Hydraulic Hose Inspection: Steps to Ensure Equipment Safety and Efficiency

Hydraulic hoses are essential components of hydraulic systems that power heavy-duty machinery and equipment used in an extensive range of industrial applications, including mining, manufacturing, oil and gas, construction, food and beverage, agriculture, and more. As such, ensuring the proper functioning and maintenance of hydraulic hoses is necessary to keep your hydraulic-powered equipment and machinery running efficiently and safely. This makes routine hydraulic hose inspection absolutely essential.

In this article, we will explore the key elements of hydraulic hose inspection – from the importance of hose inspection to the step-by-step hose inspection process and the importance of implementing a proper hose inspection program to help you better protect your equipment and employees.

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Why is Hydraulic Inspection Important?

Hydraulic hose failure can lead to critical safety hazards, significant system downtime, and even environmental pollution. By proactively inspecting your hydraulic hoses and fittings, you can readily identify potential hose issues early enough before they escalate into critical issues.

Key advantages of regular hydraulic hose inspection

• Increased Reliability and Longevity: Routine inspections ensure that your hydraulic systems always run smoothly and efficiently. By detecting and addressing problems before they lead to major malfunctions, you can extend the service life of your hydraulic components.
• Enhanced Safety: Hose failures can lead to fluid spills, equipment damage or accidents, putting your operations and workers at risk. You can prevent hose failures and improve safety by regularly inspecting your hydraulic hoses.
• Reduced Downtime: Periodic inspection of hydraulic hoses allows for timely replacements or repairs, reducing the risk of unplanned system downtimes.
• Reduced Maintenance Costs: Regular hydraulic hose inspections help prevent costly emergency maintenance and equipment downtime by enabling early detection and resolution of hose issues.

When to Inspect Your Hydraulic Hoses

Various factors influence the frequency of hydraulic hose inspections. Here are a few guidelines to help you better plan your inspections.

1. Manufacturers’ Recommendations

Manufacturers’ recommendations are based on extensive testing and are adapted to the specific features of the hose and its operating conditions. You should, therefore, consult your equipment’s operating manuals to establish a suitable preventive inspection program.

2. Equipment Mobility

Generally speaking, mobile hydraulic equipment is subject to constant movement and vibration (e.g., construction machinery). An inspection is generally recommended every 400 to 600 hours of operation or every three months.

On the other hand, stationary hydraulic equipment is subject to less movement and vibration and should be inspected every three months.

3. Critical Nature of Hydraulic Equipment

You should inspect critical equipment (e.g., heavy construction equipment, emergency response vehicles) more frequently. This helps prevent costly breakdowns and major hose failures.

4. Operating Conditions

Specific operating and environmental conditions accelerate material wear. If your equipment is subject to one or more of the following conditions, more frequent inspections are recommended:

• Extreme environments – very hot or very cold
• High-pressure hydraulic systems
• Exposure to severe conditions – corrosive chemicals, seawater, abrasive dust

5. Usage Type and Intensity

Continuous use or use at full capacity accelerates wear and tear on hydraulic equipment, requiring more frequent inspections. Similarly, applications involving rapid cycling or instantaneous pressure variations also require closer monitoring.

6. Equipment Accessibility

When your equipment hoses are hidden or difficult to access, you’ll need to schedule specific periods of downtime for a complete inspection. It is essential to prioritize the inspection of critical hoses that are difficult to see or monitor.

Step-by-Step Hydraulic Hose Inspection Process

1. Pre-Inspection Safety Protocol

Safety is the cornerstone of any maintenance routine, including hydraulic hose inspections. Hydraulic systems oftentimes operate at very high pressures, and a safety hazard during the hose inspection procedure can endanger personnel, equipment, and the environment. A complete pre-inspection safety strategy involving the following is thus of utmost necessity.

• Safety Standards and Regulations: Refer to the maintenance manuals provided by your hose manufacturer for guidelines on the safety standards and regulations to adhere to and precise operating parameters to recalibrate after hose inspection, such as working pressures, fluid types and levels, and operating temperatures.
• Inspect Safety Equipment: Check the availability and condition of required personal protective equipment (PPE).  Also, ensure that spill containment kits are available to deal with unforeseen fluid spills.
• Depressurize the Hydraulic System: Before beginning the hose inspection process, all pressure in the hydraulic system must be released. Pressure relief valves can be used to do this. Lockout/tagout (LOTO) safety procedures should also be implemented to ensure the system remains depressurized throughout the entire inspection process.
• Assess the Work Environment: Examine your work area for possible dangers, such as fluid leaks that can cause slippery floors, clutter that could obstruct access to hoses or provide tripping hazards, and poor lighting that could mask faults.

2. Initial Visual Assessment

The initial visual assessment is a vital phase in the hydraulic hose inspection process. It allows for a systematic examination of the external condition of hydraulic hoses before proceeding with more in-depth tests. When appropriately executed, initial visual assessment enables early detection of obvious hose flaws/defects, lowering the risk of system failure and downtime. It entails the following:

• Develop a methodical sequence: Begin at one end of the hose assembly and work your way to the other, taking care not to ignore any sections.
• Prioritize high-risk zones: Concentrate on the hose sections prone to movement, flexing, or abrasion, as these are frequent failure spots.
• Use appropriate lighting: Proper lighting is required to identify fine cracks, leaks, and other minor indicators of wear.

The key elements to examine during the Initial Visual Evaluation process include:

External Hose Surface

• Assess for abrasions and wear: Check the hose’s outer cover for scuffs, cuts, or worn areas from contact with equipment or surfaces.
• Check for cracks or signs of aging
• Check for swelling or blistering

End fittings and Couplings

• Check for correct seating and attachment: Ensure that end fittings are securely attached with no gaps, misalignments, or rotation visible.
• Inspect for corrosion or rust: Metal fittings that are exposed to moisture, chemicals, or severe environments may corrode, reducing their strength and sealing capacity.
• Inspect the crimp integrity: Confirm the regularity and quality of crimped fittings.

Connections and Interfaces

• Examine the sealing areas: Look for signs of leaks, residue, or seeping fluid at the contact between the hose and its connection points (such as ports or manifolds).
• Assess for contamination: Dirt, grease, and other debris around connections can degrade sealing and hasten wear.
• Confirm compatibility: To avoid chemical reactions or component deterioration, ensure that the hose and fitting materials are compatible with the hydraulic fluid in use and the operating environment.

3. Leak Detection and Assessment

Identifying fluid leaks is crucial. This process demands a systematic approach to guarantee that leaks are accurately and securely identified, avoiding escalation to more serious issues such as fluid contamination, pressure loss, or environmental dangers. It involves the following.

A) Proper cleaning and preparation procedures

Before initiating any leak detection activity, cleaning and preparation are required to ensure visibility, accuracy, and safety. The following steps are involved in this procedure:

1. Clean external surfaces

• Use a suitable cleaning product to remove dirt, grease, and debris from the hose assembly, fittings, and connections (for example, a biodegradable degreaser or isopropyl alcohol). This guarantees that leaks are not hidden behind contaminants
• To avoid introducing new pollutants, use lint-free towels while cleaning sensitive components.
• When dealing with dangerous hydraulic fluids, make sure to utilize personal protection equipment (PPE) such as gloves, goggles, and aprons while cleaning.

2. Assess the area for residual fluid

• After cleaning, check the immediate area for any remaining fluid or stains that could indicate an existing leak. This process identifies potential issue areas and narrows the scope of the inspection.

3. Prepare leak detection tools

• Assemble tools like UV dye kits (for hydraulic systems with fluorescent tracers), leak detection sprays, and adequate lighting (UV or bright LED).
• Check that all tools are in good operating order and appropriate for the hydraulic fluid and system materials.

B) Systematic Leak Detection Process

A systematic leak detection strategy guarantees that hydraulic hose leaks are readily uncovered and with the least danger to personnel and equipment. The process consists of the following main steps:

• Visual inspection under safe conditions
• Use of leak detection fluids and sprays
• Pressurize the system gradually
• Use UV dyes and lighting
• Inspect high-risk areas first

Note: If the hose leak is serious or involves hazardous hydraulic fluids, isolate the damaged area and adhere to existing fluid containment protocols. Use absorbent pads or trays to reduce environmental impact and job hazards.

4. More Physical Assessment

A comprehensive physical inspection of hydraulic hoses guarantees the detection of minor faults that may be missed during initial visual checks. This stage assesses the hose’s mechanical qualities, structural soundness, and thermal performance to detect probable failure sites. It entails the following:

A) Hose Flexibility Testing

Bend Radius Verification

• Test the hose’s ability to maintain integrity when bent to the lowest recommended radius.
• Use a measuring tool to ensure that the bend does not go beyond the manufacturer’s specifications. Excessive bending stresses the reinforcing layers, causing early failure.
• Inspect the hose for kinking, which may occur when the bend radius is compromised. Kinks impede fluid flow and reduce structural strength.

Stiffness Evaluation

• Flex the hose lightly along its length to assess its rigidity.
• Compare the observed stiffness to the expected flexibility based on the hose type and application.
• Increased stiffness may suggest aging, material degradation, or exposure to incompatible fluids, whereas exceptional softness may indicate interior structural damage.

Detecting Soft Spots or Sponginess

• Run your hands along the length of the hose to look for soft places or spongy areas.
• These locations frequently show delamination of the hose layers, deterioration of the internal reinforcement, or fluid leaks into the outer layers.
• Soft areas can be the forerunner to catastrophic breakdown, especially in high-pressure systems.

B) Length Change Measurements

• To detect elongation or contraction, measure the hose length at both no-pressure and operating pressure.
• Record changes with a tape measure or caliper, then compare them to the manufacturer’s tolerances.
• Significant length changes could indicate reinforcing layer degradation, high internal pressure, or thermal expansion concerns.
• Document measurements for future comparison, especially in systems that undergo repeated pressurization cycles.

C) Structural Integrity Evaluation

Layer-by-Layer Inspection

• Examine for exterior cover damage, which may expose the reinforcement layers to environmental degradation.
• Examine the reinforcement layers (if visible due to damage) for evidence of fraying, rusting, or weakening.
• Examine the internal tube (if accessible) for erosion, cracking, or swelling, especially in systems using abrasive or incompatible fluids.

Pressure Test Assessment

• If applicable, do a hydrostatic or pneumatic pressure test to ensure that the hose can handle working and burst pressures.
• During the pressurization process, keep an eye out for leaks, deformation, or odd noises.
• When conducting pressure testing, always follow safety guidelines and utilize calibrated equipment.

D) Temperature Assessment

Check the surface temperature

• To measure the surface temperature of the hose while in operation, use a non-contact infrared thermometer or a thermal camera.
• Compare the observed temperatures to the hose’s rated limits. Overheating can cause material deterioration, hardness, and blistering.

Cold Weather Flexibility

• Flex the hose in low-temperature conditions to keep it pliable. Hoses that stiffen or crack in cold weather may be unsuitable for such operating environments and should be replaced with an appropriate alternative.

Environmental and Fluid Compatibility

• Determine whether the pipe is exposed to external heat sources (for example, the machines or exhaust systems nearby) that exceed its temperature tolerance.
• Check that the hydraulic fluid temperature stays within the manufacturer’s recommended range. Excessively high fluid temperatures hasten hose aging and shorten service life.

5. Fitting and Connection Inspection

Hydraulic hose fittings and couplings are essential components for a secure and leak-free system. A thorough hose inspection and repair of these components can reduce system inefficiencies, fluid loss, and potential safety issues. This section examines two key aspects of fitting and connection inspection:

A) Detailed Examination

• Examine fittings for rust, cracks, or distortion that could compromise integrity.
• Ensure proper alignment to avoid uneven tension or leaks.
• Use calibrated tools to ensure that fittings are tightened to the manufacturer’s specified torque.
• Ensure that fittings are securely fastened with no gaps or movement.
• Check for frayed reinforcements, which indicate wear or poor crimping.

B) Proper Tightening Procedures and Tooling

• To avoid damaging fittings or threads, use appropriate instruments (e.g., torque wrenches).
• To prevent leaks, clean the threads and seal the surfaces.
• Sealants or tape should be applied as directed but not excessively.
• Tighten fittings to the stipulated torque levels and use systematic sequences for multi-point connections.

What are the Common Signs of Wear and Tear in Hydraulic Hoses?

Listed below are visible/ physical signs that indicate an imminent hydraulic hose failure requiring immediate attention.

Critical Warning Signs

• Hose cover abrasions or surface damage
• Hose cracks or cuts
• Hose bulging or blistering
• Hydraulic leaks or fluid seepage
• Deformation or kinks
• Corrosion on fittings
• Exposed reinforcement layer

System Performance Indicators

• Reduced system pressure
• Audible indicators
• Excessively high operating temperature
• Erratic or slow system response
• Hydraulic fluid contamination

For more information, kindly refer to our article on common hydraulic hose failures and how to solve them.

The Importance of Implementing an Inspection Program

As mentioned above, by identifying potential hydraulic hose problems in advance, your company can reduce downtime, extend equipment life, and enhance workplace safety. That’s why it’s so important to implement an effective inspection program to prevent major issues with your hydraulic systems.

The following practices contribute to a comprehensive hydraulic hose inspection program.

Creating a Hose Inspection Routine

Establishing a hose inspection routine ensures system reliability and prevents costly breakdowns. The frequency of your inspection should align with the operating conditions, equipment type, and usage – with high-pressure systems requiring more frequent checks. A thorough program includes pre-operation inspections, periodic assessments (weekly or monthly), and comprehensive annual evaluations to detect wear early and maintain efficiency.

Documentation and Record Keeping

Maintaining detailed records for each hose inspection is essential for compliance and preventive maintenance. Documenting the date, findings, and corrective actions will help track recurring issues and aging components. Well-kept records support industry standards, aid in audits, and provide evidence of due diligence in case of your equipment failure investigations.

Leveraging Professional Inspections

Integrating professional hose inspections into your inspection program enhances safety, reliability, and compliance with industry standards. Certified hydraulic technicians use advanced tools to detect issues like internal damage that routine checks may miss. These inspections often include pressure testing, thermal imaging, or material analysis, providing deeper insights into system integrity for high-risk or critical operations.

Conclusion

Hydraulic systems play a vital role in the operation of many modern industries. Their reliability and safety depend directly on the condition of hoses, fittings, and other components. This article has presented a detailed approach to hydraulic hose inspection, covering the following aspects:

• Safety before inspection
• Visual and physical assessments
• Leak identification
• Fitting assessment
• The importance of a structured inspection program

With this detailed list of best practices in hydraulic hose inspection, we hope you’ll be able to better identify and proactively correct hose problems, ensuring equipment safety and efficiency while avoiding costly downtime.

In essence, a rigorous hose inspection routine backed by accurate documentation and regular professional assessments will not only extend the life of your hydraulic system but will also improve operational efficiency and workplace safety.

Need specialized assistance?

Marshall Equipment’s team specializes in hydraulic hoses, hydraulic hose assemblies, and hose repair. We are available to answer any questions you may have following your hydraulic hose inspection and common hydraulic hose problems. Do not hesitate to contact us!