The oil and gas industry makes modern life possible. People depend on oil to fuel their cars, gas to cook and heat their homes, and petrochemicals to create many of the everyday products and high-tech devices we’ve come to rely on. Before these natural resources reach homes and offices across the world, they must be extracted from the earth, then carefully transferred, refined, and distributed.
Extreme conditions, from corrosive materials, high temperatures and pressures to constant movement and mishandling, make the journey a particularly challenging one. Downstream processes are further tested by turnarounds, routine refinery maintenance projects which involve full or partial shutdowns of operation for inspection, cleaning, and repairs.
While the oil and gas industry is notorious for boom and bust cycles, the fact remains that so long as we rely on fossil fuels to power our lives, investment in new projects and upgrades will continue.
The U.S. is projected to invest more than $500 billion in new oil and gas infrastructure by 2035, including pipelines, processing, and storage facilities. [1]
Metal Hose Use Cases in Refinery Maintenance
Every stage of the oil and gas value chain relies on hoses, valves, and fittings that must perform under harsh, often hazardous conditions. A single leak, spill, or fire can jeopardize worker safety, disrupt operations, and damage reputation.
While it’s far from the only, refinery maintenance is one of the most demanding oil and gas application areas for metal hose. Thanks to their durability and ability to perform in harsh operating environments, metal hoses are trusted components in many downstream processes.
- Hydrocarbon drain lines
- Steam injection lines
- Temporary bypass piping
- Burner connections
- Tank transfer lines
- Lubrication lines
- Chemical injection lines
- Vapor recovery hoses
Application Snapshot: Vapor Recovery
Vapor recovery focuses on capturing volatile, valuable hydrocarbon vapors that escape during storage, transfer, and processing to prevent air pollution, comply with environmental regulations, and recycle gases back into the production system. Flexible metal hose assemblies support these connections where chemical exposure, temperature swings, and routing constraints demand reliable, leak-tight performance.
Material Performance Considerations for Oil & Gas Applications
In high-risk environments such as refineries, pipelines, and offshore platforms, the materials used to build flexible connections must endure high temperatures, fluctuating pressures, and corrosive substances. Metal hoses are uniquely suited to this work.
They resist UV degradation—unlike rubber and plastic hoses, which quickly weaken when exposed to sunlight. This makes metal hose ideal for temporary connections or outdoor installations where exposure is unavoidable.
Shelf life is another advantage. Non-metallic hoses naturally degrade over time, even in storage, and require periodic replacement. Metal hoses do not have a shelf life, allowing operators to maintain inventory without concern for aging materials and reducing overall replacement frequency.
And, unlike rubber and composite hoses that emit unhealthy chemicals into the environment, metal hoses do not contain per- and poly-fluoroalkyl substances (PFAS), or forever chemicals linked to cancer, liver problems, and thyroid issues. As a result, there’s no risk of running into PFAS-related regulatory issues that could disrupt operations or impact reputation.
Finally, metal hoses are compatible with a broader range of flow media than polymer-based alternatives. Their resistance to chemical attack not only extends service life but also gives operators flexibility to use the same hose in different applications.
Hoses Designed for Maintenance and Reliability Professionals
Refinery maintenance teams operate in high-risk environments where reliability, safety, and response time matter. Penflex supports the people responsible for keeping facilities running by delivering hose assemblies engineered for durability, leak integrity, and long service life in demanding refinery conditions.
Materials: Penflex offers a wide selection of corrosion-resistant alloys and heavy-walled hoses designed to handle aggressive media. Our in-stock options, including 316L, 321, Inconel 625, Hastelloy C-276, and Monel 400, are ready for immediate delivery to support your operational demands. We’re capable of making hose from other alloys as well. For instance, we manufactured a line of hoses using AL-6XN for an offshore application. AL-6XN provides exceptional resistance to both seawater and stress corrosion cracking.
Superior corrosion resistance: While all hoses are prone to deterioration if they’re continuously exposed to harsh substances and intense pressures, our line of thicker-walled hoses offer significantly greater corrosion resistance than standard options. Take sour gas for example. It contains chemicals, like hydrogen sulfide, that are highly-corrosive and toxic. Even short-term exposure can be fatal. When handling lethal, aggressive material, a heavy-wall hose is essential—not only to prevent stress cracking that could derail operations but to safeguard the health and safety of your team.
High-performance design: Our flexible metal hoses are available in sizes ranging from ¼” to 24” to suit any application. Built from durable metal and reinforced with high-coverage single, double, triple or quadruple braids, they’re engineered to withstand extreme pressures while offering high-quality protection against external damage. To further extend service life, a selection of our hoses are made with pressure-rated Type A stub ends that prevent cracking, leaks, and damage at connection points. Take a look at the pressure rating for our various hose sizes here.
Durable construction: When pressurized, a hose naturally expands. Our heavy, high coverage braids act as a reinforcement layer, helping the hose maintain its shape, strength, and integrity under dynamic pressure and temperature swings.
High pressure ratings: When corrugated hoses are pressurized, the material expands. Braid functions like a restraining cage, preventing the hose from elongating or swelling and, thus, acts as the pressure carrier. Depending on size, wall thickness, and hose series, Penflex hoses can reach working pressures up to 5,000 PSI.
Quality welds: High-quality welds are essential to hose integrity and long-term performance. At Penflex, we achieve this through a proven process that includes TIG welding and argon purging, which together produce clean, strong welds without compromising corrosion resistance. Our team includes ASME Section IX–certified welders, on-site certified welding instructors, and non-destructive examination (NDE) specialists, ensuring every assembly is tested and leak-tight before it leaves our facility.
Recommendations for extending service life: Leveraging our experience with oil and gas applications and refinery maintenance projects, and in an effort to help hoses last longer in service, Penflex developed a video detailing common causes of failure related to hose handling.
- Braid bulging
- Braid wear
- Exposure to the elements
- Extreme over bending
- Hose stacking
- Too-tight protective covering
Recommended Products for Oil & Gas Applications
P4 Series
General purpose industrial hose used for many refinery maintenance applications, including turnaround hoses.
776 Hastelloy
For the most aggressive chemical applications, Hastelloy C-276 may be the appropriate alloy for the job.
1400 Series
Penflex’s most robust design, 1400 Series features our thickest wall construction and 3 or 4 braid layers for the highest pressure applications.
Beyond the Product: A Trusted Partner in Refinery Maintenance
At Penflex, we see every order as an opportunity to continue building our relationship with a current customer–or the beginning of a partnership with a new customer. Our customers count on us not only for a quality product, but also for expertise, responsive service, and resources to help them get the most out of their investment.
Dedicated Engineering Support
Our sales engineers work closely with you from project prototype through delivery, helping define requirements for new products and replacements. A dedicated account manager means you have a single point of contact who understands your business and responds quickly with thoughtful solutions.
Practical Technical Resources
From online calculators and engineering bulletins to in-person and virtual training, we give your team the tools to make informed decisions and the confidence to install, operate, and maintain hoses for maximum longevity.
Full Quality Documentation
On request, we provide complete record packs—including material test reports, leak and pressure test results, and cleaning procedure documentation—so you can meet compliance requirements and maintain full traceability.
Our commitment to service is reflected in our 99% customer retention rate and an average customer relationship of 20 years. We aim to make every interaction count, combining technical know-how with the kind of service that turns first-time buyers into long-time partners.
Footnotes
[1] ICF. U.S. oil and gas infrastructure investment through 2035. Retrieved November 17, 2025 from https://www.icf.com/insights/energy/us-oil-and-gas-infrastructure-investment-through-2035.