CUSTOMISATION AND IMPROVEMENT PROJECT FOR EXISTING UNIT

PYRO JACKETED FIRE-SAFE FLEXIBLE METAL HOSE ASSEMBLIES

Fire-Safe Pyro Jacketed Metal Hose Installation

CLIENT REQUIREMENT

During a safety audit for an onshore petrochemical project in Saudi Arabia ( K.S.A.), an EPC contractor identified concerns with several flexible metal hose connections installed on pump discharge and recirculation lines. The plant handles flammable hydrocarbon streams, and the audit focused specifically on equipment located within designated fire zones.

The review found that standard stainless steel braided hose assemblies were being used in areas where higher levels of mechanical protection and fire integrity were required. While suitable for general service, these metal hoses offered limited resistance to external impact and did not provide adequate protection in the event of a fire or jet-fire scenario.

In Saudi Arabia's petrochemical facilities, it is common practice to replace conventional stainless steel corrugated flexible hoses with fire-safe customized metal hose assemblies when installed in fire zones. This becomes especially important on pump discharge lines, where higher operating pressures increase the severity of a potential jet-fire if a pinhole leak or rupture occurs.

The metal hose assemblies currently installed were connected to pumps handling flammable hydrocarbon liquids and were continuously exposed to demanding operating conditions, making them unsuitable for long-term service without additional protection.

OPERATING CHALLENGES

High Pressure & Surges

High internal pressure, along with pressure surges during start-up and operation

Continuous Vibration

Vibration transmitted from rotating equipment

Mechanical Damage Risk

Exposure to external mechanical damage during routine plant activities

Fire Resistance Required

Mandatory fire resistance and leak containment for hydrocarbon service in fire zones

Harsh Environment

Harsh ambient and site conditions typical of petrochemical installations

Maintainability

Easy replacement in case of external protection failure

CLIENT EXPECTATION

The client required a fire-safe stainless steel corrugated hose assembly suitable for critical hydrocarbon service, with multiple layers of protection to address both mechanical and thermal risks with easy maintainance. The metal hose assembly needed to maintain pressure integrity under dynamic conditions, limit leak escalation in the event of damage, and provide reliable performance during fire or jet-fire exposure, in line with site safety requirements.

OCELFLEX SOLUTION

Ocelflex provided its OC101XFH-42 Series - Pyro Jacketed Steel Armored Flexible Metal Hose for this heavy-duty, high-temperature application. Our OC101XFH-42 Series flexible metal hose is a fully integrated stainless steel corrugated hose designed to combine pressure containment, external mechanical protection, and advanced fire resistance in a single unit.

At the core of the OC101XFH – 42 Metal Hose Assembly is an annular stainless steel corrugated hose, manufactured from a high-grade stainless steel selected for elevated temperature service and long-term reliability in hydrocarbon environments. The metal hose under this category is particularly designed for pump discharge and recirculation lines, so this hose is particularly thick walled and hydro formed, which can perform well in continuous vibration and minor misalignment cases.

The stainless steel corrugated hose is reinforced with a heavy-duty, full-coverage stainless steel wire braid to safely withstand operating pressure and pressure fluctuations. To provide additional external protection, the metal hose assembly was manufactured with a highly flexible stainless steel double-profile interlock armor.

The OC101XFH-42 Metal Hose Series incorporates a specially engineered silicone-coated fire protection sleeve, commonly referred to as a Pyro Jacket metal hose. Unlike standard pyro-jacketed flexible metal hoses available in the market, this fire protection system is purpose-designed for critical hydrocarbon service and high-risk fire zone applications.

Ocelflex Pyro Jacket metal hose design incorporates a textured fiberglass substrate with diagonally arranged air gaps of up to 2 mm, which promote self-cooling and help reduce heat transfer during flame exposure. When subjected to direct fire, the outer silicone rubber outer layer does not support flame propagation.

This unique construction of the fire resistant fiber glass sleeve significantly reduces heat transmission to the underlying stainless steel corrugated hose assembly, delaying hose failure and providing valuable time for emergency isolation and system shutdown.

Ocelflex's OC101XFH-42 Series pyro jacketed fire protection sleeve over the stainless steel hose is designed for continuous operation across a wide temperature range, from –68 °C to approximately 248 °C, can withstand short-duration flame exposure of up to 1094 °C under controlled conditions and peak temperatures at 1648 °C for few seconds (15 to 30 seconds).

Ocelflex's specially formulated silicone compound causes molten droplets to shed immediately rather than adhere to the surface, reducing localized heat absorption. This characteristic further enhances the safety of the underlying metal hose assembly.

The metal hose assemblies were completed with welding neck flanges manufactured from stainless steel in accordance with ASME B16.5. The assembly was manufactured to ensure leak-tight and structurally sound end connections.

KEY FEATURES

Pyro Jacket Protection Double Interlock Armor Fire Resistance up to 1648°C ASME B16.5 Flanges Hydrocarbon Service Rated

The Heavy duty Silicone Coated Fiber Glass Flexible Metal hose - OC101XFH-42 series assembly supplied by Ocelflex have demonstrated satisfactory service life and consistent performance in plant operations.

Based on these operating experiences, the EPC contractor has selectively replaced standard stainless steel braided flexible hoses with Ocelflex fire-safe metal hose assemblies on similar applications across projects in the GCC region, including Saudi Arabia, Kuwait, and Oman.

This adoption has been driven by observed reliability and alignment with site safety requirements rather than any change in process conditions.

OCELFLEX MANUFACTURES CUSTOMIZED STAINLESS STEEL CORRUGATED HOSES DESIGNED FOR FIRE SAFETY AND HARSH CONDITIONS. OUR CUSTOMISED FLEXIBLE METAL HOSES WITH EXTERNAL HIGH QUALITY SILICONE COATED FIBERGLASS COVER SOLUTIONS ARE ENGINEERED TO HANDLE EXTREME TEMPERATURE AND HIGH PRESSURES.

Why Choose Ocelflex as your manufacturer for Flexible Metal Hoses in Saudi Arabia?

At Ocelflex, we go beyond catalogue products. Each OC101XFH-42 Series hose is custom-engineered to suit your operating pressure, temperature, movement, installation constraints, and safety philosophy.

If your application demands a reliable, fire-safe flexible connection for critical applications, the OC101XFH-42 Series Hoses from Ocelflex are engineered to deliver exactly that. Designed for high-pressure, movement and fire-risk environments, these hose assemblies combine annular corrugated stainless steel hose, customized reinforced stainless steel braid, interlocked mechanical armor, and a high performance silicone and fiberglass fire protection sleeve to meet the stringent safety and performance expectations of modern petrochemical and refinery facilities.

Flexible Metal Hose