safe hose assemble: from factory to field
TRANSCRIPT
Safe Hose Assembly From Factory to Field
Thank You To Our Sponsor
ERP Business Management Software for Hose
& Fluid Power Distributors/Fabricators
Tribute offers:
• Business management software designed for hose distributors
• 32 years expertise in hose & fluid power
• Hose Assembly Generator with Cut Length Calculator & Crimp Instructions
• Counter Sales & Lot Control
• Serial Number Labeling and much more
Our Partners are Your Partners
Use our ROI calculator to see the benefits of TrulinX Software at www.tribute.com
We Know Hose!
q This webinar will be available afterwards at www.designworldonline.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar
Before We Start
Moderator Presenters
Mary Gannon Design World
Jim Reilly GHX
Rick Pitman PSC
Debbie Mitchell NAHAD
Hose Assembly Safety
Leveraging NAHAD’s Hose Safety Institute and the
Hose Assembly Guidelines
Agenda • Welcome – brief overview of NAHAD and the Hose Safety
Institute • Hose Assembly Safety – Why worry? • Case study: Hose safety in the Hydroblast industry (PSC/
GHX perspective)
Today’s Presenters • Rick Pitman, VP EHST, PSC • Jim Reilly, Region Manager, GHX • Debbie Mitchell, Standards Program Director, NAHAD
The Association for Hose & Accessories Distribution (NAHAD)
Globally recognized association with over 500 member companies
Offers a unique set of industry guidelines for the specification and fabrication of hose assemblies
Reflecting industry best practices to ensure the safest,
highest quality, most reliable hose assemblies
Performance standards for the specification, design,
fabrication and packaging of hose assemblies
Industry consensus best practices to ensure the safest, highest quality, most reliable hose assemblies
1. Chapters on industrial, hydraulic, composite, fluoropolymer and corrugated metal hose assemblies
2. Guidance on
Design & specification Testing Shipping & handling Quality And much, much more…
Supplemented by on-line fabrication guides
The result of their efforts is the Hose Safety Institute Handbook
• Promotes Guideline usage and adoption throughout the industry
• Provides enhanced employee training and recognition opportunities.
• Delivers powerful marketing advantages (differentiation) • Connects End-users with HSI Distributors
End-User Advisory Council
• Includes: end-users, experts, related standards groups and regulatory agencies
• Identifies emerging issues and critical applications related to hose assemblies
• Serves as a forum for addressing industry issues, providing appropriate input to the NAHAD Standards Committee and ensures ongoing industry dialogue and communications
• Identifies and engage industry organizations and related agencies involved in, or impacting, hose safety, quality and reliability
How Do Failed Hose Assemblies Affect
Your Business?
Safe Hose Assemblies Add to Your Bottom Line
Through Lowering Your Costs… ü Fewer accidents
ü Lost employee time, potential law suits ü Environmental impact
ü clean-up costs of spills ü fines
ü OSHA fines for safety issues
ü Less unplanned equipment down time
And increased worker productivity
Specifying Your Hose Assembly: STAMPED S = Size
T = Temperature A = Application M = Material P = Pressure E = Ends or couplings D = Delivery
STAMPED S = Size: ID/OD, flow rate / fluid velocity T = Temperature: fluid temp AND ambient temp A = Application:
o how the hose will be used (impulse, flexing, vacuum) o Static discharge considerations o Non-Conductive Hose Required? o Excessive Abrasion? o Routing Requirements? o Where Will Hose be Used? o Fluid compatibility?
STAMPED M = Material: fluid being conveyed, type and concentration (specialized oils or chemicals?) P = Pressure: system pressure and spikes E = Ends or couplings – compatibility between hose and couplings (same manufacturer) D = Delivery: • any special considerations for testing, cleaning, packaging, or
delivery • note: cleanliness is key for hydraulic systems
Safe, reliable hose assemblies require appropriate Testing
Test What It Tells You Comments Hydrostatic proof pressure Pressure integrity of the hose assembly;
appropriate component selection; can be used to measure elongation or length changes under pressure
proper pressures are crucial so as to avoid hose deformation
Hydrostatic burst pressure At what pressure the hose will burst Destructive test
Leak test Tests for leak paths in the assembly Typically uses air or helium under water
Electrical continuity Is there a grounding path for the assembly; does the assembly conduct electricity
Measured by a calibrated multi-‐‑meter
Hydrostatic Proof Pressure Testing For assembly testing, the rating of the component with the
lowest rated working pressure determines the working pressure of the assembly.
Hose Type What pressure How long Industrial 1 ½ times working pressure for new and used
assemblies 5 minutes
Hydraulic 2 times working pressure 30-‐‑60 seconds Composite
1 ½ times working pressure 1-‐‑4” nominal bore: 5 minutes >4” nominal bore: 30 minutes
Fluoropolymer 1 ½ times working pressure 1 minute Corrugated Metal At the maximum test pressure of the assembly Minimum of one minute
Project: Raising the Bar for Safety in the Hydroblast Industry • Advisory Council Member: Rick Pitman • NAHAD Member: Jim Reilly, GHX • Objective: Create recommended best practices for
hose assemblies to provide guidance to end-users, distributors, and others involved in the hydroblast industry (up to 40,000 psi)
Background • The Hydroblasting industry:
o high pressure equipment o diverse and time critical applications. o lack of agreed upon hose standards or best practices
• Hydroblasting - high risk craft if not managed properly • Needed: comprehensive approach to improve hose safety:
o standard equipment design and maintenance o best practices for use and management
• Focus here on best practices in standard equipment design relating to hose assemblies based on input from hydroblasting contractors and hose and equipment manufacturers and distributors.
Why the Project? • Strategic value for PSC – business operations and safety
o Creating an industry response to an area with little or no guidance regarding safety/quality
• Engaged the full supply chain • Guidance to industry on how to more effectively (safely)
manage Hydroblast hose • Created an opportunity for Distribution to provide
consultative assistance to a customer, and a joint solution
• Documents best practices for ensuring safety and reliability of Hydroblast hose assembly applications (5,000 – 55,000 psi)
• Represents the consensus of contributing companies and organizations
• Provides recommended best practices in the design, fabrication, and on-going maintenance of hose assemblies used in Hydroblasting applications
Result: A Whitepaper that:
What’s New?? Hydroblast hose assemblies are recognized as Assets, not just
consumable items Hose Management Program • Asset Management • Proper Use and Care Program • Inspection Program • Failure Inspection Program • Training Program to support all of the above, including documented
hands-on competency verification
Inspections • Pressure testing • Visual inspection
o Leaks at the hose fittings or in the hose o Damaged, separated or pulled back covers o Cracked, damaged, deformed or badly corroded fittings o Other signs of significant deterioration such as blisters
o Compromised reinforcement where the wires are exposed, broken or corroded
Inspections • Visual inspection - continued
o Dents, twists, or kinks
(torque can tear loose the reinforcement layers and allow the hose to come through)
o Discoloration of color coded hose cover o Verify test date and pressure are in conformity with requirements for the application o Fitting Thread and seat condition
31
Protocol: Industry’s View of Hoses
Mechanical Integrity Program High Pressure Hoses High Pressure Hose Iden6fica6on
PSC Loca)on Manufacture Date Asset Number Pressure Ra)ng
209 1111 0032 20K
New fi&ings on every hose with etched number system
– GHX Asset Tracking System • Online Asset Management of PSC Hoses
• Web-‐‑Accessible to end users • Tracks all inspection, maintenance and testing data
Tracking System
COMPLETE – January 2012
10K - Yellow
20K - Blue 40K - Orange
15K - Green
Hose Mechanical Integrity Program High Pressure Hoses
Collaborative design team: • Operations • Engineering (Vendor) • Safety
Result: • Standardize all field hoses • Independent testing and tracking
• One field training program • Identical parts inventory (in field)
• RCAF process for all losses/near losses
• Strict procurement control
Field testing of prototypes • Feedback used to refine final
design
PSC Loca)on Manufacture Date
Asset Number Pressure Ra)ng
209 1111 0032 10K
Etched number system on all hoses after Jan 13th
Etched number system on all hoses after Jan 13th
Etched number system on all hoses after Jan 13th
Mechanical Integrity Program Loss and Near Loss Tracking
PSC High Pressure System -‐ Loss and Near Loss Tracking PSC# Date Loca)on RMA # Asset # Level PSI Qty Asset Type Failure Type What Happened Current Status Failure Cause Long Term Ac)on Status
PSC0001 12/1/2011 Carrolton, KY II 10k & 20k 7 1/2" Supply Abrasive Cover Sharp edges on Ferrule loca6on shrink wrapped the ferrule Bad cut on the Ferrules Shrink wrap on the Ferrule Closed
PSC0002 12/21/2011 Calvert City PSC002 139-‐1211-‐0002-‐20K IV 20K 1 whip hose ( ") Hose Whip hose failed outside of shroud
Plan to address the kink in progress NLT 2/12; GHX inves6ga6ng using lay flat to cover opening of shroud. Locally not using 20k guns
Spir Star determined the whip had kinked and weakend the hose at that spot where the failure occurred
en6re hose assembly be protected within the safety shroud or at minimum have a form of abrasion/kink resistance, such as a protec6ve cover, installed on the hose assembly for any por6on of the assembly that will not be enclosed within the safety shroud.
Closed
PSC0003 1/6/2012 Westlake, LA IV 10K 2
(2) 20mm engine whip from the fuid end to manifold
Hose pump whip hoses both failed at the same 6me from pump end to pump manifold
checked pump for defects none found. sent to GHX and Spir Star for evalua6on 01-‐09-‐2012
Manufacturer defect Spir star sent to replacement hoses at no cost. Closed
PSC0004 1/10/2012 Granite City 9175977 563-‐1211-‐0001; 563-‐1211-‐0003 thru 563-‐1211-‐0005
I 10k 4 1/2" Supply Hose Four hoses in same lot that the crimp failed
GHX s6ll wai6ng to receive the four to ensure they were crimped correctly. Haven't shipped yet nor asked for an RMA number; shipped 1-‐30-‐2012
Open
PSC0005 1/10/2012 Cahoes, NY 9165161
209-‐1111-‐0003-‐ 10k thur 0005-‐10k; 209-‐1111-‐0008-‐10k & 209-‐1111-‐0015-‐10k
II 10k 6 1/2" Supply Abrasive Cover PVC abrasive cover pulled off and Ferrules were digging into side of hose / rubber
sent to GHX 01-‐11-‐2012 . It was shipped FedEx freight ATT Jose Juarez tracking# 222029096-‐2 on January 16th at 2pm.
Open
PSC0006 1/10/2012 Granite City 9165714 563-‐1211-‐002-‐10k 563-‐1211-‐0006-‐10k IV 10k 2 1/2" Supply Hose
Two hoses one used as a line mole with PVC cover cover pulled off possible rupture and the foot dump to the pump the hose failed.
Sent to GHX 1-‐12-‐12; Received at GHX 1-‐13-‐12, GHX did quick review and sent to Aero quip
hose #1 failed due to crimping issue; hose #2 had not failed although the PVC abrasive cover pulled back.
GHX completed Ini6al Report 1/13/12 Eaton Failure Analysis completed. PSC_004 report completed for PSC Review. GHX has modified their Procedure to mark hose fikngs, root cause was fikng blew off based on Eaton Report. See PSC_004 Report sent to Sean
Closed
PSC0007 1/11/2012 Woods Cross I 20K 11 1/2" Accessory Hose quaran6ned due to being built in the same batch as the Granite City hoses
inves6ga6on revealed that the hoses would not have been affected. No Failure found quaran6ne liled Closed
Allows “NEXT DAY” quarantine of other hoses manufactured in same lot number across the country
Failure at one PSC location….
3rd Party engineering review of failed equipment….
Provides basis for new operating procedure and new equipment requirement
On the Horizon • Next project: ….
o Liquid Vacuum (petroleum transfer) Hose Assembly Best Practices o Hose Assembly testing practices (Smithers Rapra) o Tank Truck Hose – Petroleum and Chemical Transfer o Steam Hose o Hydraulic Hoses?? (What issues most impact safety?) What are
YOU or YOUR CUSTOMERS interested in??
Questions?
Thank You! For more information on the Institute: [email protected]
or
www.hosesafetyinstitute.com
Questions? Mary Gannon Design World [email protected] Twitter: @DW_MaryGannon
Jim Reilly GHX [email protected]
Rick Pitman PSC [email protected]
Debbie Mitchell NAHAD [email protected]
Thank You q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com