Do-it-yourself high-pressure hose repair

=Repair of high pressure hoses=
I decided to make a series of projects on the topic = WE DO IT OWN =. I want to show some devices that can be used to make various repairs with high quality and for a long time, sometimes even those that seem to be impossible to do at home. But everything is done by human hands, one has only to want to do it. In my works, I will show the equipment and devices that I made myself for my work, although it may not be so beautiful aesthetically, but in terms of the parameters of work, it has completely satisfied me for many years now.

Video Do it yourself Repair high pressure hoses channel Petr Zhurba

High pressure hoses are used in pneumatic and hydraulic applications. In the automotive industry, they have found wide application in steering. Thanks to the built-in hydraulic booster, the driver has the opportunity not to apply a significant load on the steering wheel when turning.

However, under certain operating conditions, various deformations of the tubes or sleeves are possible. Subsequently, this leads to unstable operation of the unit, which can be corrected by repairing the power steering high-pressure hoses with their own hands or with the help of service station specialists.

Hoses, which are more commonly referred to as high pressure hoses, are flexible pipelines for which the main task is to pump working fluids. The transported material is specially prepared motor oils or working fluids based on mineral oils, aqueous solutions of emulsols, glycol, and greases.

Without high-quality flexible hoses that can withstand the required pressure, and an extensive piping system, it is difficult to imagine the operation of a hydraulic booster. In addition to the direct duty regarding the pumping of the working fluid, such hoses act as dampers (compensators) that increase the service life of connecting elements, fittings, fittings and the system as a whole.

Such results are facilitated by the absorption of vibration by flexible elements. The negative side of the phenomenon is that periodic replacement or repair of power steering hoses in worn areas is required. After all all scuffs or kinks soon lead to the fact that the tube leaks.

In addition to working under high pressure, the hydraulic booster hose must have a reduced susceptibility to the working fluids used. Due to this, its inner surface is made on the basis of oil-resistant and petrol-resistant synthetic rubber.

The outer surface is protected by layers of wear-resistant rubber. Under certain circumstances, this layer plays the role of thermal protection. It may have the following surfaces:

The outer and inner layers are separated by a metal braid. This gives the entire structure the required operational strength and acceptable rigidity. Wire layers alternate with rubberized elements.

It is customary to separate the following types of hoses:

• Coiling. During the manufacture of this product, the coils of wire are braided evenly around the entire perimeter.
• braided. Each turn covers the sleeve at a certain angle to the common axis in such a way that it intersects with the turns of the previous layers. This technology increases the strength of the structure and can operate at higher pressures than the previous type.

The frame for the sleeve in some models is textiles. Geometric and physico-chemical parameters of wire and rubber are standardized for various applications.

During operation, motorists may encounter various types of hydraulic damage, after which repair of power steering hoses is necessary. You can mark the following points:

1. Manufacturer's defect. The feature is typical for insufficiently known hydraulic equipment manufacturers. Breakage is characterized by poor-quality crimping of the joint of the sleeve or fitting. This happens when the equipment is not debugged or incorrectly configured.
2. Operating output. Damage occurs due to wear and tear during operation of the mechanism. The main problems are cord breaks, cuts and frayed areas. Often this occurs due to sagging of the hose due to the wrong length.
3. Structural inconsistencies. Failure occurs due to the installation of equipment that does not correspond to the characteristics specified by the automaker. In such situations, it is possible to break the wire or break the fittings due to a discrepancy between the pressure in the system and the allowable value for the hose.
4. Disagreement in temperature or chemical characteristics. Damage to the structure can occur during operation at ambient temperatures for which such rubber was not designed, as well as during the use of aggressive chemicals in the structure of the working fluid.

Damage to power steering hoses

All characteristics and permissible operating parameters for each hose are indicated by the manufacturer in the instructions for use.

Hydraulic malfunctions with which further operation of the vehicle is not recommended:

• fittings are significantly damaged by corrosion processes;
• significant fracture of the sleeve;
• significant abrasion of the outer part of the hose;
• the presence of complete or partial blockage inside the sleeves;
• lack of sealing connections;
• failure of the fitting from the landing diameter;
• liquid leakage at the joints;
• deformation or damage to the inner surface from high pressure or excessive temperature.

In all cases, replacement or repair of the sleeve is required.

Based on the nature of possible damage, it can be assumed that the most common repair of power steering hoses is to put the fittings in order or replace individual parts of the hose. For replacement, crimping with couplings will be required.

DIY repair tools

The work algorithm can be as follows:

1. The damaged hose must be disconnected from the system.
2. The new hose will need the same length so as not to create unnecessary sagging. Measurement is carried out from nipple to nipple. At the same time, we select a hose that satisfies all geometric data and pressure parameters. This will help the marking indicated by the manufacturer on the outside. The inner diameter will also be indicated there.
3. When repairing a high pressure hose, the ends are stripped both outside and inside to a metal braid. The procedure is carried out faster with the use of debarking machines.
4. Fittings are selected according to geometric parameters and technological thread data. Measurements are easy to take with a caliper and thread gauge. Domestic and foreign fittings may differ from each other according to several criteria, so it is better to take measurements yourself.
5. We crimp fittings on crimping equipment, using suitable removable cams in each case.
6. The control probe determines the quality of the work performed. In specialized factories, this operation is carried out using special industrial stands.

For non-standard connections, repair kits with recommended fittings must be used. You can detach the head of the old fitting, if it is not damaged, and solder it to the part to be pressed.This option is used in extreme cases, since the effect of this repair is short-lived.

Hose damage in most cases occurs due to the frequent turning of the steering wheel with great effort. Wear occurs at the hose connected to the restrictive valve.

When installing and repairing power steering hoses, it must be taken into account that the allowable pressure in the system may vary depending on car models in the range of 80 ... 130 kgf / cm 2.

Such significant performance indicators do not allow the use of any types of clamps during repairs. You must choose the most appropriate option:

1. Complete sleeve replacement.
2. Partial replacement of a deformed or worn section with installation of fittings on a new sleeve.

Replacement and installation of a new hose is carried out according to the following points:

• using a lift or jack, the front axle must be raised;
• the steering wheel is turned as far as possible to the left;
• a tube is put on the end of the medical syringe for pumping out the remaining working fluid from the tank;
• after pumping out, the hose must be disconnected and the hydraulic openings plugged;
• a new hose with acceptable operating characteristics is selected so that the performance characteristics of the assembly do not change;
• a new hose is installed in place of the old hose, after which the working fluid is poured into the system.

With proper work, the hydraulics are fully restored.

If the hose is torn off the flange, then you need to cut off the damaged section of the hose evenly, to the point where there are no extensions, cracks and undamaged cord.

Next, purchase the necessary flange and install it - fortunately, a large number of them are sold in auto stores and there is also a choice. The flange is inserted into the hose and simply crimped well with the help of a stop in the vise jaws and hammer blows from the third upper side.

If the damage is somewhere along the length of the hose, for example, a cut, a rupture, or something else, then we do exactly the same as in the first case, cut the hose and cut it to a whole, but here a connector of the desired diameter and a pair of clamps will help - just buy clamps not cheap, but good ones like those in the photo!

Repairing a high-pressure hose at Karcher is an almost hopeless business. If it is damaged in a straight section, crushed, chopped, and so on, then finding a double-sided Christmas tree branch pipe and compressing it at home on a hose is very problematic. You can do without buying a new (very expensive) hose only if it has begun to be torn off the outlet metal pipe. That is, the thread on the union coupling was torn off, and I don’t want to buy a new hose. Russian artisans do this:

A section of a rectangular pipe is taken, in my opinion, 45x25, the “CLIP” grip is carefully and thoughtfully cut out of it. With slots for the hose itself and for the pipe. I think it looks better in a photo. I repeat - if you don’t want to buy a new hose at all.

The design of the product, of course, is not a museum one, but it works properly. The connection may slightly dig, but this is not critical.

• High pressure hose repair
• High pressure hose damage
• How are high pressure hoses repaired?
• Repair of power steering hoses

High-pressure hoses, more commonly referred to as high-pressure hoses or high-pressure hoses, are designed to absorb or create work forces that, under the influence of high pressure, are transmitted through the liquids or gases pumped into them. High pressure hoses are mainly used in hydraulic and pneumatic systems and mechanisms. In addition to industrial production, high-pressure hoses are also found in road transport - in power steering and in high-pressure hydraulic pumps, for example, the Karcher brand, which is the most common in our country.

The causes of rupture and cracking of high pressure hoses can be divided into several types:

1. Manufacturer's defect. Often this is a poor-quality crimping of the junction of the hose and fitting due to the use of poor-quality or non-adjusted equipment.

2. Damage that was received during the operation of the main mechanism. They occur as cuts and ruptures of high pressure hoses. The most common reason for this is sagging high pressure hoses due to incorrect lengths.

3. Damage caused due to mismatch of hose parameters with operating conditions. This can be either a failure of the fitting or a rupture of the high pressure hose. As a result, the pressure exceeds the allowable pressure for which the hose itself is designed.

4. Damage to the outer layer that occurs when using the high pressure hose in the wrong temperature regime, for which the hose is not designed to work.

It's important to know! For maximum protection of high-pressure hoses from possible damage, it is necessary to seriously check their characteristics and parameters for compliance with operating conditions. First of all, this is the calculated value of the maximum allowable pressure, temperature and minimum bending of the high pressure hose.

TO the most common damage to high pressure hoses can include the following:

1. Highly corroded fittings.

2. Fracture RVD.

3. Abrasion and wear of the upper layer of the sleeve.

4. Hose blockage.

5. Depressurization of the fitting connection.

6. Breaking the fitting from the sleeve.

7. Fitting joint leak.

8. Damage to the inner rubber layer as a result of exposure to high temperatures.

From the foregoing, it can be summed up that the repair of high pressure hoses consists in replacing fittings or certain damaged sections of high pressure hoses. When replacing, both in the first and in the second option, crimping of the coupling will be required. Technologically, in both cases, these actions are almost identical. The sequence of actions is as follows:

1. The damaged hose must be disconnected from the main mechanism.

2. Cut off the new sleeve the same size as the old one. For measurement, it is necessary to take the distance between the end faces of the nipples. It is better to choose a hose designed for the maximum possible pressure in the system, or at least one that will withstand greater loads than the one being replaced. When selecting the required diameter, be guided by the markings indicated on the sleeves. Factory marking DN indicates the diameter of the internal channel of the hose.

3. If you have to repair a heavy hose that is designed to withstand increased pressure, its ends must be stripped inside and out to a metal braid. This procedure is best done on debarking machines.

4. Next, select the necessary fittings. This can cause some inconvenience, due to the fact that imported parts can be made to completely different standards. If you have any difficulties, it is better to measure the old fitting with a caliper and thread gauge. This will allow you to most accurately select the necessary parameters of the new fitting according to the tables.

5. Next, you need to crimp the fittings on a crimping machine. Removable jaws are individually selected for each diameter.

6. Then be sure to check the quality of the procedure performed using the control probe. Ideally, you need to test on a specially equipped test bench. If the connection is non-standard, a repair fitting is used. To do this, take the head of the old fitting and solder the part that will need to be crimped. This method is suitable for emergency repair of power steering hoses.

Power steering high pressure hoses are damaged mainly when the steering wheel is rotated, during which serious forces are generated.The result is a deformation of the elastic element, which changes the size of the openings of the distribution mechanism that regulates the pressure drops in the hydraulic cylinder. There is wear on the power steering sleeve connected to the restrictive valve.

This element is designed for a certain pressure, which varies depending on the make and model of the car: from 70 to 130 kgf / cm2. At such a high pressure, repairing a damaged power steering hose with clamps or wire is simply impossible. There are a couple of options left: either replace the entire power steering tube, or only its damaged parts by mounting the fittings on a new hose.

Replacing and installing a new hose power steering is carried out as follows:

1. Jack up the front of the vehicle.

2. Turn the steering wheel all the way to the left.

3. Attach a tube from the power steering reservoir to the syringe with a needle and pump out all the liquid.

4. Then disconnect the hose and plug the working openings of the hydraulic system.

5. Accurately observing all the parameters, select a new hose. Otherwise, the functional qualities of the power steering will change.

6. Install a new hose, refill the fluid and check the quality of the installation.

Modern cars that are supplied to the market are increasingly equipped with a power steering system. The hydraulic booster is included in the design of the steering mechanism and makes it easier to control the vehicle. The driver does not have to make great efforts when turning the steering wheel. For the stable operation of the hydraulic system, it is important to ensure a constant and free flow of the working fluid between the constituent elements inside - this task is solved with the help of special hoses. Over time, this structural detail fails.

The Lengidravlika company offers its assistance in replacing the connecting elements. All work is carried out by experienced specialists of the MAZDA service (address: St. Petersburg, Bobruiskaya st., 11). Our customers expect good discounts on services. As an alternative, car owners can also repair power steering high pressure hoses with their own hands.

Flexible tubes included in the power steering design are commonly called high-pressure hoses. Elements play an important role in the operation of a hydraulic structure. Through the hoses are transported, pumped into the system, liquids and gases. In addition, high pressure hoses absorb vibrations, increasing the life of the steering components. Hose connections are subject to considerable stress. In addition to mechanical deformations and bends, the tubes of the power steering system are tested by high pressure, temperature changes, withstand the aggressive effects of chemicals, on the basis of which automotive fluids are produced.

The service life of the tubes largely depends on their quality and the reliability of the connecting fittings. The construction of the hoses includes an inner and outer layer, as well as a metal braid. The outer part of the tubes is made of heat-resistant, wear-resistant rubber. The inner surface of the hose is synthetic rubber. The braid gives the high-pressure hose additional strength, allowing it to be safely used in extreme conditions.

Masters name a number of reasons why repair of the connecting hose is required:

1. 1. Poor quality of fitting crimping or marriage in the tube.
2. 2. Inconsistency of the parameters of the installed hose with the conditions of use (too high pressure, violation of the temperature regime, wrong choice of product length).
3. 3. Damage caused by long-term operation of the high-pressure hose (hose leak due to a break or cut, corrosion processes and violation of the sealing of joints, abrasion of the surface).

A high-pressure hose malfunction is indicated by hum and extraneous noise when the pump is turned on, a decrease in the liquid level in the car’s tank, and fuzzy steering operation.Before carrying out repairs, it is important to accurately determine the location and nature of the damage to the high pressure hose - you can do this yourself or seek help from MAZDA service specialists. Professionals in the auto repair shop will perform the work efficiently and inexpensively.

Each car owner closely monitors the technical condition of his steel "horse", because the safety of its operation depends on it. Worn or damaged power steering hoses are a common cause of breakdown and malfunction of the steering. Regardless of the nature of the problem, it is solved in two ways - complete or partial replacement of the high pressure hose. The pressure level in the power steering system is quite high - 70 to 130 kgf / cm2. With such indicators, clamps cannot be used to fasten hoses. It is also not recommended to solder fittings to highly stressed hoses - this can only be used as a temporary measure.

When planning to carry out a complete replacement of the high pressure hose with your own hands, follow the scheme:

• - Raise the front of the vehicle and turn the steering wheel all the way to the left.
• - Put the end of the hose on the syringe and pump out the technical fluid from the tank.
• - Plug the openings in the control system after the complete dismantling of the high pressure hose.
• - Select a new part with suitable parameters and replace it.
• - Top up the required volume of pumped liquid back.

In some situations, it will not be necessary to replace, but to repair the hose (HPR) with your own hands. Subject to certain rules and the presence of a tool, it is easy to perform such manipulations:

• - Disconnect the damaged hose, carefully measure it and look at the markings. When selecting new hoses, make sure that the parameters match.
• - The ends of the high-pressure hoses are carefully cleaned inside and out to the braid using a debarker.
• - Choose reliable and suitable fittings in size - fittings.

— Fittings are fastened to the sleeve by means of crimping equipment.

- Check the quality of the work done.

Attentiveness, accuracy and strict adherence to the instructions will allow you to quickly and efficiently repair power steering high-pressure hoses with your own hands. But if you have any questions or difficulties in the process of work, be sure to contact the specialists of our car service. Extensive experience allows us to replace the RVD in the shortest possible time.

Of course, a garden hose isn't that expensive, but I personally can't bring myself to go out and buy a new one if I can repair the existing one myself. The hose can be repaired no matter what part of it is leaking, whether it is for a high pressure washer, such as Karcher or it is a regular garden hose. Here I will tell you how to repair the end of the watering hose.

This will require:

• defective 5/8 inch (16 mm) watering hose;
• replaceable tip (in our case, a 5/8-inch sleeve);
• hose clamp;
• utility knife (anything will do, as long as you can cut the hose with it);
• screwdriver.

Having found damage, the first step is to either make sure that it is the only one, or find all and evaluate their location. In my case, only the end of the hose is damaged, the rest is quite usable. If the damaged sections are scattered along the entire length, it will be easier not to repair the hose, but to throw it away and buy a new one.
We cut off the entire damaged part of the hose with a small margin, since we need an absolutely serviceable end for repair.

Having cut off the damaged part, we put the clamp on the remaining fragment of the hose, but do not tighten it.

Carefully insert the sleeve into the tip of the hose, this should not require any extra effort. The tip should hold on its own without additional fixation. If this is not the case, then either the size of the sleeve is not selected correctly, or the structure of the hose is completely damaged.If everything is correct, the sleeve can be secured by tightening the clamp first with your hands, and then with a screwdriver.

Repair successfully completed, you can proceed to watering.

The two most commonly used hose sizes are 5/8 and 1/2 inch. Long hoses are usually slightly wider (5/8"), 1/2" (12.5 mm) hoses are usually shorter. If the exact diameter cannot be established, repair parts for both sizes can be purchased. Those that don't fit can be returned.

If the defective section of the hose is located in the middle, the procedure will be the same, only two clamps and a double-sided sleeve are required.

High-pressure hoses, more commonly referred to as high-pressure hoses (HPHs), are designed to create or absorb the working force that is transmitted under high pressure by liquids or gases pumped into them.

The main field of application of high pressure hoses is hydraulic and pneumatic systems of various devices and mechanisms. Outside of industrial production, motor vehicle owners most often deal with high-pressure hoses, these are power steering hoses (Power Steering), and those who use high-pressure pumps, for example, the most common Karcher brand in our country.

The design of the high pressure hose is due to the need to withstand internal pressure, which can reach up to several hundred atmospheres.

In addition, the inner surface of the high-pressure hose must be impervious to the media being transported. Therefore, its lower layer is made of oil and petrol resistant rubber or synthetic rubber.

For the manufacture of the upper, thicker layer of the high-pressure hose, wear-resistant rubber is used, which, if necessary, is supplemented with thermal protection in the form of a corrugated coating, metal or polymer.

A metal wire is wound in several layers between the upper and lower layers of rubber, thanks to which the hose receives the necessary rigidity and strength. Layers of wire are interspersed with thin rubber films.

Depending on the method of winding the wire, there are two types of high-pressure hoses:

1. Coiled. In the production of this type of hose, the coils of wire are wound in even rows.
2. Braided. In this case, the coils are wound at an angle to the axis of the hose so that the coils of the previous layer cross with the coils of the next layer of wire. Braided hoses are more durable and able to withstand more pressure than winding hoses.

In addition to the wire, textiles can act as an internal rigid frame.

The number of wire layers and the thickness of the rubber layers are set by standards that determine the scope of one or another type of high pressure hoses.

To fix the hoses in place, fittings (tips) are mounted at their ends, which are of the following types:

Fittings are fastened to the ends of the hose using compression couplings, which are pressed on special machines.

Depending on the type of shank, fittings are classified into series:

1. Universal. This series can be used in all high pressure hoses except coil type hoses.
2. Interlock. The series is used for winding sleeves.

When installing fittings of this type, it is imperative to remove both layers of rubber, inner and outer.

Fittings for high pressure hoses

The operation to remove layers of rubber is called hose debarking.

CS. Coiling sleeves are also crimped with fittings of this series, but it is no longer necessary to remove the rubber of the upper and lower layers.

Fitting failure is the most common cause of high pressure hose failure. This is due to the magnitude and intensity of the loads they experience.

The causes of damage can be divided into the following types:

• Manufacturing defects. Most often, this is poor-quality crimping of the joint of the fitting with the hose, due to the use of handicraft or non-adjusted equipment.
• Damage received during the operation of the main mechanism.They appear as cuts and ruptures in the hose. The most common cause of them is the sagging of the high pressure hose due to the wrong length.
• Damage caused due to inconsistency of the HPH parameters with the operating conditions. This could be a hose rupture or a fitting failure, due to which the pressure turned out to be higher than that for which the hose was designed.
• In the same row, damage to the outer layer of the high pressure hose should be mentioned when it is used in a different temperature regime for which it is designed.

Important! In order to protect as much as possible from possible damage to the high pressure hoses, when choosing them, it is necessary to carefully check the compliance of their characteristics and parameters with the operating conditions.

High pressure hoses with fittings

First of all, we are talking about the calculated value of the maximum allowable value of pressure, temperature and the minimum bending radius of the hose.
Among the damage to high pressure hoses, the most common are the following:

1. Fittings corroded.
2. Broken sleeve.
3. Abrasion and wear of the top layer of the hose.
4. Sleeve blockage.
5. Violation of the tightness of the fitting connection.
6. Hose fitting torn off.
7. Fitting joint leak.
8. Thermal damage to the inner layer of rubber.

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From the foregoing, we can conclude that the repair of high pressure hoses consists either in replacing the damaged area or in replacing fittings that have become unusable.

When replacing a damaged area, as well as when replacing fittings, it will be necessary to crimp the couplings, that is, technologically these two actions are very similar.

The sequence of operations in this case looks like this:

1. The damaged sleeve is disconnected from the main mechanism.
2. On a cutting machine, a new sleeve is cut to the size of the old one. Moreover, for measurement, the distance between the ends of the nipples at its ends is taken. It is better to choose a high pressure hose designed for more pressure than that for which the old high pressure hose was designed.
3. The markings that are placed on the sleeves will help you choose the right diameter.

Factory marking DN indicates the diameter of the internal channel of the hose.

If a hose designed for increased pressure (heavy hose) is to be repaired, its ends are cleaned from the inside and outside to a metal braid. This operation is carried out on barking machines.

Then select the desired fittings. This can be somewhat difficult as imported fittings are manufactured to different standards.
In case of difficulty, it is easiest to measure the old fitting with a caliper and thread gauge, which will allow you to accurately set the desired diameter and thread pitch and then select the desired parameters of the new fitting from the tables.

After debarking and selection of fittings, they are crimped on crimping machines. Removable swaging jaws are selected for each diameter.

The next step is to check the quality of the pressing. For this, a control probe is used, but it is best to test on a special test bench.

If a non-standard connection is found, then the repair is carried out using a repair fitting. For this, the head of the old fitting is taken, to which the part to be crimped is soldered.

This method is often used by motorists for emergency repair of power steering hoses, as well as owners of pumps and Kircher mini-washers.

The reason for the occurrence of damage to the power steering hoses most often is that when the steering wheel is rotated due to friction, a serious effort occurs. This force causes deformation of the elastic element, which changes the size of the holes in the distribution mechanism that regulates the pressure drop in the hydraulic cylinder.

As a result, the power steering sleeve, connected to the restrictive valve, wears out. This power steering sleeve is designed for pressure, depending on the brand of car, from 70 to 130 kgf / cm2.

At such a high pressure, repairing a damaged power steering hose with clamps or wire is almost impossible.

There are two options left: either replace the entire power steering tube, or replace only the damaged part of it by moving the fittings to a new hose.

Moreover, it is better to rearrange the fittings in a special workshop.

Replacing and installing the power steering hose is as follows:

1. The front of the car is raised on jacks.
2. The steering wheel turns all the way to the left.
3. A syringe with a tube attached to a needle is pumped out of the hydraulic booster reservoir.
4. After that, the hose is disconnected, the working openings of the hydraulic system are closed with plugs.

Power Steering Hoses

The selection of a new hose is carried out with exact observance of the diameter, otherwise the performance of the hydraulic booster may change.

Then a new hose is installed, fluid is poured into the hydraulic system and the quality of the installation is checked.

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People with professional skills are able to repair high pressure hoses for hydraulic systems of a car or a Karcher pump manually using the simplest equipment and fixtures. But the quality of such repairs will remain in doubt, which is highly undesirable.

It must be understood that high pressure creates a zone of increased risk, when a breakdown or abnormal operation of the high pressure hose can lead to serious consequences. Especially when it comes not to the Karcher pump, but to the hydraulic systems of heavy equipment. A far from complete list of such consequences looks like this:

• Shooting of fittings and dangerous outflow of torn hoses;
• Fire or explosion of the working fluid;
• Loss of vehicle control;
• Poisoning and burns due to liquid spilled from the hoses.

Accurate observance of instructions, attentiveness and accuracy during installation work, as well as contacting specialists if necessary, will help to avoid this and ensure long-term and high-quality operation of the repaired pipeline.