How to maximise the lifespan and safety of steam hoses

19 November, 2024

Steam is integral to numerous industrial processes, yet working with it poses significant risks and costs. Ensuring the proper maintenance and handling of steam hoses is crucial to enhancing safety and extending their service life. By adhering to best practices, businesses can prevent common issues such as superheated steam damage, popcorning, and leaks, thereby safeguarding both their equipment and personnel.

Understanding steam and its impact on hoses

Steam plays a vital role in many industrial applications, but its various forms can have significantly different effects on steam hoses. Steam exists in three states: wet saturated steam, dry saturated steam, and superheated steam, each determined by the combination of pressure and temperature.

Wet saturated steam contains unvapourised water particles, giving it a partially liquid form. This type of steam tends to have a lubricating effect on the rubber inner walls of hoses, which can be beneficial in preventing wear. However, excessive water particles may lead to wear and tear over time if not controlled.

Dry saturated steam, on the other hand, reaches a point where it no longer contains liquid water particles but is still at the boiling point. This type of steam can be harsh on hose materials if not managed properly, as it can cause the inner rubber walls of the hose to become brittle, increasing the risk of cracks and eventual failure.

The most critical form of steam to manage is superheated steam. When steam is heated beyond its boiling point without an increase in pressure, it becomes superheated. This steam state is extremely dry and can continue the vulcanisation process of the hose's rubber inner wall, leading to hardening and reduced flexibility. Superheated steam accelerates the degradation of the hose, shortening its service life significantly.

To mitigate these risks, it is essential to closely monitor the operating pressure and temperature, ensuring they do not exceed the recommended limits for the hose. By maintaining steam within safe parameters, businesses can significantly extend the lifespan of their steam hoses and enhance overall safety.

Best practices to avoid hose damage

Proper management and maintenance are crucial in extending the service life of steam hoses and preventing common forms of damage. One of the primary concerns is preventing damage from superheated steam. To avoid this, it is vital to monitor the operating pressure and temperature carefully, ensuring they do not exceed the hose's specified limits.

Another significant issue is the phenomenon known as ‘popcorning’, which occurs when the inner wall of the hose absorbs water or water vapour. After use, the hose cools, causing the steam inside to condense into water. When the hose is subsequently reheated, the trapped water vapour expands dramatically, creating air bubbles that form blisters on the inner wall. To prevent popcorning, it is essential to blow the hose dry after each use, ensuring it is completely dry before storage.