Op-ed: why it’s necessary to pressure test hose assemblies

Posted on 28 Jan 2025 by The Manufacturer

In this exclusive op-ed for The Manufacturer, Flextech’s Martin Robinson explores some of the reasons why it’s necessary to thoroughly pressure test hose assemblies before relying on them for real-world applications.

Pressure testing hose assemblies is essential for guaranteeing product safety and reliability. Industries such as manufacturing often operate in high-pressure environments that present unique challenges. A failure in a hose assembly can lead to catastrophic consequences, including significant damage to equipment, environmental hazards, and, most critically, serious injuries or fatalities.

Deconstruction tests intentionally push hoses beyond their working limits to identify potential points of failure. These tests optimise crimp or swage settings, ensuring that end connections remain secure even under extreme pressure. A key part of safety is ensuring that no fitting detaches from a hose, regardless of the conditions.

The necessity for pressure testing stems from the fact that the weakest point in any hose assembly is often its end connections. These connections endure immense stress and strain during operation. If a fitting detaches due to inadequate securement or wear, the results can be catastrophic. Pressure testing ensures that each hose and its connections are securely fastened and capable of withstanding the designated pressure, thereby protecting both operators and the surrounding environment.

Moreover, hose assemblies functioning in high-pressure systems face various conditions – such as extreme temperatures, rapid pressure changes, flexing, and pulsation – that can deteriorate their performance over time. A hose assembly that appears intact may still harbour internal weaknesses that can lead to sudden failure later on.

High-pressure hoses often transport hazardous materials. A rupture in such a system can result in leaks that not only damage equipment but also pose severe health and environmental risks. Pressure testing ensures the integrity of the hose assembly, preventing dangerous leaks and helping avoid potential compliance violations or costly shutdowns.

Hose assemblies should meet industry safety standards and provide a safety margin that exceed the working pressure. This process verifies that the assemblies can endure pressures significantly exceeding its intended use, ensuring durability and reliability in practical applications. For companies committed to safety, pressure testing is not just a regulatory obligation; it’s a fundamental practice that protects both personnel and operations.

Key reasons for pressure testing high-pressure hoses

  1. Safety assurance: High-pressure systems carry substantial risks. If a hose or its fittings fail, it can lead to dangerous situations, including equipment damage and severe injuries. Pressure testing ensures the hose assembly can safely handle the operational pressure without unexpected failures.
  2. Verification of performance: Pressure testing verifies that a hose assembly operates as intended under real-world conditions. It ensures the assembly can manage its designated operating pressure and provides a safety margin while identifying potential weaknesses or defects.
  3. Ensuring proper connection integrity: One of the most common failure points in high-pressure hoses is the end fittings. Pressure testing checks that crimp or swage connections are secure and will not detach during operation, crucial for preventing leaks or blowouts.
  4. Preventing costly downtime: Failures in high-pressure hoses can lead to expensive equipment downtime, costly repairs, and lost productivity. By pressure testing hoses before they enter service, companies can avert unexpected failures.
  5. Compliance with industry standards: Many industries impose strict safety and performance standards for high-pressure hoses, mandating pressure testing to meet regulatory requirements. Pressure testing guarantees compliance and ensures safe equipment operation.
  6. Identifying hidden weaknesses: Internal defects can develop due to material fatigue or manufacturing inconsistencies. Pressure testing reveals these hidden weaknesses by simulating real-world conditions, allowing for early detection of issues.
  7. Mitigating environmental and health hazards: A failure can lead to dangerous leaks or spills, posing risks to the environment and personnel. Pressure testing ensures that the hose can safely handle its contents under pressure, reducing the risk of accidental releases.

When a hose assembly bursts, the consequences can vary from minor disruptions to catastrophic failures. Here’s a breakdown of potential repercussions:

  1. Sudden release of pressure: A hose burst results in the immediate release of high-pressure fluid or gas, which can be explosive and cause significant damage.
  2. Fluid/gas leakage: The nature of the substance conveyed determines the hazards involved, which can include environmental contamination and severe burns.
  3. Damage to surrounding equipment: The sudden discharge can erode or damage nearby machinery, leading to additional failures.
  4. Danger to personnel: The primary concern is human safety, with risks including lacerations, burns, and hose whip injuries.
  5. Loss of system functionality: A hose burst often renders the entire system inoperable, leading to costly downtime.

Pressure testing is essential as helps identify vulnerabilities before they manifest as real-world issues. The last thing anyone wants is a near miss – or worse, a serious incident.

To eliminate risk and ensure products are always fit for purpose, Flextech has invested in a high-pressure test rig capable of testing hoses up to an impressive 2,000 Bar (29,000 psi). Each Flextech hose assembly undergoes rigorous testing before it is delivered, ensuring products are both safe and highly reliable.


About the author

Martin Robinson is the Managing Director of Flextech, bringing nearly 30 years of experience in the industrial products market.

Joining Flextech in 2014 as an External Sales Manager, Martin advanced to Sales Office Manager, Operations Director, and has served as Managing Director for the past four years.

In the past six years, the company has grown from a £2m annual turnover and 10 employees to a group of three companies with a £6m turnover and a 30-strong team.

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