Hose testing and inspection are important parts of maintaining safe industrial equipment, but understanding the legal requirements in the UK isn't always straightforward.
One common misconception is that there is a single UK regulation stating that every industrial hose must be pressure tested every 12 months. In reality, requirements depend on the hose, the wider pressure system, the substances involved, the application and the manufacturer's or site's inspection regime.
So, what do UK regulations actually require?
Is there a legal requirement to inspect industrial hoses?
There isn't one universal statutory inspection interval that applies to every industrial hose.
However, employers have general duties to protect people from risks associated with work equipment and pressure systems. Where hoses form part of a pressure system within the scope of the Pressure Systems Safety Regulations 2000 (PSSR), specific requirements may apply.
The Health and Safety Executive (HSE) explains that PSSR are intended to prevent serious injury from hazards associated with stored energy in pressure systems and their components.
The key point is that businesses need to understand the equipment they operate and establish an appropriate inspection and examination regime.
When can the Pressure Systems Safety Regulations apply?
PSSR apply to certain pressure systems used at work.
The HSE identifies relevant fluids as including compressed or liquefied gases, including air, at pressures above 0.5 bar above atmospheric pressure, as well as certain pressurised hot water and steam systems.
However, whether an individual hose is included within a PSSR written scheme depends on its role within the pressure system and whether its failure could give rise to danger.
The HSE states that a written scheme should identify the items of plant or equipment that form part of the pressure system and specifies that parts of pipelines or pipework that could give rise to danger if they failed should be included.
This is why it is important not to treat every hose in exactly the same way.
What is a Written Scheme of Examination?
Where PSSR applies, a Written Scheme of Examination (WSE) is a key part of the safety arrangements.
The scheme sets out what parts of the pressure system need to be examined, the nature of the examination, the maximum interval between examinations and other relevant requirements.
It must be prepared or certified as suitable by a competent person, and the pressure system must be examined in accordance with the scheme.
For a site using numerous flexible hose assemblies, maintaining clear identification and records can make it considerably easier to demonstrate that the appropriate equipment has been examined.
Does PSSR specify a 12-month hose test?
Not as a blanket requirement for every hose. The examination interval is determined by the Written Scheme of Examination and the requirements of the particular pressure system and this distinction is important.
You may encounter industry guidance, manufacturer recommendations or site procedures specifying annual testing or inspection. Those requirements can be appropriate for a particular application, but they should not automatically be presented as a universal legal requirement for every industrial hose in the UK.
A competent person should determine the appropriate examination arrangements for equipment covered by PSSR.
What should a hose inspection look for?
Regardless of the regulatory framework applying to a particular installation, visual inspection is an important part of good hose management. Depending on the hose and application, inspection may identify:
- Cracks or splits
- Cuts or abrasions
- Bulging
- Kinks
- Flattening
- Excessive wear
- Chemical deterioration
- Cover damage
- Exposed reinforcement
- Damaged couplings
- Corrosion
- Loose fittings
- Evidence of leakage
- Damage around the hose ends
- Signs that the hose has been subjected to excessive bending
The surrounding installation should also be considered. A hose can be in good condition but still be incorrectly routed, unsupported or subjected to forces outside its intended operating conditions.
What is involved in pressure testing?
Hydrostatic pressure testing involves filling the hose assembly with a suitable test medium and applying pressure under controlled conditions. The purpose and procedure of a test depend on the hose, assembly, standard and application. BS EN ISO 1402:2021, for example, specifies methods for hydrostatic testing of rubber and plastics hoses and hose assemblies, including leakage, burst pressure and dimensional stability testing. The applicable test pressure should therefore be established from the relevant specification, standard, manufacturer requirements or agreed testing procedure rather than simply applying one pressure to every hose.
Why hydrostatic testing is commonly used
Hydrostatic testing uses a liquid rather than compressible gas as the test medium. This can reduce the amount of stored energy compared with pneumatic testing, although pressure testing still requires appropriate risk controls and competent procedures. Integraflex has developed enclosed testing equipment to allow hose assemblies to be pressurised and visually inspected within a controlled environment.
Electrical continuity can also matter
For certain industrial applications, electrical continuity is an important consideration. This can be particularly relevant where static electricity could present an ignition risk. The requirements depend on the application and the hose construction. Integraflex provides electrical continuity testing on a range of hose assemblies and offers test certification where required. Where hoses are used with flammable substances or in hazardous areas, electrical properties should be considered as part of the overall risk assessment.
DSEAR and hose selection
The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) place duties on employers and the self-employed to protect people from risks associated with fires and explosions involving dangerous substances. HSE guidance explains that DSEAR covers workplaces where dangerous substances are manufactured, stored, processed or used and requires risks to be assessed and controlled.
This can be particularly relevant to hoses used for flammable liquids and gases. For example, the hose specification may need to consider:
- Chemical compatibility
- Static electricity
- Electrical continuity
- Pressure
- Temperature
- Hazardous area requirements
- Connection methods
- Potential release points
The hose should therefore be considered as part of the wider process rather than as an isolated component.
Why hose identification matters
Testing is only useful if you can establish which hose was tested. On larger industrial sites, hoses can look almost identical while serving completely different processes.
A robust identification system can link each physical hose to information such as:
- Unique hose ID
- Location
- Service
- Hose specification
- Manufacture date
- Test date
- Test pressure
- Next test or inspection date
- Test certificate
- Inspection history
Integraflex provides hose identification using stainless steel and aluminium tags, barcodes and RFID, alongside digital hose registers that allow test certificates and asset information to be accessed when required.
What happens when a hose fails inspection?
A failed hose should not simply be returned to service because it still appears usable. The appropriate response depends on the nature of the defect and the requirements of the site's inspection procedure. A robust hose management programme should provide a clear process for:
- Identifying the failed hose.
- Removing it from service where necessary.
- Recording the failure.
- Investigating the cause where appropriate.
- Repairing or replacing the assembly.
- Updating the hose register.
- Retesting the replacement or repaired assembly where required.
- Retaining the relevant documentation.
Failure records can also help identify recurring problems, such as incorrect routing, excessive abrasion or unsuitable hose specifications.
Building an audit-ready hose management system
For sites with large numbers of flexible hose assemblies, spreadsheets and paper certificates can quickly become difficult to manage. A digital hose register can provide a central record of the site's hose assets, including inspection and testing information. Integraflex's hose management service can include hose inventories, visual inspections, hydrostatic testing, asset registers, identification and test certification. This creates a much clearer audit trail than relying on individual certificates stored in different locations.
The key takeaway
UK hose testing requirements cannot be reduced to one universal inspection interval. The correct approach is to understand:
- What the hose is used for
- Whether it forms part of a pressure system covered by PSSR
- What the Written Scheme of Examination requires
- What standards apply
- Manufacturer recommendations
- Site risk assessments and procedures
- The substances being transferred
- The consequences of hose failure
For safety-critical applications, a documented inspection, testing and identification programme can provide an important layer of control while making compliance and auditing easier to demonstrate. If you need help developing a hose testing or management programme, Integraflex can provide hose inspection, pressure testing, identification and asset-management solutions for industrial applications.