste material in an precautions listed on page 17 to protect 9. Electrical Conductivity Inspections
to answer specific application questions by environmentally safe manner. the operator.
• Test the hose assembly with an ohmmeter or a
calling 303-744-5070. • Pressure test requirements for new hose: battery-operated voltmeter. See page 8.
6. Routine Maintenance and Testing
• Raise the pressure to twice the
Keys to Safe Chemical Hose Operations • Inspect hose and couplings daily. 10. Accurate Record Keeping
rated working pressure and hold
1. Proper Hose for the Application • Hydrostatic pressure test every 90 days. for five minutes. • Tag each hose assembly.
• All hose assemblies must be inspected and • While under pressure, carefully examine • Record all test data on the hose inspection card
2. Wear Protective Clothing
tested before entering service. the hose for leaks in the cover and at and file it with maintenance records.
• Chemical hose operators must wear the couplings. Use a sheet of paper, not
• Any hose which shows signs of wear or abuse
protective clothing including face or eye your hand, to feel for leaks. Check for
must be removed from service immediately.
protection, rubber gloves and boots. coupling slippage and any indications
• A respirator may be required in of weakness or failure in the hose.
some situations. • Pressure test requirements for used hose:
3. Monitor the Pressure and Temperature • First, make sure it is clean!
• Never exceed the maximum rated working • Clean the used hose in a 10 percent
pressure or temperature rating. sodium hydroxide solution at 180°F,
then rinse with water.
4. Monitor the Environment
• Raise the pressure to 1.5 times its rated
• Never allow the hose to lay in pools of working pressure.
chemicals or let chemicals drip on the hose Hydrostatic hose testing.
cover. A hose cover that is not resistant Monitoring pressure and temperature.
18 THE G ATES S AF ETY G U I DE 19
tightening, DO NOT USE Locate the actual Rated Working Pressure and
Temperature on the steam chart on previous
other signs of wear. • If leaks are found between the hose tube
page. Any point on the heavy line is saturated Properties of Saturated Steam
THE HOSE. steam.
th
(Abridged from Handbook of Chemistry and Physics – 39 Edition.)
• If the hose has any of the above problems, and the fitting, release the pressure, retighten
Gauge *Temperature of Gauge *Temperature of Gauge *Temperature of
4. Select the Correct Hose
• If the hose has no other From the table at right, select the hose that ful-
fills the requirements of both the condition of
Pressure
(psi)
Saturated Steam
(ºF)
Pressure Saturated Steam
(psi) (ºF)
Pressure
(psi)
Saturated Steam
(ºF) discontinue use. the clamp, and reapply pressure.
10 239 110 344 200 388
the team and the Rated Working Pressure. 25 267 115 347 205 390
problems, it can be 5. Determine Length Required
30
35
274
281
120
125
350
353
210
215
392
394
• If the hose passes the visual inspection, • If this corrects the leak, the hose can be put
40 287 130 356 220 395
recoupled or fitted with the Length required is almost always dictated by
the application. 45
50
292
298
135
140
358
361
225
230
397
399
continue to Step 3. back into use.
next smaller size clamp and 6. Select Couplings Required
55
60
303
307
145
150
363
366
235
240
401
403
Gates recommends interlocking* and
permanent crimped types of couplings for
65 312 155 368 245 404
3. Connect the hose to a suitable pump. • If the leak continues, the hose must be
put back into service. steam hose applications. These are identified
70
75
316
320
160
165
371
373
250
255
406
408
as: 80
85
324
328
170
175
375
377
260
265
409
411
recoupled or replaced.
7. ALL steam hose assemblies 14 Interlocking, ground joint 90
95
331
335
180
185
380
382
270
275
413
414 4. Restrain the hose by using a cable or chain.
15 Interlocking, washer joint 100 338 190 384 • If a leak occurs at a permanently crimped
should be pressure tested 105 341 195 386
76 Permanent Crimped
*Based on an atmosphere pressure of 14.7 psi.
5. Inspect permanent couplings for looseness or coupling, the hose must be replaced.
before being put into service. Steam Hose Couplings
Troubleshooting
Avoiding Problems Caused by Misapplications Avoiding Problems Caused by Misapplications
Problem Causes Solutions Problem Causes Solutions
Hose burst in one or more Exceeded the rated working Check pressure output of system. Use
Wire reinforcement is rusty at Hose cover was damaged Protect hose against cuts and
places along the length of the pressure. Hose twisted dur- a hose with a higher pressure rating.
site of hose burst. from cuts, abrasion, extreme abrasion with a nylon sleeve or steel
hose. ing attachment to ports during Use swivel couplings.
temperatures, chemical attack, coil guard. Check temperature and
application, causing gaps in the
internal gases diffusing through chemical compatibility rating of hose
reinforcement.
the tube and collecting under tube and cover with the application.
Hose tube swells or deterio- Hose tube is not compatible Identify the material and the tempera- the cover forming blisters which Consider pin pricking the cover of
rates, blocking material flow or with material being conveyed ture at which the system operates. break, or improper skiving and the hose to allow diffused gas to
causing a leak. and/or temperature. Refer to the Gates Chemical Resis- coupling attachment. escape and not become trapped
tance Table or contact Hose Product under the cover.
Application in Denver at 303-744-
Hose leaks profusely without High velocity erosion of hose Consider a larger diameter hose to
5070 for assistance.
bursting. inner tube. Fluid velocity in handle the volume flow at a lower
Hose tube becomes hard, Excessive heat can leach out Select a hose with a higher tempera- general may be too high. velocity.
cracks and leaks; may appear plasticizers in the tube. Air or ture rating. Look at ways to reduce
Hose leaks or bursts. Cover Hose maturity causes loss of Check the code date on the lay
charred. aerated oil can cause oxidation system temperature and aeration of
is deteriorated, hard, has fine performance properties and line of the hose, generally, anything
of rubber that is accelerated by oil.
cracks and feels stiff. eventually fails from the beyond five to seven years of age is
heat.
effects of environmental questionable. Suggest a maintenance
Cracks in hose tube and cover Flexing of hose during a period Check lowest internal and external conditions such as heat, cold, replacement schedule that meets the
result in a leak; yet tube and of extreme cold when the tube temperatures, especially at the time ozone and sunlight. application conditions.
cover are soft and pliable at and cover were too stiff. of equipment startup. If possible, use
Hose tube worn through on Abrasive material wore through Select hose with a thicker and/or
room temperature. a hose that will remain flexible below
one side and leaks. the tube. more abrasion resistant tube.
the lowest operating temperature of
Periodically rotate hose to even out
the application.
abrasion wear. Use a larger diameter
Coupling blows off end of hose Incorrect coupling used; hose Check hose and coupling compatibil- hose to reduce material velocity. Do not
when pressurized. was not fully inserted into the ity. Review crimp specifications and bend hose as severely.
coupling; not correctly skived procedure. Make sure routing does
Hose burst at end of coupling. Exceeded maximum rated Use a higher pressure rated hose.
at coupling attachment end or not impart excessive stresses to the
working pressure. Hose bent Use hose bend restrictors and do
coupling not crimped to speci- hose assembly.
sharply over the end of the not exceed the minimum bend radius
fied diameter (too loose or too
coupling. Did not follow the rating. Check the coupling used and
tight).
recommended coupling crimp diameter.
Hose inner tube collapsed Hose not designed for high Use a hose designed for high vacu- attachment procedure.
inward, folded and a portion is vacuum. Adhesion between um. Check routing to avoid exceeding
Hose cover blistered; blisters Hose not compatible with Select a hose with a tube having a
often torn away. tube and reinforcement may be the minimum bend radius.
filled with material being material being transferred. high compatibility rating with the
poor. The hose may have been
conveyed. material being transferred.
bent too sharply and kinked.
Hose cover blistered; blisters Gas in liquid. High pressure Remove gas from line. Pin prick hose
Hose burst on the outside of the Hose bent too tight in routing Check routing. Do not exceed rated
not filled with material being causing high rate of gas cover. Change to a hose with a tube
bend and burst hole is elliptical causing the reinforcement to minimum bend radius. Consider us-
conveyed. permeation of tube. of higher density/lower porosity.
in shape. open up too much on outside ing bent tube couplings, adapters or
of bend. bend restrictors to relieve stress on Cover of hose soft, gummy, Hose cover not compatible with Select a hose cover that is compatible
the hose. discolored and worn away material and/or temperature. with the material and temperature.
by friction.
Hose pulls out of the coupling. Hose when pressurized short- Check routing for proper hose length.
ens up, pulling out of coupling. Allow some slack to compensate for Discharge pressure/volume Pump output capacity too low. Increase pump output. Check for
Hose not supported with the hose movement when pressurized. too low. Hose or coupling restriction. hose kinks. Increase hose and/or
added weight of the material, Support long lengths of hose with coupling inside diameter. Add
pulls out of the coupling. clamps, cables, etc. Do not use hose “booster pump” if hose length is
as a rope or cable. extremely long.
Hose flattened in one or more Hose twisted, kinked or run Check routing. Use swivel couplings
areas. over. Extreme twisting and to prevent twisting the hose when
kinking can open up large gaps making port attachments. Use bent
in the reinforcement allowing a tube couplings and longer lengths of
blowout to occur. hose to avoid excessive bending and
kinking. Use crush resistant hose.
25
T H E G AT E S S A F E T Y G U I D E
Gates Corporation
1551 Wewatta St.
Denver, CO 80202
www.gates.com
Printed in U.S.A. 6/08 39998