Jim Reilly of The United Distribution Group, GHX Industrial, LLC, and Rick Pitman of PSC will discuss the proper use of hydraulic hose, from fabrication and assembly to industry drivers and field usage. They will also explain NAHAD’s role in improving hose standards and what engineering personnel need to know.

1. Safe Hose Assembly
From Factory to Field

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7. 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

8. Moderator Presenters
Mary Gannon
Design World
Jim Reilly
GHX
Rick Pitman
PSC
Debbie Mitchell
NAHAD

9. Hose Assembly Safety
Leveraging NAHAD’s Hose Safety Institute
and the
Hose Assembly Guidelines

10. 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)

11. Today’s Presenters
• Rick Pitman, VP EHST, PSC
• Jim Reilly, Region Manager, GHX
• Debbie Mitchell, Standards Program Director, NAHAD

12. 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

13. 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

14. 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

15. • 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

16. 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

17. How Do Failed Hose Assemblies Affect
Your Business?

18. 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

19. Specifying Your Hose Assembly:
STAMPEDS = Size
T = Temperature
A = Application
M = Material
P = Pressure
E = Ends or couplings
D = Delivery

20. 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?

21. 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

22. 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

23. 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

24. 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)

25. 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.

26. 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

27. • 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:

28. 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

29. 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

30. 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. 31
Protocol: Industry’s View of Hoses

32. 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

33. 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

34. 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

35. 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??

36. Questions?
Thank You!
For more information on the Institute: dmitchell@nahad.org
or
www.hosesafetyinstitute.com

37. Questions?
Mary Gannon
Design World
mgannon@wtwhmedia.com
Twitter: @DW_MaryGannon
Jim Reilly
GHX
jjreilly@ghxinc.com
Rick Pitman
PSC
rick.pitman@pscnow.com
Debbie Mitchell
NAHAD
Dmitchell@nahad.org

38. Thank You
q This webinar will be available at
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