Routine Inspection and Lifespan Management of High-Pressure Rubber Hoses – Practical Experience from

Even the best high-pressure rubber hoses can have significantly reduced lifespans without proper inspection and management. Statistics show that a considerable proportion of hose failures stem from inadequate daily inspections and exceeding their service life. This article summarizes the key points for inspecting high-pressure rubber hoses and lifespan management methods from a frontline maintenance perspective.

I. Pre-Operation Inspection: Three Checks

Checking the integrity of the hose before each operation is paramount. Carefully inspect its appearance to ensure there are no cracks, wear, or other damage.

1. **Appearance Check:** Before starting each shift, operators should quickly check the outer rubber layer for cracks, bulges, or exposed wear lines; check for sludge buildup at joints (an early sign of leakage); and check for stretching and whitening at bends.
2. **Temperature Check:** Touch the hose surface with the back of your hand. If there is a localized abnormally high temperature (a section significantly hotter than adjacent areas), it may indicate internal throttling or friction.
3. **Joint Check:** The hose connection points are potential leak points. Carefully check the condition of the sealing rings before and after connection to ensure there is no aging or damage.

II. **Regular Inspection: Three Checks:** High-pressure hoses used for extended periods require regular inspection. It is recommended to check the surface wear and aging, and the wear of the joints weekly.

Check for pulse fatigue: For hoses used for more than 18 months, a pressure test can be performed before the replacement cycle to confirm whether the pressure-bearing capacity has decreased. Check for hardness changes: Use a Shore hardness tester to measure the hardness of the outer rubber layer. If it is significantly higher (harder) than a new hose, it indicates that the rubber has aged. Check wall thickness: If available, an ultrasonic thickness gauge can be used to detect changes in wall thickness at key locations.

III. Replacement Criteria

Hose with the following defects should be replaced immediately: perforations, cracks, tears, exposed reinforcing layers, crazing, severe oxidation; localized deformation, blistering, expansion under pressure; severe corrosion or loosening of joints. The service life of a hose is generally 3-5 years. If signs of aging such as hardened outer rubber or exposed steel wires appear, immediate replacement is necessary.

For high-pressure, high-viscosity, high-temperature, harsh operating environments, and frequent dragging applications, the service life of high-pressure hoses is recommended not to exceed 2 years.

IV. Storage and Handling Requirements

Do not store hoses outdoors to avoid aging and contamination caused by sunlight. If a used high-pressure hose is not used for an extended period, the internal material should be thoroughly cleaned before sealing and storing it. Avoid stacking or deformation during storage, and keep it in a cool, dry place.

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