Hoses That Last in Demanding Applications
How one paper mill reduced their hose run rate costs and realized a 300% extension of hose life
The Challenge: Hose Failures Resulting in Unplanned Downtime
Industrial hoses play critical roles, yet many manufacturers lack clear specifications and policies concerning hose selection, installation, inspection, and maintenance.
- Specified hoses often perform sub-optimally and fail prematurely
- Hoses are often improperly routed and use incorrect end connection
- Hoses are not checked regularly for wear to keep workers safe and costs controlled
Industrial professionals require access to high-quality hoses available in a variety of materials and performance ratings, as well as insight on proper hose usage and upkeep.
The Solution: Swagelok® Hose Mapping and Related Advisory Services
Swagelok offers durable, long-lasting hoses with the pressure ratings, materials of construction, and flexibility to help keep team members safe, equipment online, and operations profitable. Our Swagelok-certified hose advisors can help you select optimal hoses for your applications, troubleshoot your hose problems, and teach you how to properly maintain your hoses to maximize fluid system performance.
The Results: Cost Savings Identified
Two areas were found where a potential hose failure could result in an unplanned outage which would require a shutdown of the entire machine. Taking proactive measures to address these failure points helped avoid an estimated 3 hours of unplanned downtime, equating to approximately $150,000 in savings.
The Stakes
Unplanned outages at a paper mill can pose significant risks impacting all facets of the business:
Operations
- Production loss can lead to missed quotas and delayed deliveries
- Equipment damage resulting from sudden stops, especially if systems aren’t properly shut down
- Process disruption leads to material waste or may require reprocessing
Finance
- Lost production time directly impacts revenue
- Emergency repairs are often more expensive than planned maintenance
- Restarting equipment can spike energy usage leading to increased costs
Safety & Enviornmental
- Unplanned outages increase the risk of hazardous working conditions, compromising worker safety
- Sudden shutdowns can lead to containment failures
- Disrupted processes may release pollutants if environmental controls are affected
Compliance
- Delays or quality issues can harm relationships and brand reputation
- Failure to meet environmental or safety standards during an outage can result in fines or legal action
Our Process
Unit Evaluations
Swagelok Alabama spent over 80 hours performing an onsite inspection of hoses to evaluate installation, document issues, provide part numbers, and map locations for all hoses.
Actionable Reports
The Swagelok team documented locations, fluid parameters, and specifications for each hose, as well as areas for improvement, including a list of materials to stock for future maintenance.
Prioritization of Repair
Hose issues were broken into four categories based on severity of the finding, showing the number of issues documented for each category.
Improve Hose Safety and Lower Plant Cost |
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Avoid dangerous situations and downtime while improving plant efficiency by following these three recommendations for industrial hose safety. Properly Match Hose Type to the Application Proper Hose Routing and Storage Proper Hose Maintenance |
To learn how Swagelok Evaluation and Advisory Services can benefit your facility, complete our Service Request Form or contact us directly to connect with an expert.
This data represents an actual report, however, total savings will vary based on number of leaks, size of leaks, orifice size, cost of electricity, operating hours and other factors. The data displayed here does not take into account maintenance costs as a part of total savings.