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Maintenance, LEAK CHECK, REPLACEMENT AND INSTALLATION Suggestions

FOR FLEXIBLE POST-SINTERED PTFE LINED LEADS

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Listed below are Weldcoa's maintenance AND HANDLING suggestions for flexible post-sintered ptfe lined leads

VISUAL INSPECTION

A visual inspection is the most important check that can be done to prevent a lead failure. Visual inspections should be conducted on a regular basis depending on the application and service. Regular basis is considered monthly, weekly or daily.

VISUAL INSPECTION: CHECK THE Braid
A visual inspection of the braid (or outside reinforcement of the lead) is one of the most important inspections that should be done. The braid provides the necessary pressure reinforcement for the flexible lead and once damaged will lead to premature failure.
  • Any broken braid wires is cause for immediate hose assembly replacement
  • Broken braid wires can be the result of many issues, one of the most common being abrasion
  • Braid that is damaged, dented, pinched, worn, etc. is also cause for replacement

Broken braid wire

Damaged braid
 
VISUAL INSPECTION: AVOID KINKS
A kink is the sign that a lead has been bent beyond the minimum bend radius. A kink is an over bend which mechanically damages the braid and inner core. A flexible lead assembly typically becomes kinked from some unintended occurrence in application, i.e. the item connected to the assembly falls and the lead bears the load.
Twisted Lead-2
VISUAL INSPECTION: DISCOLORATION
If there is braid discoloration this is typically the sign that the braid material has been effected chemically or thermally. Discoloration can be in local areas or over the entire length of the lead assembly. The most common cause of discoloration is chemical attack. This typically is due to chemicals coming into contact with the braid that are not compatible or at incorrect concentrations.
 
VISUAL INSPECTION: FITTINGS AND COLLARS
Visually inspect all fittings and collars for signs of damaged threads, corrosion, and general overall appearance. Visually inspect for heavy or misplaced wrench marks.  Never wrench on a lead collar. Any of the above signs indicates immediate replacement of the flexible lead assembly.
 
Cracked Hex on Lead
 
VISUAL INSPECTION: BANDS AND MARKINGS
 
Visually inspect for bands and markings to be sure they are present and legible. Verify the marking agrees with the hose application. Proper marking will provide important information about the assembly in the future or in the event of an emergency.

Minimum marking requirements are as follows:

  • Maximum operating pressure
  • Manufactured date code
  • Manufacturer name or logo
  • Marking shall be on end fitting, collar, separate band or other means which assures permanence
  • Requirements per CGA E-9 2017 section 7.2

In the event an assembly is in application and is not clearly marked the following is recommended:

  • Determine the maximum operating parameters for the application and verify the lead assembly can meet the full requirements
  • Attach new and accurate marking per CGA E-9 2017 section 7.2
  • If verifying the lead assembly or marking per CGA E-9 2017 section 7.2 is not possible, the lead must be replaced

LEAK CHECK

All flexible lead assemblies must be leak checked periodically to ensure assembly integrity and safety.

  • Apply a leak solution to the assembly in service. Follow the leak solution manufactures recommendations for use, limitations and concentrations
  • If able to, hydrostatically pressure test an assembly use the following industry standards
  • The test pressure shall be 1.5 times the maximum working pressure when testing hydrostatically
  • Static pressure shall be applied for a minimum of 30 seconds to a maximum of 1 minute with no leakage
  • The proper safety precautions must be enforced when pressure testing to avoid injury

Recommended Leak Check Interval

flexible lead replacement suggestions

Typically a lead is the last item to be specified in a system. In doing so the lead usually is not placed on a maintenance program and subjected to over use.

  • Regular replacement of flexible lead assemblies based on application and use will lead to less down time and improved safety
  • These guidelines assume the lead is in good working order and does not have any of the conditions discussed prior
  • When in doubt replace the lead assembly to ensure maximum safety
Weldcoa recommends the following:
Flexible Leads used in a Cylinder Fill Facility should be replaced every 10,000 Fill Cycles or every 5 years, whichever occurs first.

Please Note: Fill System Leads (Double Braided/Post Sintered/3600 PSI MAWP) should be visually inspected every morning prior to the first fill of the day to detect any kinks, frays in the stainless-steel weave or discoloration of the leads. If any leads are found to have kinks, frays or discoloration the lead needs to be replaced immediately. (You should never use a damaged lead during the fill process.) In addition, the leads should be leak checked during every fill cycle.

Flexible Leads used on Gas Packs should be replaced every 10,000 Fill Cycles or every 10 years, whichever occurs first.

Please Note: Gas Pack Leads (Double Braided/Post Sintered/3600 PSI MAWP) should be visually inspected before each fill to detect any kinks, frays in the weave or discoloration of the leads. (Gas Packs used in acidic or reactive atmospheres may suffer discoloration.)  If any leads are found to have kinks, frays or discoloration the lead needs to be replaced immediately. (Isolate the pack until the damaged lead has been replaced.)  In addition, the leads should be leak checked during every fill cycle.

if you have any further questions or are in need of a replacement lead (pigtail or hose), PLEASE REACH OUT TO SALES@WELDCOA.COM FOR ASSISTANCE.

flexible lead INSTALLATION suggestions

This section is intended to provide some general information regarding lead installation.

  • Minimum bend radius is the maximum amount a lead can be bent before causing kinking or damage
  • When routing do not exceed the lead minimum bend radius (measured to the inner most curved surface)
  • Secure the lead in such a way to avoid damage staying away from points of abrasion or wear
  • Choose a length which allows for proper attachment and operation. 
  • Use elbow adapters to avoid exceeding the minimum bend radius and kinking the lead
  • Never torque or twist a lead in application or installation
  • A lead is a pressure bearing device not a load bearing device
  • Poor handling or installation is a major cause of reduced lead service life

Minimum Bend Radius on Leads

 

 

Right and Wrong Lead Bend Illustration

 

 

Right Wrong Twisted Lead Image

 

 

WE ARE WITH YOU EVERY STEP OF THE WAY

For any questions, please feel free to contact us at (630) 806-2000 or email us at sales@weldcoa.com 
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