Untitled Attachment 07022 PDF

Doc. No OMSLL-AS-01-16 Rev.
0 Page 1 of 17
Installation, Operating, Maintenance,

Inspection and Storage of Long Length hoses
0 08/09/16 First issue A. Siliquini G. Marucci

Rev. Date Prepared Approved
MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Registered Office/Sede Legale: Via Pietro Paleocapa 7, 20121 Milano - Italy
Operating Office / Sede Amministrativa: Via Luigi Cadorna 73, edificio B2 – 20090 Vimodrone (MI) - Italy
Tel. +39 02 62713.1 – Fax +39 02 62713.382 – info@manuli-hydraulics.com
www.manuli-hydraulics.com – Indirizzo PEC: manulihydraulicsitalia@legalmail.it
V.A.T. & Tax Code/P.IVA e Codice fiscale IT 08462530968 - Trade Register Number of Milan/N. Registro delle Imprese di Milano: 08462530968 - R.E.A. number/numero R.E.A.: MI-2028328
Share Capital/Capitale Sociale: € 3.000.000,00 fully paid/i.v. – Company subject to direction and coordination of /Società soggetta a direzione e coordinamento di Manuli Rubber Industries S.p.A.
Doc. No OMSLL-AS-01-16 Rev.0 Page 2 of 17
TABLE OF CONTENTS
1.0 Introduction
2.0 Description of hoses and accessories.
3.0 Hose storage and preservation recommendations.
4.0 Operating temperature and aromatic content
5.0 Spooling and despooling of the hose
6.0 External Inspection of the hose
7.0 Pre-assembly hose inspection and testing requirements.
8.0 Hose assembly and bolt tightening
9.0 Post assembly and pre-towing testing and inspection
10.0 Generic hose installation procedure
11.0 Post installation testing and inspection
12.0 Inspection of the hoses
13.0 Service, storage and period testing
14.0 Records
15.0 References

1.0 Introduction
This technical manual is a basic reference document for the installation, inspection, testing,
and maintenance of the Long Length hoses supplied to Lundin. This manual is based on
Manuli expertise and the general guidelines given by Oil Companies International Marine
Forum (OCIMF).
2.0 Description of hoses and accessories.
A typical Long Length hose section is given in Figure 1.
Figure 1. Long Length Hose section
3.0 Hose storage and preservation recommendations.

Hose life in storage may be affected by temperature, humidity, ozone, sunlight, oils,
solvents, corrosive liquids and vapours, insects and rodents. Hoses should be stored on
steel reels in accordance to the Manuli Rubber Standard.
Hoses should be stored in a cool, dark, dry area or building having freely circulating air.
Where closed storage is not possible, hoses should be covered to protect them from
sunlight.
For locations where extreme temperatures apply, additional measures may be necessary
such as storing the hoses in a climatically controlled warehouse. This is especially important
at extremely cold locations. The ends of the hoses should be covered with wooden blanks
with holes to allow for air circulation and to prevent internal attack by rodents. Hoses should
not be stored adjacent to operating equipment that could generate ozone or heat.
These details should be carefully recorded to ensure that the oldest hose is issued first and
that a rotational system is employed. After use and before returning a hose to storage, it
should be drained completely and flushed out fully with water to remove any toxic or
combustible vapors.
4.0 Operating temperature and aromatic content

The standard Long Length hose is suitable for use with crude oil and liquid petroleum
products having a minimum temperature of -20°C to a maximum of 92°C a and an aromatic
hydrocarbon content up to 60 per cent. Hoses will also be suitable for use in areas where
ambient temperatures may range from -29° to a maximum of 52°C.
5.0 Spooling and despooling of the hose

Normal reeling operations should be from the bottom of the reel. The hose is very durable
and although twists may form, they will work out towards the “free end” if the hose is properly
handled. Most twist in the hose will work their way out if 7 bars internal pressure is applied
and if the conduit has a “free end”.
The elastomeric hose stretches under axial load; a small portion of the load induced
elongation is permanent and irreversible. However, this permanent stretch is small and is not
progressive with successive loadings, provided that the safe working load is not exceeded.
Under safe working conditions, the permanent stretch is less than 2 percent of the original
length.
The hose is extremely flexible it has a high degree of torsional resistance when pressurized
with either air or liquid.
The hose is a very rugged and forgiving product. However, if it is abused, or if prescribed
procedures are not followed, the hose will exhibit those characteristics that could create
operational problems; i.e. “neck down” that will inhibit flow.
Installation reel: long length hoses can be installed on installation reels. In order to avoid
hose collapsing on the reel, in particular for the inside layers when multiple layers are
installed, it is important to keep the tension to a minimum while reeling. This is especially
important for the inside two (2) layers.
6.0 External Inspection of the hose

Recovery of the hose: During recovery of the hose seawater should be used to clean any
marine growth from the cover. Also, it is extremely important to inspect the hose completely
during recovery photographing any unusual wear or external damage to the hose.
Cover: The rubber cover on the hose serves the primary function of protecting the
reinforcement of the hose from damage. The cover should be cleaned and examined to
detect areas where reinforcement damage may have occurred. Inspect the hose cover for
cuts, gouges, tears, kinks, twists and abraded spots. Damages should be repaired before
the hose is returned to service.
Hose liner: It is extremely difficult to inspect the hose liner. The liner can be inspected using
a small camera but the section of the hose to be inspected must be taken out of service and
inspected off the reel.

7.0 Pre-assembly hose inspection and testing requirements.

Prior to hose assembly each hose should be visually inspected and eventually tested if
stored for a period longer than 6 months.
Visual Inspection of Hoses Onshore.

An elastomeric layer applied over and along the entire hose body protects the hose body
from the marine and environmental elements. The cover should be cleaned and carefully
examined to detect areas of damage, such as cuts, gouges, tears or abrasions. If the
reinforcement layers are exposed, the extent of damage should be further investigated
during the hydrostatic pressure test. The cover may show surface cracking or crazing due to
prolonged exposure to sunlight or ozone, such deterioration is not normally cause for
retirement.
Exposed internal and external steel surfaces of flanges and nipples should be cleaned and
examined for cracks, excessive corrosion or pitting. Such conditions should cause the hose
to be retired from service. Exposed internal and external steel surfaces may be protected
with epoxy paint (not flange sealing faces). Minor damage to hot dip galvanised fittings may
be touched up with zinc rich paint.
Hydrostatic Pressure Test

All the hoses have been individually tested at the time of the hose manufacturing. In case
the hoses have been stocked for a long period of time each hose should be subjected to a
Hydrostatic Pressure Test to ensure integrity before going to service.
 The test is performed using water as test medium.
 The following table defines the test pressure in function of the test conditions.
Hose state Test condition Test Pressure

New Hose laid out straight on supports that allows 1.5 * Rated Working Pressure
the hose to elongate freely
Used Hose laid out straight on supports that allows 1.2 * Rated Working Pressure.
the hose to elongate freely
New Hose installed on Manuli shipping reel Rated Working Pressure
Used Hose installed on Manuli shipping reel NOT RECOMMENDED
 Duration of the test: at least 30 minutes.

 The hoses can be tested laid straight on supporting rollers or installed on reels at
ambient temperature.
 The test can be performed on multiple hoses connected in series installed on separate
reels.
 Place a PIG at one end of the hose (or series of hoses).
 Connect the blind flange with the inlet port at the PIG side, while the other end of the
hose (or hoses in series) is free to move and positioned higher than the rest of the hoses.
 Fill the hose (or series of hoses) with water until the PIG comes out at the opposite end.
Stop the pump and install the test flange fitted with a relief valve on the free end.
 Connect the pump and the pressure gage (and if available the pressure and temperature
recorders).
 Flush for a few minutes, then stop the pump and close the relief valve.
 Increase the pressure until the test pressure is reached (WP =X 1.5). The test pressure
must not exceed 110% of the nominal test pressure (WP X = 1.5).
 Wait until the pressure has stabilized for at least 2 hours. The pressure will be considered
stabilized when the pressure drop will be less than 1% in the period of 1 hour.
 Close the double feeding valve and disconnect the hose from the pump.
 Maintain the test pressure for 22 hours, periodically inspecting the hose for any pressure
loss (or malfunction of recording equipment when available).
 Compared to the beginning of the test pressure, the pressure drop should not be more
than 1%, or to 2 bar. (excluding falls attributable to the change in ambient temperature.
The hoses that leak or show permanent deformation must not be installed.
TYPICAL STRUCTURE OF TESTING PERFORMED ON REELS IN SERIES
Bobina 1 Bobina 2 Bobina 3 Bobina 4
2 mt
4 6
2
HIGH PRESSURE PUMPE

1
5
PRESSURE CHART RECOR
FILLING PUMPE
1 HIGH PRESSURE VALVE

2 FILLING VALVE
3 VENTING VALVE
4 PRESSURE GAUGE (100 Bar)
5 PRESSURE TRANSDUCER
6 TEMPERATURE RECORDER

8.0 Hose assembly and bolt tightening.
Flange Preparation.
Flange preparation is essential to ensure a tight, leak-free joint. Inspect all flanges for
imperfections. Prepare flange faces by wire brushing, removing any rust, dirt or paint. File
smooth any imperfections. After the flanges have been properly dressed, inspect them once
again to ensure no deformation of the mating surfaces exists.
Flange Assembly.
In case of connection of several hoses ensure that all hose sections and ancillary equipment
are in their correct order and relative position before assembly. Check bolts and nuts for
wear/thread damage. Clean the bolts before assembly, if necessary.
Clean flange faces of sand and debris, insert bolts and gaskets and follow standard bolt
tightening procedures, as described in the following section.
Flange bolting
All flange connections are generally made using PTFE COATED stud bolts and heavy hex
nuts.
Bolt
Material: ASTM A193 Grade B7
Minimum breaking load: 860 MPa
Minimum Yield Stress : 720 MPa
Minimum Elongation at break : 16%
Area reduction at break: 50%
Maximum Hardness: 321 HB o 35 HRC
Nut
Material: ASTM A194 Grade 2H
Coating of bolts and nuts: Zinc plated for PTFE
Bolt torque and bolt tightening sequence

The proper bolt torque should be calculated based on flange type, bolt diameter, friction
factor, pre-load, lubrication.
The bolt tightening should be carried following the appropriate sequence, based on the
number of flange drills.
To achieve uniform joint load/stress distribution, the bolts should be tightened in three stages
representing 30%, 60% and 100% of the torque values.
 At each stage of tightening, bolts should be tightened in a controlled sequence.
 Finally the bolts should be chased round using the 100% torque value, until no nut
movement occurs.

It is recommended to record each tightening step on the Bolt Tightening Sequence
Spreadsheets.
The most common way of tensioning the bolts is by controlled torque wrenching using either
manual or hydraulic torque wrenches. The method chosen is dependent upon bolt loading,
access, clearance and tooling availability.
Ancillaries
Before testing, it must be ensured that all the ancillaries are installed in the correct
sequence.
9.0 Post assembly and pre-towing testing and inspection

After completion of the hose string assembly, a pressure test should be conducted on the
assembled hose string (in case of connection of several hoses or connection of ancillaries to
the hoses).
If a particular joint is not tight, it must be made tight and the hose string re-tested. If a hose is
damaged, it must be replaced. Under no circumstances should a suspect joint or hose be
placed in service.
A hydrostatic test should be performed on each hose string as follows.
A low volume high pressure pump is required to pressurize the system.
A pump with a higher flow rate should be used to fill the hoses.
The pressure test should be monitored and recorded by a traceable means.

 Bolt the blank flange with filling valve and vent valve on the other end of the hose string.
In order to facilitate venting trapped air, the vent valve should be positioned at the top of
the hose bore.
 Attach fill hoses and begin to fill the hose with water. Avoid airlocks during the filling
process by manipulating the vent valves. If this does not eliminate the airlock, it may be
necessary to raise the hose at various points along the string as water is introduced into
the hose.
 Raise the internal pressure in the hose to its rated pressure, or operating plus 50%,
whichever is lower, and then hold it for a period of three hours.
 Thoroughly inspect all joints after the pressure has stabilized.
 If no leaks are detected, reduce the pressure over a period of five minutes to zero.
 If a leaking joint is discovered, it may be possible to eliminate the leak by simply
tightening the bolts while the system is still under pressure. (Do not over torque bolts.)
 Should tightening fail to stop the leak, the pressure should be released and the joint
broken.
 Inspect and clean the flange faces of the compromised joint. Install a new gasket and re-
mate the joint.
 Repeat pressure test.
 If the corrective procedures above fail to stabilize the pressure and no other significant
leaks are detected, check all the valves and blind flanges to ensure that they are not
leaking. (A soap test may be required to detect small leaks.)

 If the pressure continues to fall after all possibilities have been investigated, check each
hose at the joint between the steel nipple and the rubber cover. A defective nipple may
be the fault.
 Replace defective hoses, flanges, fittings, etc. as necessary. Repeat tests until
satisfactory.
 Remove blind flanges from the hose string.
 Record all findings.
10.0 Generic hose installation procedure

Specific installation procedures should be prepared for each installation.
Deployment of the Manuli Long Length hose via a spooler has considerable advantages
over the traditional method of deploying flexible pipe from powered reel:
 Cost Effective
 Reduced Installation time - - DP1 Vessel
 Smaller footprint = smaller deployment vessel
 Rapid deployment over smaller radius stern/side chute
 No requirement for tensioners
 Manuli Hose can be deployed in higher sea states
 Manpower requirement is reduced
Example 1 Example 2
The following installation sequence should be considered generic and only an example.

Passing the hose to the rig
Riding line

Commencing deployment
Touching Down

11.0 Post installation testing and inspection
After completion of the floating hose string installation, a pressure test should be conducted
on the installed hose. All joints should be checked for tightness. The pressure test should
consist of raising the internal pressure in the hose to its rated pressure, or operating
pressure plus 50%, whichever is lower, and holding it for a period of three hours. A visual
inspection of the hose string should also be performed. (Note: Pressure readings will
fluctuate by as much as 0.7 barg (10 psig) on either side of the specified pressure due to the
motion of the hose in the water.) This test should be performed approximately every six
month depending upon environmental conditions at the site.
12.0 Inspection of the hoses

Recovery of the hose: During recovery of the hose seawater should be used to clean any
marine growth from the cover. Also, it is extremely important to inspect the hose completely
during recovery photographing any unusual wear or external damage to the hose.
Cover: The rubber cover on the hose serves the primary function of protecting the
reinforcement of the hose from damage. The cover should be cleaned and examined to
detect areas where reinforcement damage may have occurred. Inspect the hose cover for
cuts, gouges, tears, kinks, twists and abraded spots. Damages should be repaired before
the hose is returned to service.
Hose liner: It is extremely difficult to inspect the hose liner. The liner can be inspected using
a small camera but the section of the hose to be inspected must be taken out of service and
inspected off the reel.

13.0 Service, storage and period testing
Service life
Provided that the hose performance requirements are not exceeded (such as operating
pressure, flow velocity, fluid and ambient temperature ranges, aromatic carbon content,
allowable loads) and that the hose the recommended for hose change out is 5 years life.
Storage life
With the hoses properly stored it is recommended not to exceed a 7 years storage life.
It is recommended to despool the stored hose from the reel every three years and then
spooled onto the reel again making sure that the end that first comes out of the reel is then
be spooled onto the reel first.
When one of these limits are exceeded, it is recommended to contact the manufacturer for a
hose inspection and evaluation.
Once the hose returns to service after long term storage it is recommended to hydro-test the
hose.
Period testing
It is recommended that hoses be periodically pressure tested every one to two years.
14.0 Records
The keeping of adequate records on the history and performance of the individual hoses is a
prerequisite for the efficient operation and maintenance. Proper records and inventories are
necessary for the following reasons:
 To provide operating personnel with a ready record of hoses that are on order,
available on site as backup spares, installed and operating on site or damaged and
taken out of service
 To permit the operators to assess the quality of performance of the hose and thus
provide a basis for future selections and purchases
 To pinpoint design inadequacies by focusing on hoses in the system that are prone to
failure, damage or excessive wear
 To provide a rational basis for the establishment of anticipated service life and the
stockpiling of backup hoses
 To exercise any manufacturer's warranties that may apply
 To meet requirements of local governmental regulations
There are many types of hose record systems in use. A manual card system is clear, brief
and easy to maintain. It should, however, be considered as the minimum requirement.
Computer users may consider incorporating the card system into a database using software
such as Microsoft Excel® or Access®.
Hose Performance Card System.

The suggested card system is described here for use as a minimum standard. The system is
composed of the following components:

 The "Hose Card Disposition File" (HCDF).
 The "Hose Performance Card" (with front and rear faces).
Hose Card Disposition File System (HCDF)

1. The "Hose Card Disposition File" is a system of "Cardex" file drawers, or a similar
system, whereby "Hose Performance Cards" may be filed separately, in order and in
the categories below. Warehouse, Marine Yard, Berths, Scrap and any other general
disposition that is employed at the particular site.
2. The "Cardex" file system is recommended as the most convenient and manageable
system.
3. The file system must match the actual hose system configuration at a particular berth.
4. When the location of a hose section is changed on site, the "Hose Performance Card"
must be shifted to the appropriate position in the "Hose Card Disposition File." When
the hose section is in berth service, in addition to having the "Hose Performance
Card" filed in the appropriate berth file, it must also be filed in the same sequence as
it occurs in the hose string.
5. The "Hose Card Disposition File" must, at all times, reflect the actual location of each
hose delivered to the terminal. Any changes in location must be posted immediately.
WAREHOUSE
MARINE YARD
FPSO
SCRAP YARD
Hose Performance Card.

A sample of the hose card is given hereinafter. Following are instructions for filling out the
card.
COMMENTS
Refer to front face only
1. Make out one "Hose Performance Card" for each individual hose.
2. Fill in lines 1 and 2 on this face when the hose section is received on site.
3. Fill in line 3 when the hose section enters service.
4. Fill in line 4, etc., when the hose is moved or subsequently retired.
5. File the “Hose Performance Card” at all times in the “Hose Card Disposition File” in the
category representing the actual location of that particular hose. Shift the position of the
general disposition or location within a hose string. When the hose section is in berth
service, the “Hose Performance Card” should be maintained in the same file sequence as its
actual sequence at the berth. This permits ready reference, minimizes the chance of error in
recording and makes for an orderly, efficient record-keeping
sequence.

6. Number floating hose sections in order from the FPSO (section 1) to the tanker rail hose.
7. When space is exhausted on one card, attach a second card.
COMMENTS
Refer to reverse face only
8. Fill in line 1 with the “factory test data” for each hose when it arrives on site. The “factory
test data” is fully outlined on the hose test certificate that is supplied with every hose.
9. Fill in line 2, etc. Upon completion of annual or periodic inspections, the “Test Data” and
“Visual Inspection/Comments” sections should be filled in where appropriate.
10. When the hose section is ultimately retired, the “Visual Inspection/Comments” column
will indicate this, and the card should be placed in the SCRAP YARD file.
11. When space is exhausted, attach a second card.

Sample Hose Card

15.0 References
 A 193/A 193M – 01b - Standard Specification for Alloy-Steel and Stainless Steel Bolting
Materials for High- Temperature Service
 A 194/A 194M – 01a - Standard Specification for Carbon and Alloy Steel Nuts for Bolts
for High Pressure or High Temperature Service, or Both
 ASME B16.5 – Pipe flanges and Flanged Fittings
 Oil Companies International Marine Forum (OCIMF), SPM Maintenance and Operations
Guide, 2nd Edition, January 1995.
 Oil Companies International Marine Forum (OCIMF), Recommendations for Oil Tanker
Manifolds and Associated Equipment, 4th Edition, 1991.
 Oil Companies International Marine Forum (OCIMF), Guidelines for the Handling,
Storage, Inspection and Testing of Hoses in the Field, Second Edition,1995.
 Oil Companies International Marine Forum (OCIMF), Standards for Equipment Employed
in the Mooring of Ships at Single Point Moorings.
 GMPHOM 2009, Guide to Manufacturing and Purchasing Hoses for Offshore Moorings
 Oil Companies International Marine Forum (OCIMF), SPM Hose System Design
Commentary, 2nd Edition, 1993
 API 17 K – Specification for Bonded Flexible Pipe


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Doc. No OMSLL-AS-01-16 Rev.

Installation, Operating, Maintenance,

0 08/09/16 First issue A. Siliquini G. Marucci

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

2.0 Description of hoses and accessories.

A typical Long Length hose section is given in Figure 1.

Figure 1. Long Length Hose section

3.0 Hose storage and preservation recommendations.

4.0 Operating temperature and aromatic content

5.0 Spooling and despooling of the hose

6.0 External Inspection of the hose

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

7.0 Pre-assembly hose inspection and testing requirements.

Visual Inspection of Hoses Onshore.

Hydrostatic Pressure Test

Hose state Test condition Test Pressure

 Duration of the test: at least 30 minutes.

TYPICAL STRUCTURE OF TESTING PERFORMED ON REELS IN SERIES

Bobina 1 Bobina 2 Bobina 3 Bobina 4

HIGH PRESSURE PUMPE

1 HIGH PRESSURE VALVE

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Coating of bolts and nuts: Zinc plated for PTFE

Bolt torque and bolt tightening sequence

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

9.0 Post assembly and pre-towing testing and inspection

The pressure test should be monitored and recorded by a traceable means.

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

10.0 Generic hose installation procedure

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Passing the hose to the rig

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

12.0 Inspection of the hoses

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Hose Performance Card System.

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Hose Card Disposition File System (HCDF)

Hose Performance Card.

4. Fill in line 4, etc., when the hose is moved or subsequently retired.

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

7. When space is exhausted on one card, attach a second card.

11. When space is exhausted, attach a second card.

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

Sample Hose Card

MANULI HYDRAULICS ITALIA S.r.l. a Socio Unico

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