How can the industrial hose maintenance program save your factory a lot of money

 

How can the industrial hose maintenance program save your factory a lot of money

The common concern of many plant managers and engineers is the proper time for industrial hose replacement. There are good reasons for this concern. Waiting too long to replace the hose will greatly increase the risk of failure, which may lead to safety problems and unplanned downtime. On the other hand, premature hose replacement - although there is no safety risk - can be costly in terms of time and cost.

Preventive maintenance programs can help supplement standard operating procedures by providing information about each hose in the plant. This means tracking the service life and performance of each hose, i.e. checking the hose frequently, replacing the hose ahead of time and identifying key replacement parts in the facility. While it may seem laborious to make such a plan, the cost saving benefits make the upfront investment more valuable.

Each hose in your facility varies depending on the application parameters you are experiencing, so you need to determine different replacement intervals based on the environment. Consideration should be given to everything from pressure to movement requirements to equipment and related issues.

Steps to make preventive industrial hose maintenance plan

Although your supplier can provide general inspection and replacement guidelines, the actual replacement interval will vary depending on the operating environment, construction materials and other factors of each hose. The replacement interval of these hoses cannot be predicted. Replacement intervals can only be determined by observation and careful record keeping..

1. Identify all hoses

First, perform a complete factory audit, including identifying and labeling each hose. The audit should be comprehensive and specific, including recording hose type, part number, process fluid, pressure or temperature rating, and supplier name and contact information.

In the spreadsheet, record other details, including the length, size, inner material and structure, reinforcement layer, termination, installation environment, outer type, application environment, cleaning procedure of each hose, and the date of hose installation and planned replacement. This process alone can be a valuable supplement to the factory operating system.

2. Track the life cycle of each hose

Follow the regular hose inspection schedule and inspect each hose at intervals recommended by the supplier. Only visual inspection is required, so system shutdown is rarely required. You mainly check for signs of wear, such as scratches, cuts, corrosion, kinks and general deterioration. These signs indicate that the hose should be replaced. Please note all observations in the spreadsheet.

After the hose reaches its service life, please pay attention to its maintenance interval. This information provides a defined replacement cycle for the hose.

If the hose fails during operation, please record every detail: the location of the failure on the hose, the severity of the fracture and the installation method of the hose. These details will help to troubleshoot with the hose supplier and determine how to prevent further accidents.

3. Reduce the hose stress

If the system is running at the time of the inspection, determine any known conditions that the hose is creating. Check for hoses that rub against equipment, are subject to vibration, are exposed to external heat sources, or are installed in arrangements that may cause excessive strain. The above conditions should be corrected immediately, otherwise the service life of the hose will be shortened or the failure will be caused. The following are common causes of hose strain:

*Twist the hose or bend it in multiple planes

*Bend the hose out of the recommended radius

*Bend too close to the hose / fitting connection

*Use a hose of insufficient length, so the hose is stressed during impact

*Elbows and adapters are not used to relieve hose stress at horizontal end connections

4. Determine the need to protect the outer layer

Sometimes it is necessary to use a hose to protect the outer layer. The heat sleeve helps to protect the hose from weld metal spatter and ultraviolet rays, the fireproof sheath can insulate the fluid limit temperature of the internal system, the spiral protection device can protect the hose from abrasion, the armor protection device can prevent kinking and abrasion, and the spring protection device can protect the hose from kinking and abrasion. The outer layer of the hose does not change the technical data of the hose. However, when choosing the protective outer layer, it is necessary to carefully understand the operating temperature of each option and the main purpose of its function. For example, the thermowell protects the hose from weld metal spatter, but does not prevent wear.

5. Follow the inspection and replacement protocol

When you know the replacement interval of each hose, your hose maintenance plan will be initially formed. However, even after determining the replacement interval, you should continue to check regularly to ensure that changes in system parameters do not cause strain in the hose.

6. Data analysis

Based on the established frequency of hose inspection and replacement, the historical data is analyzed periodically to determine whether any interval is shortened or extended for safety or budgetary reasons. Destructive testing of the replaced hose can determine whether the hose is replaced too early or too late.

In addition to regular data analysis, if specific hoses are frequently replaced, consider using alternative designs that provide longer service life. In this case, verify that the cost-benefit analysis is in the best interests of your plant.

7. Prepare spare parts

If you connect the replacement interval of the hose, you can order replacement parts in advance. In addition, for some hose categories, it is better to keep some spare parts in the factory inventory:

*Hose for major safety or process applications: ready made spare parts need to be retained to correct hose applications that may have major safety concerns or severe downtime.

*Possible failure hose: if there is a high possibility of premature failure in the operating environment of the hose, your team needs to have additional hose to adapt to frequent replacement. For example, a hose that is kinked, moving in two planes, or subjected to vibration may fail earlier than other hoses. It may be better to choose a more suitable hose for such applications or to thoroughly adjust the system to eliminate strain on the hose.

*Hose for special application: please keep any spare hose which is difficult to obtain due to special material, length, end connection and other variables. For example, if you understand that a specially ordered hose requires a three week lead time, you may even want to stock two spare parts for good measurement results.

It takes time to check and record regularly. However, hose maintenance programs may mean significant cost savings and improved plant safety. With a plan in place, your team will be able to replace fewer hoses while always having replacement parts. These results may mean increased profitability, increased security and reduced delays. Once your plant starts tracking, the numbers will prove the value of your investment.


Post time: Sep-18-2021