CUSTOMISATION AND IMPROVEMENT PROJECT FOR EXISTING UNIT
stainless steel braided flexible hose connectors.
client requirement.
A large refinery utility contractor in Colombia, responsible for maintenance of circulating water pumps, chilled water pumps, and auxiliary process pumps across multiple units approached us after their existing systems installed across Colombia and close by regions had been experiencing repeated premature failures of the flexible pump connectors, including:
Our audit report revealed that standard stainless steel braided flexible hose were being misused as metal expansion joints, stretched to compensate for misalignment and thermal growth. In several locations, the connectors had been compressed, torqued, or laterally offset beyond allowable limits, contrary to manufacturer guidelines. Secondly, the specification of stainless steel corrugated hoses and metal expansion joints currently installed were not designed to absorb the working conditions, and needed to be redesigned for their application requirements.
application requirement and our suggestions.
The end user required replacement stainless steel braided flexible connectors strictly for vibration isolation and minor lateral offset, not for axial movement or thermal expansion. The approved required sizes and configurations were:
Threaded NPT Connection
Flanged Connections
Operating Conditions
Design Pressure: 10 bar to 25 bar
Design Temperature: Up to 90°C
Ambient Conditions: Coastal, humid, high salinity
As this was a maintenance replacement project rather than a new installation, the pumps were already in operation. However, the maintenance team had been dealing with frequent breakdown call-outs, repeated leakage issues, and elevated vibration levels across several pump sets. All the existing problems were identified by our team:
design specification consideration and manufacturing.
To address the recurring failures, the client was supported with detailed engineering calculations, clear installation instructions, and complete inspection and testing documentation. The final solution was developed with a strong focus on correct application rather than simply replacing components.
Following installation at their site in Colombia, the client observed an immediate and measurable improvement in overall system performance.
Vibration levels transmitted into the piping were significantly reduced, pump nozzles were no longer subjected to undue stress, and no leakage or signs of early wear were noted during commissioning and initial operation.
When compared with the previously installed units, the client was particularly satisfied with the improved flexibility, accurate fit-up, and robust construction of the new stainless steel braided flexible connectors.
From a maintenance perspective, the most notable improvement was the elimination of field adjustments and forced installation practices. The connectors fit correctly from the outset and performed exactly as intended.
The correct selection of stainless steel braided flexible connector and metal expansion joint becomes a reliability asset rather than a maintenance liability.
