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Hose  Assembly  
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Before We Start
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q  Q&A at the end of the presentation

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Moderator Presenters

Mary Gannon Rick Pitman Jim Reilly Debbie Mitchell

Design World PSC GHX NAHAD
 Hose Assembly Safety

Leveraging NAHAD’s Hose Safety Institute

and the
Hose Assembly Guidelines
 Agenda
•  Welcome – brief overview of NAHAD and the Hose Safety
Institute
•  Hose Assembly Safety – Why worry?
•  Case study: Hose safety in the Hydroblast industry (PSC/
GHX perspective)
 Today’s Presenters
•  Rick Pitman, VP EHST, PSC
•  Jim Reilly, Region Manager, GHX
•  Debbie Mitchell, Standards Program Director, NAHAD
 The Association for Hose & Accessories
Distribution (NAHAD)

Globally recognized association with over 500 member

companies
Offers a unique set of industry guidelines for the
specification and fabrication of hose assemblies
Reflecting industry best practices to ensure the safest,
highest quality, most reliable hose assemblies
 Performance standards for the specification, design,
fabrication and packaging of hose assemblies

Industry consensus best practices to ensure the safest,

highest quality, most reliable hose assemblies
 The result of their efforts is the
Hose Safety Institute Handbook
1.  Chapters on industrial, hydraulic, composite,
fluoropolymer and corrugated metal hose
assemblies
2. Guidance on
Design & specification
Testing
Shipping & handling
Quality
And much, much more…

Supplemented by on-line fabrication guides

•  Promotes Guideline usage and adoption throughout the
industry
•  Provides enhanced employee training and recognition
opportunities.
•  Delivers powerful marketing advantages (differentiation)
•  Connects End-users with HSI Distributors
End-User Advisory Council
•  Includes: end-users, experts, related standards groups and regulatory
agencies
•  Identifies emerging issues and critical applications related to hose
assemblies
•  Serves as a forum for addressing industry issues, providing appropriate
input to the NAHAD Standards Committee and ensures ongoing
industry dialogue and communications
•  Identifies and engage industry organizations and related agencies
involved in, or impacting, hose safety, quality and reliability
How Do Failed Hose Assemblies Affect
Your Business?
Safe Hose Assemblies Add to Your Bottom Line
Through Lowering Your Costs…
ü Fewer accidents
ü Lost employee time, potential law suits
ü Environmental impact
ü clean-up costs of spills
ü fines
ü OSHA fines for safety issues
ü Less unplanned equipment down time

And increased worker productivity

Specifying Your Hose Assembly:
S = Size STAMPED
T = Temperature
A = Application
M = Material
P = Pressure
E = Ends or couplings
D = Delivery
 STAMPED
S = Size: ID/OD, flow rate / fluid velocity
T = Temperature: fluid temp AND ambient temp
A = Application:
o  how the hose will be used (impulse, flexing, vacuum)
o  Static discharge considerations
o  Non-Conductive Hose Required?
o  Excessive Abrasion?
o  Routing Requirements?
o  Where Will Hose be Used?
o  Fluid compatibility?
 STAMPED
M = Material: fluid being conveyed, type and concentration
(specialized oils or chemicals?)
P = Pressure: system pressure and spikes
E = Ends or couplings – compatibility between hose and couplings
(same manufacturer)
D = Delivery:
•  any special considerations for testing, cleaning, packaging, or
delivery
•  note: cleanliness is key for hydraulic systems
 Safe, reliable hose assemblies
require appropriate Testing
Test What  It  Tells  You Comments
Hydrostatic  proof  pressure Pressure  integrity  of  the  hose  assembly;   proper  pressures  are  crucial  so  as  to  
appropriate  component  selection;  can  be  used   avoid  hose  deformation
to  measure  elongation  or  length  changes  under  
pressure

Hydrostatic  burst  pressure At  what  pressure  the  hose  will  burst Destructive  test

Leak  test Tests  for  leak  paths  in  the  assembly Typically  uses  air  or  helium  under  water

Electrical  continuity Is  there  a  grounding  path  for  the  assembly;   Measured  by  a  calibrated  multi-­‐‑meter
does  the  assembly  conduct  electricity
Hydrostatic Proof Pressure Testing
 For assembly testing, the rating of the component with the
lowest rated working pressure determines the working
pressure of the assembly.
Hose  Type What  pressure How  long
Industrial 1  ½    times  working  pressure  for  new  and  used   5  minutes
assemblies
Hydraulic 2  times  working  pressure 30-­‐‑60  seconds
Composite 1-­‐‑4”  nominal  bore:  5  minutes  
1  ½  times  working  pressure >4”  nominal  bore:  30  minutes

Fluoropolymer 1  ½  times  working  pressure 1  minute

Corrugated  Metal At  the  maximum  test  pressure  of  the  assembly Minimum  of  one  minute
 Project: Raising the Bar
for Safety in the Hydroblast Industry
•  Advisory Council Member: Rick Pitman
•  NAHAD Member: Jim Reilly, GHX
•  Objective: Create recommended best practices for
hose assemblies to provide guidance to end-users,
distributors, and others involved in the hydroblast
industry (up to 40,000 psi)
 Background
•  The Hydroblasting industry:
o  high pressure equipment
o  diverse and time critical applications.
o  lack of agreed upon hose standards or best practices
•  Hydroblasting - high risk craft if not managed properly
•  Needed: comprehensive approach to improve hose safety:
o  standard equipment design and maintenance
o  best practices for use and management 
•  Focus here on best practices in standard equipment design relating to
hose assemblies based on input from hydroblasting contractors and
hose and equipment manufacturers and distributors.
 Why the Project?
•  Strategic value for PSC – business operations and safety
o  Creating an industry response to an area with little or no guidance regarding safety/
quality
•  Engaged the full supply chain
•  Guidance to industry on how to more effectively (safely)
manage Hydroblast hose

•  Created an opportunity for Distribution to provide

consultative assistance to a customer, and a joint solution
                                      Result:            
A  Whitepaper  that:
•  Documents best practices for ensuring safety and
reliability of Hydroblast hose assembly applications (5,000
– 55,000 psi)
•  Represents the consensus of contributing companies and
organizations
•  Provides recommended best practices in the design,
fabrication, and on-going maintenance of hose assemblies
used in Hydroblasting applications
 What’s New??
Hydroblast hose assemblies are recognized as Assets, not just
consumable items

Hose Management Program

•  Asset Management
•  Proper Use and Care Program
•  Inspection Program
•  Failure Inspection Program
•  Training Program to support all of the above, including documented
hands-on competency verification
•  Pressure testing
Inspections
•  Visual inspection
o  Leaks at the hose fittings or in the hose
o  Damaged, separated or pulled back covers
o  Cracked, damaged, deformed or badly corroded fittings
o  Other signs of significant deterioration such as blisters

o  Compromised reinforcement where the wires are exposed, broken or corroded

 Inspections
•  Visual inspection - continued
o  Dents, twists, or kinks
(torque can tear loose the reinforcement layers and allow the hose to
come through)

o  Discoloration of color coded hose cover

o  Verify test date and pressure are in conformity with requirements for the application
o  Fitting Thread and seat condition
Protocol: Industry’s View of Hoses

31
 Mechanical  Integrity  Program  
         High  Pressure  Hose  Iden6fica6on High  Pressure  Hoses  
PSC    Loca)on   Manufacture  Date   Asset  Number   Pressure  Ra)ng  

209     1111   0032   20K  

New  fi&ings  on  every  hose  with  

etched  number  system
Tracking  System

–  GHX  Asset  Tracking  System

•  Online  Asset  Management  
of  PSC  Hoses
•  Web-­‐‑Accessible  to  end  users  

•  Tracks  all  inspection,  
maintenance  and  testing  
COMPLETE  –  January  
data
2012
 Hose  Mechanical  Integrity  Program  
High  Pressure  Hoses  
Collaborative  design  team:
10K - Yellow 15K - Green •  Operations
PSC    Loca)on   Manufacture  
Date  
Asset  Number   Pressure  
Ra)ng   •  Engineering  (Vendor)
209     1111   0032   10K   •  Safety

Field  testing  of  prototypes

•  Feedback  used  to  refine  final  
Etched  number  system  on  all   design
hoses  after  Jan  13th

20K - Blue 40K - Orange Result:

•  Standardize  all  field  hoses  
•  Independent  testing  and  
tracking
•  One  field  training  program
•  Identical  parts  inventory  (in  
Etched  number  system  on  all   Etched  number  system  on  all   field)
hoses  after  Jan  13th hoses  after  Jan  13th
•  RCAF  process  for  all  losses/near  
losses
•  Strict  procurement  control
 Mechanical  Integrity  Program  
3rd  Party  engineering   Loss  and  Near  Loss  Tracking  
Failure  at  one  PSC   review  of  failed  
location…. equipment….
 PSC  High  Pressure  System  -­‐  Loss  and  Near  Loss  Tracking  
PSC#   Date   Loca)on   RMA  #   Asset  #   Level   PSI   Qty   Asset  Type   Failure  Type   What  Happened   Current  Status   Failure  Cause   Long  Term  Ac)on   Status  

PSC0001   12/1/2011   Carrolton,  KY           II   10k  &  20k   7   1/2"  Supply   Abrasive  Cover   Sharp  edges  on  Ferrule   loca6on  shrink  wrapped  the  ferrule   Bad  cut  on  the  Ferrules   Shrink  wrap  on  the  Ferrule   Closed  

en6re  hose  assembly  be  protected  within  the  safety  shroud  or  
Plan  to  address  the  kink  in  progress  NLT   Spir  Star  determined  the  whip  
at  minimum  have  a  form  of  abrasion/kink  resistance,  such  as  a  
2/12;      GHX  inves6ga6ng  using  lay  flat  to   had  kinked  and  weakend  the  
PSC0002   12/21/2011  Calvert  City   PSC002   139-­‐1211-­‐0002-­‐20K   IV   20K   1   whip  hose  (      ")   Hose   Whip  hose  failed  outside  of  shroud   protec6ve  cover,  installed  on  the  hose  assembly  for  any  por6on   Closed  
cover  opening  of  shroud.    Locally  not  using   hose  at  that  spot  where  the  
of  the  assembly  that  will  not  be  enclosed  within  the  safety  
20k  guns   failure  occurred  
shroud.      

 (2)  20mm  engine  

checked  pump  for  defects  none  found.    
whip  from  the   pump  whip  hoses  both  failed  at  the  same  
PSC0003   1/6/2012   Westlake,  LA           IV   10K   2   Hose   sent  to  GHX  and  Spir  Star  for  evalua6on   Manufacturer  defect   Spir  star  sent  to  replacement  hoses  at  no  cost.   Closed  
fuid  end  to   6me  from  pump  end  to  pump  manifold  
01-­‐09-­‐2012  
manifold    

GHX  s6ll    wai6ng  to  receive  the  four  to  

563-­‐1211-­‐0001;  
ensure  they  were  crimped  correctly.    
PSC0004   1/10/2012   Granite  City   9175977   563-­‐1211-­‐0003  thru   I   10k   4   1/2"  Supply   Hose   Four  hoses  in  same  lot  that  the  crimp  failed             Open  
Haven't  shipped  yet  nor  asked  for  an  RMA  
563-­‐1211-­‐0005  
number;  shipped  1-­‐30-­‐2012  

209-­‐1111-­‐0003-­‐  10k  thur   sent  to  GHX  01-­‐11-­‐2012  .    It  was  shipped  
0005-­‐10k;                       PVC  abrasive  cover  pulled  off  and  Ferrules   FedEx  freight  ATT  Jose  Juarez  tracking#  
PSC0005   1/10/2012   Cahoes,  NY   9165161   II   10k   6   1/2"  Supply   Abrasive  Cover           Open  
209-­‐1111-­‐0008-­‐10k  &   were  digging  into  side  of  hose  /  rubber     222029096-­‐2  on  January  16th  at  2pm.  
209-­‐1111-­‐0015-­‐10k          

GHX  completed  Ini6al  Report  1/13/12  

Two  hoses  one  used  as  a  line  mole  with   hose  #1  failed  due  to  crimping  
Sent  to  GHX  1-­‐12-­‐12;  Received  at  GHX   Eaton  Failure  Analysis  completed.  
563-­‐1211-­‐002-­‐10k           PVC  cover  cover  pulled  off  possible  rupture   issue;  hose  #2  had  not  failed  
PSC0006   1/10/2012   Granite  City   9165714   IV   10k   2   1/2"  Supply   Hose   1-­‐13-­‐12,  GHX  did  quick  review  and  sent  to   PSC_004  report  completed  for  PSC  Review.    GHX  has  modified   Closed  
563-­‐1211-­‐0006-­‐10k   and  the  foot  dump  to  the  pump  the  hose   although  the  PVC  abrasive  cover  
Aero  quip   their  Procedure  to  mark  hose  fikngs,  root  cause  was  fikng  blew  
failed.   pulled  back.  
off  based  on  Eaton  Report.    See  PSC_004  Report  sent  to  Sean  

quaran6ned  due  to  being  built  in  the  same   inves6ga6on  revealed  that  the  hoses  would  
PSC0007   1/11/2012   Woods  Cross           I   20K     11   1/2"  Accessory   Hose   No  Failure  found   quaran6ne  liled   Closed  
batch  as  the  Granite  City  hoses   not  have  been  affected.  

Allows  “NEXT  DAY”   Provides  basis  for  new  

quarantine  of  other   operating  procedure  
hoses  manufactured  in   and  new  equipment  
same  lot  number  across   requirement
the  country
 On the Horizon
•  Next project: ….
o  Liquid Vacuum (petroleum transfer) Hose Assembly Best Practices
o  Hose Assembly testing practices (Smithers Rapra)
o  Tank Truck Hose – Petroleum and Chemical Transfer
o  Steam Hose
o  Hydraulic Hoses?? (What issues most impact safety?)

What are
YOU or YOUR CUSTOMERS
interested in??
 Questions?

Thank You!
For  more  information  on  the  Institute:  dmitchell@nahad.org  
or

www.hosesafetyinstitute.com

 Questions?
Mary Gannon Rick Pitman
Design World PSC
mgannon@wtwhmedia.com rick.pitman@pscnow.com
Twitter: @DW_MaryGannon

Debbie Mitchell Jim Reilly

NAHAD GHX
Dmitchell@nahad.org jjreilly@ghxinc.com
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