• • • SAFETY IN ENGINEERING • • •
FORGET LIGHTBULBS,
HOW MANY PEOPLE DOES IT TAKE TO CHANGE A HOSE - PROPERLY?
So, let’s demystify the installation process and equip you and your team with the knowledge to do the job safely and effectively, first time, every time.
BY MARTIN ROBINSON, MANAGING DIRECTOR, FLEXTECH HOSE SOLUTIONS
ou’ve invested in the best equipment, your business is underpinned by high standards, your staff are experienced and your customers expect nothing less than excellence. Perfect! However, sometimes, even in the largest establishments and most professional environments, it’s often the smallest task that carries the biggest risk, especially when it’s performed incorrectly.
Y
One of the most common culprits is often hose installation and replacement, particularly within electricity environments and associated fluid systems where hoses support cooling, fluid transfer, or equipment protection, which should be treated as a priority during equipment training or onboarding. It’s often overlooked as it’s seen as a simple task, even intuitive, that anyone can do with a few ‘lefty loosey, righty tighty’ turns of a spanner. The truth is, without proper understanding, changing a hose can quickly turn a routine install into a costly and avoidable failure.
It is imperative to install hoses correctly in many industries, like power generation, renewable energy, data centres and advanced manufacturing. In these environments, electrical systems often rely on hoses and piping to safely move fluids and coolants. Because precision, safety and compliance are critical, proper installation isn’t something you can cut corners on, it’s essential for the system to work reliably.
18 ELECTRICAL ENGINEERING • APRIL 2026
Hose installation is a process, not a swap
Whether you are replacing a worn hose or fitting a brand-new assembly, within a cooling circuit or fluid handling system supporting electrical equipment, the procedure matters. A hose is a vital component in these systems, which, if fitted incorrectly, can lead to a plethora of issues, some immediate and others hidden until it’s devastatingly too late.
Before installing, inspect the new equipment thoroughly, looking for any signs of visible damage that might have happened in transit. Ensure the hose is the correct one you ordered and suitable for the job in hand.
Even the best quality hose can fail if it’s not properly selected for the required job. If it’s exposed to the wrong temperatures, pressures, or media, it won’t perform as expected and could pose serious safety risks including loss of cooling efficiency or system performance issues.
Do not reuse hose end fittings Re-ending or reusing hose fittings is never advisable, as it jeopardises the safety and integrity of the hose assembly. This approach can result in connection failures, leaks, or even severe accidents due to weakened or improperly fitted components. Additionally, it voids the manufacturer’s responsibility, meaning any subsequent issues are the sole responsibility of the installer. Although some companies may promote this as a way to cut costs and gain business, it is neither a safe nor acceptable practice.
Always buy new, industry-approved correct fittings to ensure that each hose complies with the necessary safety standards.
Use the right tools for the job You need to get the right tool for the job. Don’t improvise. You need to use properly sized equipment that won’t damage the fittings or cause incorrect force or damage while fitting. Also, you should avoid excessive twisting and turning, as this can impact the fitting and the hose, weakening the structural integrity and shortening its lifespan.
Give the hose itself love and affection, too. Ensure that there aren’t any bends or kinks and avoid contact with abrasive surfaces, particularly in tight installations or high-vibration environments often found around electrical equipment. Reducing strain gives your hose the best possible chance of its full intended lifespan.
Test after installation
A newly installed hose assembly must always be tested in a controlled environment before being used. This vital step helps verify that the setup is not leaking and is safe for use during operation. Skipping this is not an option; it’s a serious part of the process, and if it’s not carried out, it’s a recipe for disaster. If you try to bake a cake without an oven, it won’t turn out right. This won’t either. In addition to installing the assets, it is essential to maintain accurate records to manage them. It’s best practice to do so through documentation as it forms part of the quality assurance process and provides traceability in the event of any incidents. Maintaining these records demonstrates a commitment to safety and compliance, protecting the operator and operation from liability.
electricalengineeringmagazine.co.uk
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