Maintaining Fuel Transfer Hoses for Safety and Savings

Ensuring the reliability of refuelling infrastructure and reducing associated business risk requires effective management tactics. 

Refuelling is a critical daily task. Procuring correctly specified fuel transfer equipment and incorporating proactive maintenance and operational inspections will help avoid catastrophic equipment failure, and the potential for uncontrolled discharge of fuels.

The recommendations below relate to Fuel Transfer Hoses, and provide the visibility so early intervention can mitigate risk and enhance operational certainty throughout the refuelling chain.

fuel transfer hose degradation

Each fuel transfer hose manufacturer can specify inspection routines, maintenance requirements, and the appropriate applications for their hoses specifically.

Tips for Hose Selection and Onsite Management that deliver Safety and Savings


Hose Selection and Installation

  • Liaise with Banlaw, your local hose and fitting supplier or your preferred fuel hose manufacturer to plan which hoses will suit the onsite environment, application, flow rate, and expected working pressure

  • Place all new and existing hoses (fixed and mobile) on a maintenance program to track their age and condition over time

  • Install a break-away valve at each refuelling location to protect your fuelling infrastructure and prevent uncontrolled spills should a drive-away event occur


Periodic Inspection of Hoses

  • Fuel hoses should be visually inspected for damage each time they are used

  • Fuel hoses should be subjected to hydrostatic testing on an annual basis

  • Fuel hoses should be subjected to electrical continuity / insulation testing on an annual basis

  • Fuel hoses should be further inspected or tested in line with specific OEM recommendations


Automatic Conditions for Hose Replacement

Conditions for Automatic Fuel Hose Replacement
If a hose is older than 5 years from the manufacture date, then it should be routinely replaced to eliminate the risk of failure. Likewise, visible degradation or driveaway events should initiate the immediate replacement of a fuel transfer hose.

The periodic replacement of fuel hoses every 6 months may be the best way to mitigate the risk of failure, particularly if the testing regimes outlined above are infeasible for your worksite. 

Banlaw recommends that the following list of symptoms should initiate the automatic replacement of a hose:

  • The fuel hose has been in a drive-away scenario

  • The fuel hose has received a cut or penetration to the outer sheath

  • The fuel hose has been run over by a vehicle and has not returned to its original geometry

  • The fuel hose has visible cracks, splits, blistering or significant abrasion

  • The fuel hose has leakage from any section

  • The fuel hose is older than 5 years from the date of manufacture


The recommendations above for managing fuel hoses are pragmatic and actionable and will help your business maximise the ROI from your selected refuelling equipment through enhanced Safety and Performance. To speak with a specialist regarding your own specific needs, please Contact Banlaw or your local Authorised Banlaw Distributor.

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