On day-to-day basis we search for solutions to new or existing applications doing our best to satisfy the needs of our customers as fast as possible. This time it was a real emergency situation. It was late in the evening, a massive pit for an office building in a new business park in Katowice was ready to be poured with concrete. Then, one of the boom pump operators noticed that his concrete hose had plugged, he tried to remove the plug but nothing worked. With several concrete mixer trucks on the way to the construction site, there was no time for trying, they needed a new hose. Our 24h Service team in Katowice was called and asked for help. With a wide range of hoses and fittings in stock we were ready to deliver a rubber hose for a concrete pump immediately.

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To provide durability and reliability to the boom pump application we decided to supply an assembly comprised of a rubber tube made of black, smooth rubber compound reinforced with four steel wire braids. The rubber compound includes natural and synthetic rubbers for excellent abrasion resistance and outstanding performance when conveying such abrasive materials as concrete, sand or plaster.  The rubber tube of 125 mm diameter, 4m long was assembled with 5,5’’ fittings made of special, hardened carbon steel to stand up to the most demanding conditions. The approximate hardness of such fittings ranges between 56 and 58 of Rockwell hardness scale.  The fittings were of a full flow type to prevent blockage due to concrete build up.

However, not only the wear of the pipeline but also pressure required to move concrete to the point of placement was a key factor. Because the concrete slurry must be pushed up the standpipe, the pressure in the boom pipeline must be very high to handle the task. Moreover, the pressure in the end hose must also be very high due to friction, which makes pumping through rubber hoses three times harder than pumping through steel pipes. The cement hose that we decided to use was intended to work at pressure ranging up to 80 bar maximum so it was ideal to accommodate the pumping pressure.

The rubber hose was to be attached at the end of the boom, above a working area. A hose-hand is a person who manually adjusts the end of the rubber hose to pour concrete to the right place and he is the most at risk . As the concrete hose hangs down loose, it must be fitted with the most reliable Victaulic coupling to protect the hose-hand and all workers nearby. The coupling , if clamped properly, sustains the maximum pressure applied by the pump and so protects  the hose against disconnection and  undesired discharge of concrete.

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Once again our service team saved the situation with a great hose solution. The rubber tube was delivered to the construction site, connected to the boom with the clamps and pouring of concrete started. The pit was successfully filled with concrete. The performance of the rubber tube was excellent. Since then, the rubber tubing has served dozens of such concrete placement operations. With the highest quality of the hose as well as full flow fittings we eliminated the top source of pump installation failures, therefore the boom pump works efficiently, constantly and safely.

[/fusion_text][fusion_imageframe image_id="8444" style_type="none" stylecolor="" hover_type="none" bordersize="1" bordercolor="#dddddd" borderradius="" align="none" lightbox="no" gallery_id="" lightbox_image="" alt="" link="" linktarget="_self" hide_on_mobile="small-visibility,medium-visibility,large-visibility" class="" id="" animation_type="" animation_direction="left" animation_speed="0.3" animation_offset=""]http://www.hose-solutions.com/wp-content/uploads/2016/03/Emergency-at-the-construction-site-1.jpg[/fusion_imageframe][fusion_imageframe image_id="8443" style_type="none" stylecolor="" hover_type="none" bordersize="1" bordercolor="#dddddd" borderradius="" align="none" lightbox="no" gallery_id="" lightbox_image="" alt="" link="" linktarget="_self" hide_on_mobile="small-visibility,medium-visibility,large-visibility" class="" id="" animation_type="" animation_direction="left" animation_speed="0.3" animation_offset=""]http://www.hose-solutions.com/wp-content/uploads/2016/03/Emergency-at-the-construction-site.jpg[/fusion_imageframe][fusion_text]Your hose expert[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Whenever we deal with a gas installation we take special care to provide a reliable and safe solution. This time we had to connect a rigid pipe supplying gas with a steel hose assembly feeding a gas burner fitted on the revolving door of a blast furnace. It seemed to be quite easy, however if the door opened the hose started to twist. Unfortunately this  motion led to twisting – a destructive kind of motion.

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To get rid of these twists, we decided to install a rotary union.

A rotary joint is intended to connect a stationary unit ( in our case,  gas supply pipe) and a moving unit ( hose assembly)  allowing free flow and rotation at the same time. It basically comprises four basic components: a housing, a shaft, a bushing and seals. The housing has a threaded inlet at one end, the other end holds a shaft with a threaded end connection as well.  The bushing and seal are assembled around the shaft. The bushing is used to allow the shaft to rotate and thus makes the most important part of the rotary  union for natural gas. The seal prevents the medium from leaking outside the rotating union.  Threaded ports at both ends of the rotary joint facilitate connection.

The rotary joint for natural gas  of our selection was assembled with stainless steel flanges DN80 PN16 and secured with PTFE seals. It was mounted between a rigid gas supplying pipe and a corrugated steel hose DN80. The steel hose fitted with the rotary joint made an assembly of unconstrained flexibility. It could easily swivel when the door with the burner was either opened or closed.

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Sometimes small things can make a really big difference. It proved to be true this time. Thanks to the natural gas rotary union with flanges, the steel hose does not twist anymore and is much easier to handle. What is more, the flow rates are not reduced at all. Gas is carried through the straight passage of the shaft in the rotary union, then it flows undisturbed through the hose down to the burner. The rotary union for natural gas significantly increases the hose service life as it stops twisting and reduces stress. What we needed was free motion, reliability and safety – a rotary joint has it all!

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Your hose expert

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The hand crank hose reel of our choice can easy handle 30m of twin line hose (blue DN9/red DN9).  The carbon steel large frame is covered with long lasting powder coat. Even if it operates in the roughest working conditions, the service life is almost endless.

Although the reel is designed for manual winding of oxy acetylene hoses, the rotation is very smooth and the hose reel is perfectly stable during operation. The handle of the crank is long enough  for the operator to grasp it and turn easily.

Usually hose reels are connected to a single source of supply, however in the case of twin hose, an oxygen hose and acetylene hose are fed by gases from different  pipelines. Inlets are at both sides of the spool so oxygen and acetylene supply hoses can be  easily connected.  The connection is  flexible – to avoid strain when the hose reel is in use.

The hoses work at different pressure, the one conveying oxygen works at 8 up to 10 bar and the other at 0,5 up to 1 bar.

Inlet and whole fluid path are in stainless steel . All components in contact with the medium are thoroughly cleaned and degreased. Handling gases, this procedure is a must to prevent explosion.

This reel system features a rotary union, actually two of the rotary unions, one at each side of the spool. These swivel joints can rotate in each direction eliminating tension and torque. The gas supplied from the installation to the port of the rotary union is transferred down to the outlet in the spool and delivered further to reach the welding torch.

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The oxy acetylene hose reel suits specific needs of this application. The twin hose is wound or released when needed. Although the hose reel is pretty bulky it takes up less space than lengths of hose lying on the floor. Once again we managed to deliver improvements that our customers will surely appreciate.

[/fusion_text][fusion_slider hover_type="none" width="100%" height="100%" class="" id=""][fusion_slide type="image" link="" linktarget="_self" lightbox="yes"]http://www.hose-solutions.com/wp-content/uploads/2016/03/b514fb9e-0be2-4c68-9669-d1b1f7831a1e.jpg[/fusion_slide][fusion_slide type="image" link="" linktarget="_self" lightbox="yes"]http://www.hose-solutions.com/wp-content/uploads/2016/03/6a1d675d-9db0-4382-8fcc-bba563c5c1d1.jpg[/fusion_slide][/fusion_slider][fusion_text]Your hose expert[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

One of the projects we worked on was serving a power plant which used to have one of the largest SO2 emissions in the world. Such excessively high levels of emissions lay behind the decision to introduce a flue gas desulphurization (FSG) system within the plant. This project involved cooperation of several companies that needed to: design, manufacture and deliver necessary equipment to limit SO2 emissions. Tubes International was involved in all stages of this process thus ensuring best hose assembly choice.

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Tubes International task was to choose, assemble and install hose assemblies (hoses with flanges) for gypsum transfer, that is a by-product during flue gas desulfurization process. The hose assemblies were located between a centrifuge and pipeline. They not only needed to be resistant to working conditions (gypsum, 10 bar, +70°C) but also to combine two additional features such as flexibility (to compensate centrifuge movements) and robust construction (not to collapse during work at 90° ). What is more, the operating time specified for the hose assemblies was 8670 hours per year during 36 months warranty period. That means continuous work for 3 years without a single stop. Our first and, as it turned out, perfect hose choice was an abrasive material hose DN100. It is a hardwall hose used widely in the industry as a cement hose, sand hose, gravel hose or seed hose. For the purposes of this desulphurisation system it was assembled with aluminium flanges suitable for gypsum installation. However, selecting proper hose assembly was not enough for the project.  We were the only who could deliver the product and with the use of our service team, cut the hoses to the required length, assemble them and then install properly in the power plant (in one plane). We completed the task but only thanks to the combination of our knowledge, technology and hard work of highly qualified employees who mounted the hoses, we provided the top quality service for the customer.

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The scale and responsibility of this flue gas desulphurization project was extreme. That is why we felt more pride after successful finish than after any other project. But this one had one more additional value. Thanks to our technical knowledge, available technology and services we helped our customer to become more green. And this is a by-product that we all benefit from.

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The hydraulic hose was needed for a servo-motor in a wind turbine. When watched from the ground, the wind turbines look like simple wind mills, but they are not so. High, in the body of a nacelle, there is an installation set to minimize mechanical loads , maximize power production but built to work on its own.  The installation responds to signals received from wind sensors and controllers. Then a servo-mechanism must position the blades with respect to the flow of the wind. The mechanism not only adjusts for the optimum speed but also puts the blades into a safe position if the speed is too high or even stops them to protect the wind turbine from damage.  The importance of the servo-mechanism is really high and so is the cost of its maintenance.  Having a wide range of hydraulic pipes at hand, we decided to choose a top performance hose for hydraulic oil.

The 1/2’’ hydraulic rubber hose with two steel braids of reinforcement (2SN) can withstand a minimum of 400000 impulse cycles. The working pressure of the application is 160 bar, but the maximum working pressure of the hose is 275 bar (bursting pressure 1100 bar). The working conditions in the wind turbine are pretty harsh. The hydraulic pipe is exposed to high ambient temperature fluctuations.  Our high pressure  hose can work in temperatures ranging from -40°C up to +100°C. To make a complete hydraulic hose assembly, hydraulic fittings were mounted with stainless steel 316L ferrules. To facilitate connection, screw-to-connect hydraulic couplings were mounted to make the hose assembly complete.

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We managed to deliver a top quality hydraulic hose assembly perfectly matched with the requirements of the application, working conditions and loads.

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Solution

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After thorough analysis of all technical requirements, a flexible corrugated stainless steel hose was chosen for the nitrogen furnace installation. The nitrogen hose ensures outstanding performance throughout the whole service life estimated at 50 000 bending cycles. With the corrugated tube made of 316L steel and braid of 304 steel, the hose offers outstanding resistance to corrosive fluids or gases, therefore the liquid nitrogen hose is the only one capable of transferring 100% nitrogen at +600⁰C and 100% ammonia at +315⁰C to feed the furnace installation. The corrugations of nitrogen hose produced by hydroforming ensure total leak tightness. Due to this feature the nitrogen hose can be used for the third type of media: 25% hydrogen and 75% nitrogen compound transferred at +600⁰C.  Leaks of hydrogen from hydrogen hose or fittings are very dangerous as its mixture with air may be easily ignited by a spark or heat.

In order to make a complete assembly, nitrogen hose fittings were mounted on the DN 6 nitrogen transfer hose. The fittings must offer the same quality and resistance to the unique and extreme working conditions, so 316L stainless steel was the best choice. The nitrogen hose fittings, with a swivel nut at one end and a pipe fitting at the other, were welded to AISI 304 ferrules. The superior quality of the nitrogen hose assembly was confirmed by a quality certificate supplied with the product.

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Result

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The hose assemblies that we selected perfectly suited the application. They completely eliminated the risk of furnace malfunction or possible breakdowns adding precision and reliability to the equipment.

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Challenge

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Phenol is classified as a highly poisonous material. When handling or shipping phenol, strict safety recommendations must be followed.  The operators of tank trucks must be familiar with the potential hazards connected with phenol handling before loading or unloading of this product starts.  As careful as they are, though, they cannot predict the defects or malfunctions of installation. Having this in mind we designed and made a hose system for phenol unloading.

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Solution

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The phenol hose loading system is intended for tank truck unloading using a bottom unloading method. Phenol is pumped via phenol reloading hose from the tank truck into the receiving vessel. The pump is a fixed part of the loading station. A top quality composite chemical hose DN 75 (phenol hose) operates as product line. The same type of a chemical hose but DN 50 works as vapour recovery line.  Both tank truck hoses are assembled with emergency breakaway couplings – the same as are usually used for oil transfer hoses or petroleum hoses.  In emergency situation, the breakaway couplings transmit the load of the strained hose to breaking bolts. The bolts break before the hose and its fittings collapse. Simultaneously the coupling disconnects, the spring valves in both coupling valves lock so phenol is not released to the atmosphere.

The tank truck is connected to the pump of the receiving vessel via the phenol loading hose. For the connection to be safe, it is assembled with Tank Wagen couplings. The TW coupling consist of two parts locked together by a turn of the coupling and then secured by a locking handle.

The temperature of molten phenol during transport, loading and unloading, must be maintained at about + 60°C. Both the tank truck and the phenol loading hoses are heated to such temperature, otherwise phenol solidifies and plugs the lines.

To prevent phenol corrosive activity, our composite chemical hoses are lined with E-CTFE and reinforced with stainless steel inner and outer wire helix. The same applies to the couplings used within the hose loading station – they were all made of stainless steel.

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Result

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One may think this was a challenge for us, but it was rather a standard project for our team. The state-of-the-art phenol hose loading station was built to meet the highest safety standards and technical requirements. The phenol reloading hoses work reliably with no leakages, no obstacles disturbing the flow of chemicals.

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Your hose expert[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Challenge

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Before it gets to our households, water must be first treated to meet drinking water standards. Water supplies must go through purification and disinfection processes to change from ground water into tap water. Water treatment plants must operate smoothly to provide undisturbed supply of water to our home, school, office, etc. The water treatment plant delivering daily almost 400 000 m³ of drinking water  to one of the biggest cities in Poland wanted to eliminate a single, troublesome point of failure in their water treatment installation. In that system, water was treated with chlorine as a disinfectant to make it safe for public consumption. But to make water safe, chlorine must be first safely and precisely added to water supply and at this point we were asked to find the best possible way to convey chlorine, gaseous and liquid, from tanks into the system. Our goal was to provide a chlorine hose assembly of improved quality, to reduce equipment and maintenance costs.

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Solution

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In dry environment, with no moisture present, chlorine is considered as non-corrosive, but these properties change drastically in the presence of moisture, even all-present atmospheric moisture. Then it becomes extremely oxidizing agent. The majority of chemicals can be safely transferred by steel braided hoses yet not chlorine. Chlorine, especially in contact with moist is potentially aggressive to stainless steel. One may try to prevent this corrosive impact and may be successful but not in a water treatment plant. There, only a special chlorine hose can be used. The best of chlorine transfer hoses is PTFE tube with Hastelloy wire braid. The PTFE tube resists almost all chemicals, can be used to transfer reactive and corrosive chemicals, chlorine as well. Unaffected by chemicals it can operate in a wide temperature range, however since a complete hose assembly is considered, the working temperature is additionally limited by the working temperature of the Hastelloy braid and its fittings, which is 60°C maximum. In the case of such applications, the higher the temperature, the more corrosive is the environment. Even such alloys as Hasteloy are at risk of trace quantities of chlorine halogens diffusing through the PTFE tube and attacking the braid material.  Fortunately,  in this case working temperature is the same as ambient,  it ranges from 5°C up to 35°C so chlorine transfer hose in Hasteloy braid withstands in the conditions where steel braided hose will undoubtedly fail.

To produce a complete hose assembly, we used  1/2″ chlorine transfer hose 2,5m long with 1″ female thread fittings at both ends,  conforming to DIN 477-1 standard for gas cylinder connectors. Both fittings and ferrules were made of Monel, another alloy resistant to chemicals. The hose assembly connected a chlorine one-ton tank to the pipeline of water treatment installation. The chlorine tank was set on a platform scale designed for weighing and thus monitoring feed rate of process chemicals.  Properly mounted to the valves, the chlorine transfer hose assembly was ready for use at working pressure ranging up to the maximum of 10,5 bar.

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Result

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Durability is critical for all processes involving chemicals, aggressive chemicals in particular. The chlorine transfer hose assembly that we introduced  greatly reduced the chance of chlorine leaks. Regular maintenance and inspections show that the assembly displays no corrosion or degradation.  The service life of chlorine transfer hose and connectors made of adequate alloys is not determined by frequent leaks any more. In addition to the economic benefits, we added some quality and safety as well.

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Challenge

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An electrically heated hose is the key element of an adhesive application system. Adhesive is transferred through the hose and then applied on a product. The failure of one electrically heated hose causes dozens of hours or even days of downtime. This problem was faced by our customer – a company providing packaging solutions for food industry. A faulty electric hose operated in a machine that binds cardboard wrappers on plastic cups.  When it broke down, we were asked to find a more reliable electric hose assembly.

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Solution

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We selected the premium quality electric hose that effectively resists mechanical and thermal loads therefore  best suits the application.  The most important part of an electrical hose assembly is a core hose, where adhesive goes through. To ensure highest level of transfer, we decided to provide a glue hose  with  a Teflon (PTFE) hose as a core – a durable and effective solution.  The PTFE hoses guarantee resistance to a whole range of chemicals, solvents or acids. Moreover, unaffected by almost all chemicals PTFE hose is also non-porous and non-sticky so the medium in it does not adhere easily to the hose walls. It can be successfully used to transfer hot glue. The working temperature of this heated hose was 200°C,  adjusted to suit the temperature of glue conveyed in this application (180°C). A heating sensor, type NI 120, is crucial for any application conveying adhesives as its readings decide not only on temperature but also on viscosity of glue. The sensor must also instantly response to changes of ambient temperature.  The hot melt hose was reinforced with stainless steel braid  for resistance to pressure, bending and heat. The working pressure of the glue hose was 4 bar. It had an external cover made of black, wear-resistant polyamide to provide resistance to abrasion.

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Result

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The electrical hose we provided successfully operates applying hot adhesive on cardboard wraps. It ensures excellent thermal efficiency, consistent  flow rates and improved wear-resistance. It proves to be more durable and reliable. Downtime is significantly reduced.

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Our customer is a leading transportation company specializing in the transport of liquid asphalt. A customer’s service team at one of the terminals were facing problems with finding a liquid asphalt hose solution for loading and unloading of rail tankers to a pipeline. As liquid asphalt must be unloaded at high temperature, our customer highlighted enhanced working conditions. The application was of a heavy duty type but still operated by a single worker.

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A loading arm was not an issue so we decided to use a flexible metal hose. Only a few flexible metal tubes are suitable for such demanding applications so the choice was obvious – stainless steel hose (321 SS) in stainless steel braid (304 SS) with the bending radius of 563 mm in dynamic conditions. This stainless steel hose handles the transfer of petroleum-based products and can be used at working temperature as high as 800°C so it was perfect to transfer asphalt at 180°C. Of course any flexible metal hose used in such demanding application must meet the requirements of relevant quality standards – our tube is compliant with ISO 10380 standard so withstands cyclic bending (50 000 cycles). An ideal hose solution.

However, it is not only a metal hose that counts but also its high-quality industrial fittings. The hose was assembled with a fixed stainless steel flange DN100 PN10 (304 SS) at one end. The other end was equipped with 4” Camlock coupler, made of 316L stainless steel.

Usually when asphalt transfer is over, there is some stubborn residue left in the hose. To facilitate smooth operation and maintenance we decided to weld an L-shaped stainless steel pipe to the Camlock coupling. The pipe was designed to facilitate cleaning with compressed air. It was assembled with a ball valve – female thread ¾” (316 SS) equipped with a claw coupling.

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The delivered solution was a perfect match for such harsh conditions. With this stainless steel metal hose, the customer could easily handle loading and unloading of asphalt. Even though the hose assembly was made of stainless steel, it was not that heavy and yet very flexible. At this point we advised our customer that liquid asphalt can also be transferred by jacketed metal hoses or rubber hoses. Once again our team proactively responded to the customer’s needs!

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