Failure of Hydraulic hoses

Hydraulic hoses are used in many instances and a wide range of

applications. Currently a company making these hoses is struggling
with a large number of claims relating with failure of their hoses.
Three examples are given below:

Case 1: Drilling rig fire

During an onshore drilling a fireball was observed during drilling

originating from a hose on a separator. The hydraulic liquid caught
fire, while it was spraying on a hot engine part. Luckily nobody got
injured. The failed hose was in operation for approximately 5 years
and all components where OEM. The location and a zoom in of the
50.8 mm (100r1 type as specified b in AS 3791-1991 Hydraulic
Hoses hose) are shown in Figure 1.

Figure 1: Right the failure location of the hose, left the zoom in of the failed
wires.

The operating pressure of this type of hose is 2.6 MPa the maximum
allowable working pressure of the system was 1.03 MPa.

Case 2: Excavator Boom lift hose

During excavation a hose on the boom lift exploded and propelled

mechanical parts towards the cabin of the operator, nearly hitting
operator. The hose was in service for only 6 months while the policy
is to replace the hoses every 2 years. The normal operating pressure
of the hose was approximately 34 MPa with very limited pressure
spikes. The upper limit of the hose is 35 MPa a close-up of the failure
location is given in
 Figure 2: Close up of failed hydraulic hose excavator
Case 3: Front end loader Hoist lift hose

At the time of failure the loader had approximately a operating time

of 14.773 hours. The hoses where still OEM parts, supplied by the
loader manufacturer. The hose has a maximum operating pressure
of approximately 35 MPa (50.8mm internal diameter 100R3 type
hose with six alternating heavy wire spirals around a synthetic inner
tube with a synthetic outer tube. The operating pressure was around
20.7 MPa. There was some outer tube damage observed 4 months
prior to the failure, see Figure 3. A closeup of the failed hose spiral is
given in

Figure 3: Cross section of damaged area next to the failure location. Showing the
damaged outer tubing.
 Figure 4: Spiral wire ends of the failed hose.

The main questions now arising are:

1. What is the failure mechanism behind these failures?
2. How can the maintenance policy be adjusted (intervals and
methods) to prevent these failures.