RPM Engineering "IntegraFlex" Composite Hoses
Manufactured in Virginia Beach, VA
We are a stateside manufacturer and supplier for industrial transportation hose that is used in oil flushing/filtration, petrochemical transportation/suction, ship-to-shore & tank truck/rail car transfers, bottom loading, plant processing, and other various uses.
We specialize in manufacturing composite hose which if you are not familiar is a multi layered hose consisting of an interior wire spiral, layers of polypropylene sealing films & reinforcing fabrics, a pvc impregnated protective outer layer, and compressed together by an exterior wire spiral. Our hose is an excellent alternative to traditional rubber or metal encased hose offering a 20-40% weight reduction with 1/3 the bending radius all while maintaining an excellent temperature/pressure range of -22F up to 212F at working pressures up to 250psi. Simply put, it's a general purpose transfer/suction hose suitable for a very wide range of conveyance media including fuels, oils, and chemicals.
Based on a 1000psi Minimum Burst Pressure
A 4:1 safety factor has 250 PSI Working Pressure
A 5:1 safety factor has 200 PSI Working Pressure
GG - Petroleum Products
GS - Petroleum and Petrochemical vapor
SS - Chemicals
SG - Chemicals
PG - Chemicals
PS - Chemicals
1st letter = Internal wire of hose
2nd letter = External wire of hose
G = Galvanized wire
P = Polypropylene coated steel wire
S = Stainless Steel wire
All fittings are designed and assure 100% performance by each hose. Attachment methods are specifically developed for a perfect union and ensure performance up to rated burst pressure. Our exclusive double threaded scroll tail engages the inner wire and ensures positive location of the outer wire after crimping. Precise machining assures maintenance of hose film pack and wire integrity. The raised sealing face is vital to a leak proof connection. Our crimp process assures that the hose is permanently engaged and sealed to the fitting.
A comprehensive range of fittings is available per your request with threaded or flanged stock connections, designed to current US and international standards. We also have the ability to offer custom fittings designed for particular applications and compatibility requirements with availability upon request.
Materials we offer include but are not limited to; Carbon steel, Stainless Steel, Brass, Aluminum, and Polypropylene.
Our Composite Hoses
GG Petroleum Transfer Hose - Petroleum and petrochemical vapor recovery in bottom loading, ship-to-shore and tank truck transfer
GG/GS Vapor Recovery Hose - Marine, plant processing, rail car, ship-to-shore, tank truck
NOTE: Not for dry material service.
GG Bottom Loading Hose - Hose loading arms in bottom loading applications at bulk distributing and refining facilities
NOTE: Not for dry material service.
PG/PS Chemical Transfer Hose - Chemicals, inks, paints, plant processing, rail cars, tank trucks
NOTE: Not for dry material service.
SS/SG Aggressive Chemical Transfer Hose - Chemicals, inks, paints, plant processing, rail cars, tank trucks
NOTE: Not for dry material service.
Proper Hose Support and Usage
Why Use RPM Engineering IntegraFlex Composite Hose?
- The primary reasons for its popularity and use are:
- Hydrocarbon, Petroleum Product, Chemical, and Harsh Working Environment Resistance
- 100% Manufactured In the U.S.A.
- Flexibility and Lightweight
2/3 more flexible and 20 - 40% lighter than most any other hose types!
The many layers of plastic that are used in the construction of a composite hose are not glued or sealed together. As a result of this, when the composite hose is moved or bent, the layers slide upon the other layers giving ease of bending and an excellent bend radius.
Composite hoses are designed to be "fail safe"
there are basically 2 areas on a composite hose that can fail:
- a) The Hose
Because of the many layers of tubes and film that make up a composite hose there is not a direct leak path for liquid to follow. For a leak to occur, liquid must serpentine its way through the many layers of the hose until it reaches the outer cover. Once the liquid reaches the outer cover, small drops will form along the seam line indicating that a leak is occurring.
In other types of hose, leaks are usually more catastrophic, where the wall of the hose will rupture, without any warning, and create a large scale failure and unsafe environment.
- b) The End Fitting
The end fittings on composite hose are specifically designed to "fail safe" and reduce the chance of a fitting blowing off the end of the hose. Composite hose fittings have a spiral shank or tail piece that actually screws into the composite hose. Therefore, for the end fitting to blow out of the hose it has to be unscrewed from the hose. We use a larger gasket in our couplings to ensure a leak proof product and the screwed in end fitting in combination with the high pressure crimp on the ferrule make this type of coupling one of the safest to use.
- Chemical Resistance
Composite hoses are most commonly used in the transfer of chemicals. With the bore of the hose made from wide varieties of plastics including Polypropylene or Teflon; most common chemicals can be accommodated by the many different styles of composite hose available.
The large variety of chemicals that can be easily handled with composite hose in combination with the great flexibility, lightweight, high safety factors, and "safe failing" designs, and the wide variety of compatible transport media all add up to make this a very versatile hose for the industrial market place.
Ordering Procedures - orders should include the following information:
Use RPM’s Part Number or a complete description of the hose, couplings, and/or assembly
When selecting your hose, consider using the STAMPED method:
- Size: The appropriate inside and outside diameters and length of the hose should be determined. Live-length is the portion of the assembly that is flexible; Overall length is the maximum length of the assembly including the end fittings.
- Temperature: The maximum temperature of the material being conveyed. Temperatures have a considerable impact on the working pressure of a hose; as the temperature goes up, the recommended working pressure goes down (all working pressures are stated at room temperature). Never operate a hose towards its highest recommended working pressure while at or near its maximum temperature range.
- Application: External conditions including abrasion, climate, heat, flexing, crushing, kinking and degrees of bending.
- Material: The composition of the substance being conveyed and compatibility with the hose.
- Pressure: The maximum pressure and/or vacuum of the system, including pressure spikes. Never allow the system to surge above the maximum working pressure of the hose. Likewise for vacuum ratings.
- Ends: The appropriate end connection and attachment method for the application. The type of fittings and clamps must take the pressure, size, material being conveyed, type of hose and the manufacturer’s recommendations into consideration. Remember: the weakest link and greatest cause of hose failure will typically be at the hose and fitting connection.
- Delivery: Testing, packaging and delivery requirements
Inspection, testing and cleaning
Visual inspection – check hoses before each operation and before conducting hydraulic tests...
Hoses and hoses with rope lagging should be given a brief visual examination before each operation and a more thorough visual inspection at periods not exceeding six months. The inspection should pay attention to:
- Tears and abrasion of the hose cover or in the rope.
- Dents or nicks.
- Displacement of the hose reinforcing wires from its normal pitch or displacement and any areas where the outer cover exposes the hose below.
- Corrosion or abrasion of the hose outer wire.
- Signs of displacement of the end fittings or evidence of leakage at the ends.
- Any other abnormal features, including wear or damage to the end fittings.
Hydrostatic testing – annually or more frequently...
At periods not exceeding one year hoses should be hydraulically tested as follows:
- Drain and thoroughly clean hose.
- Carry out visual inspection. Hoses failing the visual inspection due to displacement of the hose wires, severe abrasion of the cover, or significant corrosion of the outer wire should not be tested.
- Lay the hose straight out on supports which allow free movement under pressure.
- Blank off the ends and fill the hose completely with water, ensure trapped air is released from the hose.
- Pressurize the assembly to 1.5 times the maximum rated working pressure of the hose and hold this pressure for 10 minutes while examining for leaks. Also test for electrical continuity between the end connections with resistance to be <10 Ωs.
- Reduce pressure and drain hose.
- On completion of this test the hose should be tested again for electrical continuity.
NOTE: Thermoplastic composite hoses elongate under pressure compared to rubber hose. Elongation under pressure is not an indication of hose condition or failure of reinforcements.
Electrical continuity tests – every 6 months or more frequently...
In order to prevent the accumulation of static charge generated in use, all metal parts of the assembly have been electrically bonded together during manufacture. At periods not exceeding six months the following test should be carried out.
- Lay the hose flat on the ground. Avoid contact on metallic parts to earth.
- Check that the hose is electrically continuous from end to end. This can be done using a simple battery and bulb test or alternatively using an ohm meter. Resistance should be 10 Ωs or less.
Cleaning – after use or prolonged storage, before testing...
- Hoses should be cleaned after use and certainly before prolonged storage or testing.
- Flushing out is sufficient in many circumstances using a variety of fluids, e.g. clean water, hot water detergents, common solvents at ambient temperature or seawater. If seawater is used for cleaning, this must be thoroughly drained out afterwards to minimize risk of corrosion on mild steel end fittings and on stainless or Galvanized Steel inner wires.
- Loose steam may be used but the hose must be open ended and the maximum working temperature must not be exceeded.
- Compressed air may be used but the hose must be open ended and the maximum working pressure must not be exceeded.
- During any cleaning operation the hose must be electrically earthed.
- Pigging must not be used under any circumstances.
CAUTION: High pressure steam or high pressure compressed air can be hazardous if hoses are restricted or clogged.
Hose repairs – consult RPM Engineering or your local distributor...
Depending on overall condition, it may be possible to repair hoses damaged in service. The repair of polypropylene hoses requires specialized knowledge and procedures.
NOTE: All repairs should be undertaken by trained and authorized personnel.
Electrical Properties Of Marine Dock Hose Assemblies Or Electrically Conductive Hose Assemblies
Low conductivity petroleum products and solvents such as gasoline & toluene become electrostatically charged when flowing through a pipeline and the pipeline itself acquires a charge of opposite polarity. If the pipeline is earthed, the accumulated charge flows safely to ground. However, if the pipeline is not earthed, a charge could accumulate which may then be discharged instantaneously by an incendive spark to a nearby earthed conductor. If the spark has sufficient energy and a flammable air/product mixture is present, an explosion will result. It is therefore normal practice for hoses generally to be specified that they be electrically conductive (with a maximum resistance of 10 Ωs) so that the electrostatic charge is continuously drained away. Even so, it is common practice in the petroleum industry to specify a maximum flow velocity of 7m/sec when pumping low conductivity products to ensure that a charge is not generated more quickly than can be dissipated through normal arrangements. Charges generated can be of many thousands of volts, but currents are of the order of a few microamps.