How to Properly Route Industrial Hose for Safer, More Reliable Fluid Systems

Industrial hoses can help keep your processes safe and cost-effective. Because hose lends itself to convenient bending and routing, system designers can eliminate many of the connectors required when using rigid materials.

However, improper installation can undermine your process, put personnel at risk, and compromise your bottom line.

One of the most important aspects of hose installation is proper routing. In this video, you'll learn best practices that should be followed when routing and installing hoses.

The leading cause of hose failures in the field is poor routing practices. The most common outcome of improper routing is kinking.

Kinking occurs when a material is bent beyond its elastic limit and becomes permanently deformed. If the hose core wall is damaged, the hose may no longer maintain its full working or burst pressure. The resulting leaks, ruptures, or bursts can be both costly and potentially dangerous.

Kinking damage can occur for several reasons, typically related to how the hose is installed and routed.

First, the hose may have been routed without consideration of its minimum bend radius. Installing a hose with bends smaller than those recommended by the manufacturer can lead to kinking, shortened hose life, leakage, or rupture.

Hose rupture or leakage can also result from bending too close to the hose's end connection. It is recommended to allow a minimum straight length of hose equal to at least two times the hose's outer diameter before starting any bend.

Next, excessive hose strain due to improper routing can also lead to kinking or other failure modes.

For example, if a hose exits a wall or fitting horizontally, gravity will continuously pull down on the hose and create stress at the end connection. Over time, this can damage the hose.

Elbows and adapters should be used to reduce hose strain at connection points. Hoses are sometimes installed without elbows and adapters as a perceived cost-saving measure, but in the long run, the cost of hose failure is often far greater.

In dynamic applications, excess motion can cause a hose to kink if it is the wrong length for the application or has been routed incorrectly.

It is important to determine hose length while considering the full range of motion the hose may encounter during operation. Dynamic bend radii should always be larger than static bend radii because the hose experiences additional strain when subjected to continuous movement.

Proper hose length helps distribute movement and prevents bends that are smaller than the hose's minimum bend radius. Allow enough hose length to accommodate motion and pressure fluctuations within the system.

Another common cause of failure in dynamic applications is bending the hose across multiple planes.

While a static hose bent in multiple planes may have a long service life, dynamic motion causes repetitive twisting in the same area of the hose. This can damage the hose core material or loosen the end connections, leading to premature hose failure.

To avoid twisting, ensure bending occurs in only one plane by using elbows, adapters, and other methods of securing the hose.

Proper routing is key to maximizing hose life and performance.

Remember to:

• Always follow the manufacturer's minimum bend radius recommendations.
• Use elbows and adapters to relieve hose strain.
• Properly size hoses to accommodate dynamic motion and pressure changes.
• Never bend a hose across multiple planes in dynamic applications.

By following these routing best practices, you can contribute to safer, more reliable hose operation.

For more information about hose installation, hose routing, and hose advisory services, contact your local authorized Swagelok Sales and Service Center today.