Destruction Testing Hose Assemblies: Why It’s Necessary and Why We Do It

Pressure testing hose assemblies is essential for guaranteeing product safety and reliability. Industries such as oil and gas, manufacturing, hydraulics and chemical processing often operate in high-pressure environments that present unique challenges. A failure in a hose assembly can lead to catastrophic consequences, including significant damage to equipment, environmental hazards, and, most critically, serious injuries or fatalities.

At Flextech, we fully understand the importance of safety and reliability, which is why we manufacture assemblies capable of withstanding pressures of up to 550 Bar (8,000 psi). At these levels, a failed connection could result in a catastrophic, potentially fatal, incident so we also test them vigorously under controlled conditions.

Understanding the Need for Pressure Testing

To eliminate risk and ensure our products are always fit for purpose, Flextech has invested in a high-pressure test rig capable of testing hoses up to an impressive 2,000 Bar (29,000 psi). This allows us to thoroughly test every hose assembly, giving us the assurance that our products are both safe and highly reliable.

While it may sound unusual, there’s a certain satisfaction in conducting "destruction tests" on hoses. These tests intentionally push hoses beyond their working limits to identify potential points of failure. These tests enable us to optimise crimp or swage settings, ensuring that end connections remain secure even under extreme pressure. It’s a key part of our commitment to safety, ensuring that no fitting detaches from a hose, regardless of the conditions.

The necessity for pressure testing stems from the fact that the weakest point in any hose assembly is often its end connections. These connections endure immense stress and strain during operation. If a fitting detaches due to inadequate securement or wear, the results can be catastrophic. Pressure testing ensures that each hose and its connections are securely fastened and capable of withstanding the designated pressure, thereby protecting both operators and the surrounding environment.

Moreover, hose assemblies functioning in high-pressure systems face various conditions—such as extreme temperatures, rapid pressure changes, flexing, and pulsation—that can deteriorate their performance over time. A hose assembly that appears intact may still harbour internal weaknesses that can lead to sudden failure later on.

Pressure testing helps identify these vulnerabilities before they manifest as real-world issues, enabling our customers and operators to replace or repair faulty components proactively.

High-Pressure Risks and Their Consequences

High-pressure hoses often transport hazardous materials like chemicals, oils, or gases. A rupture in such a system can result in leaks that not only damage equipment but also pose severe health and environmental risks. Pressure testing ensures the integrity of the hose assembly, preventing dangerous leaks and helping avoid potential compliance violations or costly shutdowns.

By conducting pressure tests at our factories, Flextech can be confident that our hose assemblies meet industry safety standards and provide a safety margin that exceed the working pressure. This process verifies that the assemblies can endure pressures significantly exceeding its intended use, ensuring durability and reliability in practical applications. For companies committed to safety, pressure testing is not just a regulatory obligation; it’s a fundamental practice that protects both personnel and operations.

Key Reasons for Pressure Testing High-Pressure Hoses

1. Safety Assurance: High-pressure systems carry substantial risks. If a hose or its fittings fail, it can lead to dangerous situations, including equipment damage and severe injuries. Pressure testing ensures the hose assembly can safely handle the operational pressure without unexpected failures.
2. Verification of Performance: Pressure testing verifies that a hose assembly operates as intended under real-world conditions. It ensures the assembly can manage its designated operating pressure and provides a safety margin while identifying potential weaknesses or defects.
3. Ensuring Proper Connection Integrity: One of the most common failure points in high-pressure hoses is the end fittings. Pressure testing checks that crimp or swage connections are secure and will not detach during operation, crucial for preventing leaks or blowouts.
4. Preventing Costly Downtime: Failures in high-pressure hoses can lead to expensive equipment downtime, costly repairs, and lost productivity. By pressure testing hoses before they enter service, companies can avert unexpected failures.
5. Compliance with Industry Standards: Many industries impose strict safety and performance standards for high-pressure hoses, mandating pressure testing to meet regulatory requirements. Pressure testing guarantees compliance and ensures safe equipment operation.
6. Identifying Hidden Weaknesses: Internal defects can develop due to material fatigue or manufacturing inconsistencies. Pressure testing reveals these hidden weaknesses by simulating real-world conditions, allowing for early detection of issues.
7. Mitigating Environmental and Health Hazards: A failure can lead to dangerous leaks or spills, posing risks to the environment and personnel. Pressure testing ensures that the hose can safely handle its contents under pressure, reducing the risk of accidental releases.

High-Pressure Testing: A Key to Safety

At Flextech Hose Solutions Ltd, we recognise that high-pressure testing is essential for helping our customers minimise risks and ensuring hose assemblies meet the highest safety standards. Our investment in a high-pressure test rig capable of testing hoses at pressures up to 2,000 Bar (29,000 psi) allows for thorough inspection of each hose assembly before delivery.

How do we Pressure Test a Customer’s Existing Assembly?

1. Low-Pressure On-Site Testing Method: For customers needing a convenient, on-site solution, Flextech can visit the customer’s location and set up a manual test rig. Each hose is tested to 1.5 times its working pressure, ensuring its durability under expected operating conditions. Once tested, results are recorded and securely uploaded to our online hose register, maintaining accurate records for the customer.
2. High-Pressure Testing in Controlled Environments: When higher pressures are required, we conduct testing in a strictly controlled, enclosed environment at our facilities. Some customers send hoses back to us for re-testing and certification—especially those without on-site access to the online register, or those who manage a low volume of hoses. This approach eliminates the need for a Flextech team to visit on-site, providing a more cost-effective solution.

A Case Study in Destruction Testing

Recently, we conducted a destruction test on a stainless-steel braided PTFE-lined hose from our T6100 standard wall smooth bore series, which has a working pressure of 241 Bar. Following standard procedures, we subjected the hose to 1.5 times its working pressure (361 Bar) for at least 60 seconds. The manufacturer-published burst pressure for this hose is 724 Bar, providing a 3:1 safety margin.

During the test, the hose burst at 810 Bar, significantly exceeding the expected threshold, while the end connection remained fully intact. This outcome demonstrates that the hose exceeded its safety limits while maintaining connection integrity under extreme conditions.

Learning from Failure: What Happens When a Hose Bursts

In the accompanying video, during testing you can see the hose assembly securely fastened at both ends of the test rig while clean water was pressurised through the system. The failure occurred due to a weakening of the tensile strength in the outer braid, where a single compromised strand can affect the integrity of the entire hose. Despite the hose bursting, the end connection remained secure, preventing any hazardous outcomes. This underscores the importance of thorough testing to ensure the safety and reliability of hose assemblies.

When a hose assembly bursts, the consequences can vary from minor disruptions to catastrophic failures. Here’s a breakdown of potential repercussions:

1. Sudden Release of Pressure: A hose burst results in the immediate release of high-pressure fluid or gas, which can be explosive and cause significant damage.
2. Fluid/Gas Leakage: The nature of the substance conveyed determines the hazards involved, which can include environmental contamination and severe burns.
3. Damage to Surrounding Equipment: The sudden discharge can erode or damage nearby machinery, leading to additional failures.
4. Danger to Personnel: The primary concern is human safety, with risks including lacerations, burns, and hose whip injuries.
5. Loss of System Functionality: A hose burst often renders the entire system inoperable, leading to costly downtime.

Safety and Service Always

At Flextech, we take this responsibility seriously. We help our customers manage their on-site hose assemblies with our online hose asset register, Flextech Hose Register This tool allows customers to categorise and monitor their hoses, ensuring that inspections and replacements are carried out before any safety risks emerge.

The last thing anyone wants is a near miss—or worse, a serious incident. That’s why we invest heavily in both testing and assisting customers with maintaining the safety of their hose assemblies. Safety is at the heart of everything we do at Flextech, and it’s what drives our continuous improvement and commitment to excellence.

By investing in thorough testing and offering customers the tools to maintain their hose assemblies, Flextech is committed to providing the safest and most reliable products in the industry. Sign in to our Flextech Hose Register to find out more and start managing your hose assets today.