Contributed by Alex Ng, CES Application Engineering Manager • ContiTech USA Inc.
Selecting the right hydraulic hose on a piece of industrial equipment is often an afterthought — if it gets any thought at all — even though a hose failure can be catastrophic. A ruptured hose can be life threatening, harmful to the environment, costly and substantially disruptive to operations, and is almost entirely avoidable.
Understanding why hose failure happens, industry standards, hose selection best practices, and working with a knowledgeable distributor or application engineers of hose manufacturers can help companies choose the right hose for the job — and keep workers safe and production running on track.
1.Why hose failure happens
Hydraulic hoses are essential components on a vast array of machine types, from construction to manufacturing, and they are susceptible to wear and tear like many workhorse components. Common causes of hose failure include:
Abrasion and external damage – Exposure to rough surfaces, sharp objects, and environmental conditions can wear down hoses over time.
Improper selection – Using the wrong hose coupling or termination and incorrect hose and coupling sizes for a specific application can lead to premature failure, could be life threatening to the operator or others, and can negatively impact the environment.
Incorrect installation – Twisting, kinking, or incorrect couplings can weaken hoses and their connections. Improper routing and the wrong torque on the appropriate termination could also cause issues.
Age and material degradation – Over time, rubber and other hose materials degrade, reducing their effectiveness and increasing the risk of failure. Different types of polymer have different effects with hydraulic fluids. There are also biodegradable hydraulic fluids that have different impacts on polymer types.
Hose failures can lead to severe consequences for operators, other employees and for the operation. Ramifications of a hose failure can include fluid leaks that could cause environmental contamination and costly cleanups, personal injury from hot and pressurized fluid that can pose risks of severe burns or high-pressure injection injuries, or machine downtime which leads to productivity losses and expensive repairs.
Visual inspections of hydraulic hose assembly should be part of routine equipment maintenance and should be carried out regularly, depending on how often the machines are used. The older the machine, the more frequently it should be inspected.
2. Using STAMPED, ISO to get the right hose for the job
Experts rely on the STAMPED selection process, the industry-wide practice used by engineers and operators, to determine the right hydraulic hose for the job. STAMPED considers:
Size: inside diameter, outside diameter, and length
Temperature: operating and ambient temperatures
Application: specific usage conditions
Material: the substance being conveyed
Pressure: working pressure and pressure surges
Ends: fitting types and connections
Delivery: special requirements such as certifications or custom specifications
By considering the seven variables identified using the STAMPED acronym and consulting with a knowledgeable equipment dealer or distributor, businesses can prevent hose failures and enhance operational efficiency. Selecting the right hose from a trusted manufacturer ensures reliability, safety, and compliance with industry regulations.
ISO-18752 certified hoses represent the latest standard in the industry. With a minimum requirement of 200,000 cycles, these hoses provide consistent durability and reliability. This standard has been in place for over 20 years, proving its effectiveness in ensuring the highest performance. Companies that choose ISO-certified hoses benefit from increased longevity, reduced downtime, and enhanced safety.
3. Why reliability matters more than ever in hydraulic systems
Reliability is a top priority for OEMs that design machines with specific performance requirements. In hydraulic systems, hoses must meet strict specifications to ensure they function properly under high-pressure conditions — often 3,000 to 6,000 psi.
Meeting industry specifications is critical to reliability. Before releasing a hose to production, manufacturers must validate both design and manufacturing processes to ensure compliance, including running rigorous tests to confirm performance under specified conditions, following strict guidelines and specifications of ISO quality management systems and appropriate industry specification such as SAE or ISO for production, and conducting ongoing quality control checks to maintain consistency.
For example, standards like SAE J517 or ISO 18752 indicate that a hose has been validated and passed all required tests. When end-users see this certification, they can trust that the product meets the highest industry requirements.
Reliability can also take form in the basic engineering of a hose, which happens at the manufacturing level. Continental’s five decades of experience manufacturing hydraulic hoses, for example, has enabled the company to hone its processes and meet customer standards and requests with precision. In today’s environment, where labor shortages and downtime are critical concerns, reliability is more important than ever.
Reliability testing can be expensive, but it is an essential investment. Partnering with a high-end manufacturer ensures quality control, superior performance, and long-term dependability. Continental recommends working closely with the distributor or dealer and asking for a hose that not only meets industry standards but exceeds them.
4. Safety: a critical consideration
Hose failures are more than just an inconvenience, they can be life-threatening. Many people underestimate the risks associated with a broken hose. High-pressure hoses operate at extreme psi levels, and a ruptured hose can release a powerful burst capable of cutting through materials — and people.
By investing in high-quality, reliable hoses, companies can protect their workforce and minimize risks. Safety should always be a priority, and selecting the right hose is a key step in preventing accidents and injuries.
If a hose fails in the field, the standard practice is to take the failed hose assemblies to a hose dealer for proper servicing and replacement. Dealing with professional hose dealers ensures the replacement is selected and installed properly, minimizing the risk of recurring failures.
Hose failure is a serious issue, but with proper selection, adherence to ISO standards, and expert engineering, businesses can enhance reliability and safety. Consulting with experts and using the STAMPED method ensures the right hose for each application, while high-quality materials and manufacturing expertise help prevent costly failures. When safety, efficiency, and reliability matter, choosing the right hydraulic hose makes all the difference.
ContiTech USA Inc.
continental.com
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