SPM/MBM HOSE CARE AND HANDLING

NOVEMBER 1990

PAGE 1 OF 8

EGE 05-B-2 1990

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References General Handling, Suspension, and Operation Care and Maintenance 6. Ancillary Equipment Appendix A Guidelines for Returning Hose to Service Appendix B Instructions for Completing EGE 05-D-2

1.

SCOPE

This Guide gives detailed field instructions for the handling, care and maintenance, storage, and field inspection of offshore hoses for single point mooring (SPM) and multibuoy mooring (MBM) installations. Also defined are requirements for hose ancillary equipment, which should be ordered separately from the hose. 2. REFERENCES

The following publications form a part of this Guide. Unless otherwise specified herein, use the latest edition.
Mobil Engineering Guides EGE 05-B-1 EGE 05-D-1 EGE 05-D-2 SPM/MBM Hose Purchasing Offshore Hose Data Sheet Purchasing Offshore Hose Data Sheet Care and Handling

ASTM (American Society for Testing and Materials) Specifications A193 A194 Alloy Steel and Stainless Steel Bolting Materials for High-Temperature Service Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service

OCIMF (Oil Companies International Marine Forum) Hose Guides Buoy Mooring Forum Hose Guide SPM Hose Ancillary Equipment Guide Single Point Mooring Maintenance and Operations Guide

3.

GENERAL

At offshore mooring installations, the hose strings are a critical link between the terminal and the tanker. The hoses are constantly subjected to severe loads and stresses. Therefore, to provide greater reliability and longer hose life, it is imperative that hoses be handled and stored correctly, and that they be inspected and tested in a consistent manner at appropriate intervals. In addition to the material presented in this Guide, the following three OCIMF documents provide details

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concerning the care and handling of SPM hose systems: Buoy Mooring Forum Hose Guide; Hose Ancillary Equipment Guide; Single Point Mooring Maintenance and Operations Guide. 4. HANDLING, SUSPENSION, AND OPERATION 4.1 In the transport of offshore hoses, the following cautions shall be observed: (a) A hose shall never be lifted by a single sling at the midpoint or by two slings positioned one at each end unless specifically designed for this handling procedure. (b) The recommended method of lifting a hose is to use a spreader bar with nylon lifting straps at least 15 cm (6 in.) wide. A three-point lift is recommended, with a strap over the nipple area at each end and a strap in the middle. (c) A hose shall never be dragged across the ground; it should be carried on dollies or rollers or be moved by a derrick. (d) A hose should not be rolled more than one revolution unless it is supported in such a way as to prevent the flanges from rolling faster than the hose body, which would twist the body of the hose. Special caution should be given to this when a string of hoses is rolled in an arc with one end fixed. (e) When hoses are being towed, all necessary precautions shall be taken to insure buoyancy. Towing speed shall not exceed 5 knots. 4.2 The following rules apply to connecting and disconnecting hose: (a) A hose shall never be supported near the middle with a single rope sling. However, the rope may be placed around the nipple section so that the hose hangs vertically. (b) During installation, the hose string should have no twist and its curvature should be evenly distributed over its full length. Care should be taken in repositioning SPMs and retensioning SPM chains so as not to induce twist in the submarine hose. (c) After tanker rail hoses are disconnected, the flange faces shall be protected with blind flanges and care shall be taken that the hose is not dropped on the ships deck or into the water. (d) Most damage to hoses in MBM installations consists of kinkings (especially at the connection to the pipeline) and entanglements caused during lifting and lowering of the hose string. To avoid such damage, it is suggested that lines be straightened when being lowered to the seabed and that the hose string be pressured before lifting and lowering. 4.3 The following cautions should be observed while the hoses are in operation: (a) Gages should be used to check the loading/discharge pressure at the ship.

(b) Reciprocating pumps should be adjusted to reduce pulsation to a minimum. Relief valve settings should not exceed the factory test pressure of the hose, and air chambers should be kept full of air during the entire pumping operation. (c) Centrifugal pumps should be regulated so that the no-flow pressure does not exceed the factory pressure of the hose assembly. (d) All valves should be open before additional oil is pumped into the hose. Care should be taken

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EGE 05-B-2 1990

not to suddenly shut off any valve, including shore valves, while the fluid is flowing. This will avoid any unnecessary shock pressures on the hose assembly. (e) Oil temperature should be kept below 82C (180F); otherwise, the life of the hose may be shortened. (f) Every effort should be made to keep the hose assembly from chafing against any part of the ship. This recommendation is particularly important where reciprocating pumps are in use and the hose is pulsating significantly. (g) The hose assembly should not be allowed to touch any hot surface.

(h) Extra attention should be paid to the configuration of lines during loading operations. At MBM loading terminals, hose strings are apt to be kinked as a result of overbending because they can be caught under the bottom of the tanker as the loading operation is progressing. (I) At discharge terminal installations, the hoses and pipelines must be full before the ship is allowed to pump at full rate. (j) The hose string should be kept under close observation during operation in order to avoid undue stresses. The workers performing this duty should have authority to take any necessary corrective action to protect the hose. 5. 5.1 CARE AND MAINTENANCE Storage of hose shall be effected as follows: (a) Hose shall be laid out straight on solid supports. Lightweight hose (for example, flexible rail hose without a helix), in particular, shall be laid out in such a way that it is not subject to flattening. (b) As a minimum requirement, all hoses shall be covered to protect them from sunlight. A cool, dark, dry storage place with natural ventilation is preferred. (c) Before a hose is returned to storage, it should be drained completely, flushed to remove any potentially explosive vapors, and stored in such a way that air can circulate freely through it. (d) (e) Stored hose should be placed so as to insure easy access for periodic inspection. Hose should be protected against insects and rodents.

5.2 In addition to observance of the guidelines in Paragraph 5.1, the maintenance of hoses in storage shall include frequent visual inspections to insure that the hoses continue to be stored properly. Also, all hoses that have been in storage shall be pressure tested at the rated pressure before being placed in service. 5.3 A routine visual inspection, to be conducted before each loading or unloading operation, shall cover the following: (a) (b) (c) Serious damage (cuts, gouges, or tears) to hose cover and body. Permanent deformation of hose body. Cracks or craze on hose body.

MOBIL ENGINEERING GUIDE EGE 05-B-2 1990 (d) (e) Damage on flange surface. Oil leaks.
PAGE 4 OF 8 NOVEMBER 1990

5.4 As a minimum, hoses in service at a new installation should be hydrostatically tested, for at least the first five years, in accordance with the following criteria: floating, tanker rail, first off the buoy once a year; submarine, underbuoy midway between buoy dry-dockings (maximum of three years). Once a specific hose type (manufacturer and design) life expectancy has been established for a given location through operating experience, and if permitted by regulations, the frequency of testing may be adjusted to reflect that experience, taking into account the environmental concerns for the specific location. This applies to both double carcass and single carcass hose. The test procedure is as follows: (a) Lay hose out as straight as possible on supports that permit the hose to elongate freely.

(b) Blank off each end and fill hose with water. Connect test pump at one end and release trapped air at other end. Apply a pressure of 0.7 bar gage (10 psig). (c) Measure and record overall length of hose.

(d) Over a period of 5 minutes, increase the pressure from 0.7 bar gage (10 psig) to one-half the rated pressure. Hold this pressure for 10 minutes; then, over a period of 5 minutes, reduce the pressure to zero. (e) Over a period of 5 minutes, raise the pressure to the rated pressure; then hold for 10 minutes.

(f) Before releasing the full test pressure, measure the overall length of the hose assembly to ascertain the temporary elongation. Record the increase as a percentage of the original length, measured at 0.7 bar gage (10 psig). (g) (h) Over a period of 5 minutes, reduce the pressure to zero. After an interval of at least 15 minutes, raise the pressure again to 0.7 bar gage (10 psig).

(I) Measure the overall length of the hose assembly to ascertain the permanent elongation. Record the increase as a percentage of the original length, measured at 0.7 bar gage (10 psig). (j) Reduce the pressure to atmospheric and drain the hose.

(k) Using EGE 05-D-2 (page 2 of 5), keep a permanent test record for each hose. Thus, the temporary elongation measured under the pressure test [see Items (a) through (j), above] can be compared to the original test and subsequent routine tests. Since both permanent and temporary elongations at which different hoses should be retired from service will vary according to the type of construction, only general rules can be established to guide the operator when determining whether a hose should be retired from service. The following general guidelines may provide assistance: (1) Should either the permanent or temporary elongation increase significantly (50 percent) between measurements, the hose may be weakening and replacement should be considered. (2) When the field test permanent or temporary elongation exceeds the corresponding factory test length by 2 percent of the original overall length, the hose should be retired from service.

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EGE 05-B-2 1990

(3) Operator experience based on recorded elongation data for a specific hose design related to past hose performance may be the most reliable indicator for determining when to retire a hose. Especially for this reason, good hose records should be kept. 5.5 While the hose is available for hydrostatic testing (Paragraph 5.4), an electrical continuity test should be made as follows: (a) For electrically continuous hose, electrical continuity should be checked before and after the hydrostatic test. (b) For electrically discontinuous hose, the resistance between the flanges of each length of hose should not be less than 25,000 ohms. 5.6 A vacuum test shall also be carried out on hose removed from service for hydrostatic tests. The vacuum test procedure is as follows: (a) Seal off both ends of the hose with transparent Plexiglas plates of sufficient strength; use putty as a sealant or bolt up with a soft rubber gasket. One plate shall be fixed for connection to a vacuum source. Lay a flashlight at this end, with its beam directed toward the opposite end. (b) Apply a vacuum of at least -510 millibar gage (15 in.) of mercury, and preferably -680 millibar gage (20 in.) of mercury, for a period of 10 minutes. (c) Inspect the interior of the hose for blisters or bulges.

5.7 After hydrostatic, electrical, and vacuum tests are completed, the hose shall be examined internally by utilizing a flashlight and looking into the end of the hose, or by physically crawling through the hose if the hose size will permit. The following irregularities should be noted: (a) (b) 5.8 6. Blisters, bulges, soft spots, cracks, or separation in the liner; also, tears, cuts, or gouges. Cracks or excessive corrosion in the nipples.

The Appendix of this Guide shall be used to determine whether the hose should be repaired or retired. ANCILLARY EQUIPMENT

6.1 All hose strings used for carrying oil products at sea require the use of ancillary equipment; that is, equipment or accessories that are not a permanent part of the normal hose assembly. 6.2 Because ancillary equipment varies widely among manufacturers, no further details shall be specified in this Guide. The purchaser shall indicate on EGE-05-D-2, Part 2, under "Ancillary Line Equipment," the required accessories for a specific installation. The manufacturer shall provide detailed drawings, physical dimensions, materials of construction, and any other specifications concerning either the accessories noted by the purchaser or additional accessories the manufacturer may suggest. 6.3 Flange bolts, nuts, and gaskets are considered to be ancillary equipment. Flange bolts shall be of the stud type and conform to ASTM A193, Grade B7. Heavy hex nuts shall conform to ASTM A194, Grade 2H. Stud bolts, nuts, and washers may be hot-dip galvanized or fluorocarbon coated. Washers should be used between nuts and flanges. Gaskets shall be full-faced, 3 mm inch thick compressed asbestos or spiral-wound, chlorite-graphite filled. "Inside bolt circle" gaskets may be considered for ease of installation. Again, the purchaser shall specify these items on EGE 05-D-2, Part 2.

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APPENDIX A GUIDELINES FOR RETURNING HOSE TO SERVICE Defects 1. Liner a) Cracks, cuts, or gouges Penetration to, or exposure of, the tube breaker or reinforcement layers. Height > 2 mm (0.07 in.) 2 2 Area > 3 cm (1.18 in. ) More than five per hose. Except for nonrepairable conditions cited. Height # mm (0.07 in.) 2 2 Area # 3 cm (1.2 in. ) Five or fewer per hose not located in same area and not subject to evolution during vacuum testing. Nonrepairable* Repairable+

b) Blisters

c) Soft areas

Often indicate deterioration of hose body caused by leakage through the liner. Retire hose.

d) Separation from body 2. Flanges and Nipple a) Scratches and gouges: Flange face

If sealing surface cannot be repaired to effect full seal capability without reducing strength.

If sealing surface can be repaired.

Other areas

If repairs do not decrease strength of fittings or hose. Recoat as required. Excessive corrosion thickness not adequate. Where corrosion is full depth of nipple end thickness, or where t > thickness of nipple with significant corrosion over 50 percent of the circumference. Minor corrosion clean and recoat as required.

b) Corrosion c) Corrosion adjacent to liner

LINER

NIPPLE

b) Stains or sea growth

*Reject hose. + Hose acceptable after repairs.

Clean and recoat as required.

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EGE 05-B-2 1990

Defects 3. Hose Body and Cover a) Permanent deformation (kinking or crushing) b) Cracks, cuts, or gouges

Nonrepairable* Major damage retire hose.

Repairable+ Minor damage consider for reuse at easy point in hose string. Damage not extending into reinforcement layers can be repaired. Caused by expansion of gas or other nonstructural failure. Normally repairable or replaceable.

Helical wire and/or reinforcement layer exposed or damaged. Caused by leaking of tube or rupture of reinforcement.

c) Bulges or blisters 4. Integral Flotation a) Crushing, cracks, cuts, blisters, etc. 5. Hydrostatic Tests a) Temporary elongation b) Permanent elongation c) Leaks or bulges 6. Electrical Continuity Tests a) Continuous hose

Exceeds allowable; retire hose. Exceeds allowable; retire hose. Retire hose. Retire hose unless emergency requires it to be used until replacement is available. Minimum, 25,000 ohms resistance. Retire hose. Retire hose.

b) Discontinuous hose 7. Vacuum Tests a) Separation of lining b) Deformation of hose body

*Reject hose. +Hose acceptable after repairs.

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APPENDIX B INSTRUCTIONS FOR COMPLETING EGE 05-D-2 In order to simplify record keeping by field personnel, EGE 05-D-2 has been separated into Parts 1, 2, and 3. Instructions for use are as follows:

Part 1 Log for Recording Hose Assembly Service Tests

This log provides a permanent record for each hose for the SPM/MBM installation. Its form may be adapted to record books as operations management sees fit. However, in its stated form, the log is a useful means of keeping inventory control at storage locations and, more importantly, yields a performance evaluation for information for later installations. The manufacturer shall complete the initial information and the factory test results; the hose record shall then be kept by the purchaser.

Part 2 Ancillary Line Equipment

Part 2 is to be completed by the purchaser or the manufacturer. The manufacturer shall complete all information about ancillary equipment checked "required" by the purchaser. If the purchaser wishes the manufacturer to specify accessories required by the manufacturers design, the purchaser shall so note on the data sheet, and the manufacturer shall complete the entire page.

Part 3 Supplementary Information

This supplement should be used by existing installations for requisitioning replacement hoses, once Parts 1 and 2 are on permanent file, as required by the procedure in Section 4 of this Guide.
NOTE: The completed data sheets are a useful means of cataloging detailed information about hoses and their service records in use. Much is still to be learned about the behavior of offshore hoses, and the information which could be compiled if good records were kept would be useful not only within Mobil but to the entire hose industry. Therefore, it is worthwhile for operations management of existing installations to complete data sheets and to insure that all future installations maintain detailed records from their beginning.

MOBIL ENGINEERING GUIDE OFFSHORE HOSE DATA SHEET

EGE 05-D-2 1990

CARE AND HANDLING

ISSUE 1 2 FOR (OWNER) SITE SPM/MBM HOSES FOR SUPPLIER NOTE: The party to complete the information is as follows: MANUFACTURER APPROVED 3 4 ISSUE APPROVED JOB NO. P.O. NO. LOCATION ITEM NO. DATE UNIT

Page 1 of 5

Purchaser

Manufacturer

Either Purchaser or Manufacturer

APPLICABLE DOCUMENTS: SPM/MBM Hose Purchasing (EGE 05-B-1) Offshore Hose Data Sheet Purchasing (EGE 05-D-1) SPM/MBM Hose Care & Handling (EGE 05-B-2) PART I LOG FOR RECORDING HOSE ASSEMBLY SERVICE AND TESTS

G G G G G G G G F F F F F

Location Manufacture Date of Manufacturer Hose Size, in. ID* Original Hose Length at 69 kPa gage (10 psig), m (ft) Hose Type and Serial No. Factory Test Pressure, kPa gage (psig) Factory Temporary Elongation Under Rated Pressure, % Date Received Date Placed in Service Particulars of Service

Date Retired from Service Reason for Retirement

Note: (*) Nominal inside diameter.

MOBIL ENGINEERING GUIDE OFFSHORE HOSE DATA SHEET

EGE 05-D-2 1990

CARE AND HANDLING

Page 2 of 5 PART I (Contd) TEST RESULTS Pressure Test Total Hose Lengths, m (ft) Temporary Elongation Permanent Elongation Percent Change vs Factory Vacuum Test Temporary Elongation Permanent Elongation (in. Hg) Time (min) Electrical Continuity Test Visual Inspection & Remarks

Date

Max. Test Pressure, kPa gage (psia)

MOBIL ENGINEERING GUIDE OFFSHORE HOSE DATA SHEET

EGE 05-D-2 1990

CARE AND HANDLING

Page 3 of 5 PART I (Contd) HOSE ASSEMBLY SERVICE RECORD Hours in Service This Operation m (Mbbl) Pumped This Operation
3

Date

Total

Total

Remarks

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EGE 05-D-2 1990

CARE AND HANDLING

Page 4 of 5 PART II

ANCILLARY LINE EQUIPMENT Required Quantity Material

(a) ACCESSORIES LINE END: Pickup or Marker Buoys Pickup Chain Blind Flanges Coupler with Cams Spool Pieces Butterfly Valves Hose Lifting Assembly

(b) ACCESSORIES FLOATING LINE: Floating "Y" or Reducer Winker Lights Lifting Rings

(c) ACCESSORIES SUBMARINE LINE: Low-Depth Floats Special Buoyancy Tanks Reducers Spreader Bars

(d) ACCESSORIES MISCELLANEOUS: Bolts Nuts Gaskets

NOTE: (*) Nominal inside diameter.

MOBIL ENGINEERING GUIDE OFFSHORE HOSE DATA SHEET

EGE 05-D-2 1990

CARE AND HANDLING

Page 5 of 5 PART III

NOTE: This supplement shall be completed by the purchaser and attached to EGE 05-D-1 for requisitioning replacement hoses for existing installations. UNDERBUOY Type and Manufacturer of Existing Hose

Number and Location of Hose Lengths Required

Number, Manufacturer, and Type of Spare Hoses

FLOATING Type and Manufacturer of Existing Hose

Number and Location of Hose Lengths Required

Number, Manufacturer, and Type of Spare Hoses

REMARKS: