Document owner: Maintenance Manager

TITLE: Flexible Hose Management Guidelines

DOCUMENT No: KPO-AL-MEC-GLS-00001-E

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A1 Comments incorporated 8/7/2011 D Halliwell R Farley T Hardacre

R0 Draft for comment 7/5/2011 D Halliwell

Rev Purpose Date Prepared Checked Approved

 Flexible Hose Management Guidelines
Document No: KPO-AL-MEC-GLS-00001-E
Revision A1

Revision History
Revision Changes

R0 Draft for comment

Issued for use

A1
Comments incorporated and Addendum 4 added

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 Flexible Hose Management Guidelines
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Executive Summary
These guidelines are based on those published by the United Kingdom Offshore Operators
Association (UKOOA) titled, Flexible Hose Management Guidelines Issue 1, January 2003.

The purpose of these guidelines is to provide operators of KPO production plant and
Field Operations with a reference framework of management and technical controls
necessary to ensure the continued integrity of Flexible Hose Assemblies (FHAs)
throughout their lifecycle.

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 Flexible Hose Management Guidelines
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Contents

REVISION HISTORY 2

EXECUTIVE SUMMARY 3

CONTENTS 4

DEFINITIONS/ABBREVIATIONS 6

1 SCOPE 7

2 REFERENCES 7

3 INTRODUCTION 9

4 PERSONNEL COMPETENCE 9

5 SAFETY 9
5.1 Vibration / Movement 10
5.2 Misalignment 10
5.3 Temporary Applications 10
5.4 Degradation Issues 11

6 HOSE SELECTION GUIDELINES 11

6.1. Responsibilities 11
6.2. Certification 12
6.3. Marking 12

7 STORAGE, TRANSPORTATION AND INSTALLATION 12

7.1. Storage 12
7.2. Transportation 12
7.3. Installation 13
7.3.1. Safe Handling of FHAs 13
7.3.2. Installation of FHAs 13
7.3.3. Minimum Bend Radius (MBR) 14
7.3.4. Temperature 14

8 MAINTENANCE, INSPECTION AND TESTING 14

8.1. Hose Register and Tagging 14
8.2. Inspection Strategy, Criteria and Frequency 15
8.2.1. Inspection Frequency 15
8.2.2. Periodic Visual Inspection 15
8.2.3. Inspection 15
8.2.4. Rejection Criteria 16
8.3. Pressure Testing of FHAs 16
8.4. Modifications or Change of Service Conditions 17
8.4.1. Changing Conditions 17
8.4.2. Risk Assessment 17

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8.4.3. Modifications 17
8.4.4. Disposal 17

9 APPENDICES 18
9.1. Addendum 1 – Personnel Competency Requirements 18
9.2. Addendum 2 - Human Factors Associated with Flexible Hose Assemblies 20
9.3. Addendum 3 - Hose Checklist 21
9.4. Addendum 4 - Photographs Showing Good Practice 22

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Definitions/Abbreviations

ALARP As Low As Reasonably Practicable.

CMMS Computerised Maintenance Management System
Delivery A hose or FHA, which has a service duty to convey fluids or gases
Hose throughout its useful life.

Flexible
Hose
Assembly A complete hose with end fittings and any associated accessories.
(FHA)

A flexible conduit normally of circular cross-section and usually with an inner

Hose lining, reinforcements and an outer cover.

The minimum radius of curvature, measured from the straight hose

Minimum
centreline (or other manufacturer defined datum), which the hose can
Bend Radius
tolerate without sustaining damage, distortion, excessive load or impaired
(MBR)
performance.

A change in service for which the FHA was originally specified. Change may
include function, internal environment, external environment, operating limits,
installation arrangement, flowing versus static conditions etc. Replacement
Modification
components must be fully matched (like for like) to the original specification
in all respects (including length) if not to be regarded as a modification.

Temporary
Flexible A FHA which is used for a specific short duration activity is covered by a
Hose local Risk Assessment and controlled by the Permit-to-Work system.
Assembly

Working The maximum and minimum working pressure at any given temperature,
Pressure confirmed by the hose manufacturer, to which the FHA maybe submitted.

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1 SCOPE
This document describes the maintenance and inspection management controls necessary
to ensure the continuing technical integrity of flexible hoses.
It is applicable to flexible hoses and their accessories in all KPO operations.
For guidance, the following hose service and types are typically covered by this document
although this list is not exhaustive and is included for information only.

Service

Hydrocarbon process (fluids and gases)

Chemical transfer bulk loading
Compressed gases (bottled gas installations)
Temporary hoses
Sampling hoses
Steam hoses
Hydraulic hoses
Fire hoses

Exceptions

Proprietary hoses integral with vehicles

Packaged units (eg drilling, generators, firepumps, cranes)
Breathing apparatus hoses

These guidelines apply essentially to temporarily portable FHAs. If permanently installed

FHAs are being considered, further guidance on their use is given in the UKOOA guidelines
on which this document is based.

2 REFERENCES
United Kingdom Offshore Operators Association (UKOOA) Flexible Hose Management
Guidelines Issue 1, January 2003.

1 ISO 1307 Rubber and Plastic Hoses for General-

purpose Industrial Applications.
2 ISO 8331 Rubber and Plastics Hoses and Hose
Assemblies Guide to Selection, Storage, Use
and Maintenance
3 ISO 7313 High Temperature Convoluted Hose
Assemblies in PTFE
4 ISO 10380 Corrugated Flexible Metallic Hose and Hose
Assemblies
5 SAE AS 1339 Society of Automotive Engineers - Hose
Rev e Assembly, PTFE, Metallic Reinforced
6 BS 1435 Rubber Hoses for Oil Suction and Discharge,
Specifications for the assembly of, and
recommendations for the storage, testing and
use of.
7 API 17 B American Petroleum Institute, Recommended
Practice

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8 IP Guidelines Institute of Petroleum, Model Code of Safe

Practice Part 1, Electrical Safety Code,6 th
Edition (1991)
9 BFPA/P47 British Fluid Power Association Guidelines to
the use of Hydraulic Fluid Power Hose and
Hose Assemblies
10 BS 6501 Flexible Metallic Hose Assemblies Part1-
Specification for corrugated hose assemblies
11 HSE Safety in Pressure Testing
Guidance
Note GS4
(Third
Edition)
12 KPO-50-OPN- Purging / Flushing Assembly Sketch
SKT-00001-E

13 KPO-AL-HSE- Waste Management Procedure

PRO-00212-
ER
14 GOST 6286- Un-reinforced High Pressure Rubber Hoses
73 with Metal Braids.
GOST25452-
90
15 GOST10362- Pressure Hoses of Vulcanised Rubber with
76 Thread Reinforcement and without End
Fittings.
16 GOST18698- Textile Carcass Rubber Pressure Hoses
79

17 GOST 5398- Un-reinforced Textile Carass Rubber Pressure

76 Hoses

18 GOST 28968- Outside Surface Wear Resistant Rubber

91 Hoses

19 GOST9356- Rubber Hoses for Gas Welding and Metal

75 Cutting

20 BGA-OPS- BG-Group Flexible Hose Assembly

MAIN-GL- Management Guideline
0007
21 KPO-AL-HSE- KPO Waste Management Procedure
PRO-00212E

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3 INTRODUCTION
FHAs are used extensively for delivery of products on a wide range of process, drilling and
service/utility systems. Failures in their integrity create hazards such as leakage of
flammable or toxic substances, and compromise the operation of safety and control systems
and impact on the safety of personnel. In addition environmental burdens maybe placed on
management through pollution issues.
FHAs are often an integral part of pressurised systems carrying hydrocarbons (liquids and
gases), chemicals, fuels, power fluids, and are used in many process plant and drilling/Well
Engineering applications. Flexible hoses are also used extensively during bulk loading and
unloading operations.

Effective management in particular the assurance of personnel competency is key to

ensuring the quality of the whole lifecycle management of FHAs. To ensure the integrity of
flexible hoses, it is necessary to establish a performance based maintenance and inspection
strategy in accordance with approved guidelines and inspection practices.

4 PERSONNEL COMPETENCE
The integrity of FHAs is very dependent on the correct selection of hose and adherence to
installation procedures. Personnel competency is therefore a key issue and should be
considered at all stages.
All personnel required to install, inspect and maintain FHAs should be deemed competent,
and be fully conversant with the appropriate installation and maintenance procedures and
failure criteria.
All personnel required to test FHAs should be formally authorised and registered to do so
and be fully conversant with the relevant test procedure.
Refer to Addendum 1.

5 SAFETY
Consider the following issues which have safety implications

 Permanent FHAs should not be used where it is safer to install permanent

pipework/instrument tubing.

 Appropriate fire rating of the application.

 The hose must be compatible with the piping class and equipment design pressures
and temperatures of the system

 Compatibility with the application, in particular, FHAs used in suction applications

should be capable of withstanding a negative pressure.

 FHAs should only be used if they have been assembled and tested by the
vendor/Competent Person and supporting documentation has been supplied. The
asset owners are responsible for ensuring the supporting documentation is in place
and kept current

 Hose assemblies will only be used for duties for which they are approved, taking due
consideration of the environmental conditions in which the hose is to be used or
stored.

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 Dependent on the application, all metallic or conductive components maybe required

to be electrically continuous and, in some cases, bonded to earth.

 Hoses should be firmly attached to their end fittings by the hose

manufacturer/approved supplier.

 FHAs should be adequately supported and installed to the manufacturer guidelines.

 FHAs should be identified with a suitable unique numbering system

 FHAs should be installed, tested and inspected by Competent personnel.

 Internal and external effects of chemicals on all components associated with the
FHAs

5.1 Vibration / Movement

FHAs may eliminate the transmission of vibration or movement in a specific application
FHAs will only efficiently eliminate the transmission of vibration, movement or noise if the
adjacent pipework is properly anchored on the downstream side of the hose. In the worst
cases, failure to ensure this can lead to uncontrolled movement of the FHAs and premature
failure.

Where an existing system requires 'damping' to the extent that the pipework cannot be
engineered in a way that will reduce vibration to an acceptable level, then an FHA maybe
considered, if there is no other suitable or safer alternative solution.

5.2 Misalignment
FHAs should not be used as a remedy for poor design or installation, eg to correct
misalignment of rigid components.

5.3 Temporary Applications

Flexible hose may be used where it is necessary to carry out specific temporary tasks
associated with normal process production, supported by a Risk Assessment ie:
Process sampling
Process diversion to closed drain or vent
Connection of a process line to import or export point,
Hydrostatic test hook-up for installed system testing

Flexible hose may also be used as a temporary method to transport fluids, after a suitable
Risk Assessment has been completed, ensuring that the hose is correctly specified and
tested for the application.
Hoses should be clean before use, to prevent mixing of dissimilar chemicals within the hose,
especially if the hose has been used in previous applications.
Where FHAs are initially installed as a temporary arrangement, this should normally be for a
predefined short period. If periods of use become extended, the application should be
subject to a critical review process. Use of temporary FHAs for longer periods should be
subjected to a Risk Assessment and a suitable permanent solution sought which
demonstrates the risks are ALARP. The Management of Change process should manage
this.
It is incumbent on the user to ensure that the FHA is fit for purpose prior to each
application.
Hoses must only be used for the purpose for which they were manufactured. Failure
to do so may result in injury.

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5.4 Degradation Issues

Degradation of FHAs can be accelerated due to heat, environmental conditions or

contamination of the outer coverings and braids due to chemicals, ultraviolet light, ozone,
salt, water etc. Materials & Corrosion Engineer and the manufacturer should be consulted as
necessary, taking due regard of the predicted working environment and fluid composition. It
should be noted that the fluid composition could change over the expected lifecycle
Note: Heat tracing and insulation can considerably accelerate any corrosion mechanisms

6 HOSE SELECTION GUIDELINES

6.1. Responsibilities
When evaluating the performance and safe operational requirements of a FHA, it is
important that a dialogue is established between the manufacturer vendor and KPO.
FHAs should be chosen for their suitability for the proposed service conditions, by
means such as:
Referring to a manufacturer's compatibility chart
Consulting with the manufacturer's or vendor's representative and material
specialist
Consultation with a material specialist and or relevant engineering documents

The following parameters should be considered prior to selection:

KPO Responsibility Manufacturer/Vendor Responsibility

Media to be Define fluid composition and phase for all Ensure compatibility of all components
Carried foreseeable operating modes

Working Define expected minimum and maximum Ensure compatibility of all components
Environment environmental conditions, including process or with all specified fluids
environmental contaminants if relevant

Flow Define full range of flow conditions (including Define construction requirements and hose
Requirements pulsating flow, multiphase flow, limiting pressure bore size
drop requirements)

Pressure Range Define maximum and minimum pressures
(including vacuum) for all foreseeable operating
modes
Temperature Define minimum and maximum operating
Range temperatures for all foreseeable operating
modes
Flexibility Ensure the FHA is installed as per
manufacturer's/vendor's recommendations
Ensure compatibility of all components
with specified range
Ensure compatibility of all components
with specified range
Advise minimum bend radius and other
installation limitations (eg creep)

Weight Ensure that the FHA is installed as per Define weight and support requirements
manufacturer's vendor's recommendations

Volumetric Ensure that the FHA is installed as per Advise expansion performance and
Expansion manufacturer's/vendor's recommendations installation requirements based on
specified function and hose properties

Fire Rating Define requirements Ensure compatibility of all components or

advise on fire resistance

Piping Class Define materials and pipe rating of connecting Ensure compatibility of all components
pipe work or equipment with connected system

Erosion and Ensure that the FHA is installed as per Ensure compatibility of all components
Abrasion manufacturer's/vendor's recommendations
Requirements
End Fittings Define requirements, including materials, thread Ensure compatibility of all components
type and orientation

Other Specify any other relevant information, which Ensure other measures are compatible or
Requirements could affect lifecycle performance. advise user of consequences
If in doubt CONSULT manufacturer

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6.2. Certification

The FHA should be supplied with a certificate, which includes the following as a minimum:

Manufacturer's name
Manufacturer's hose batch number
Manufacturing standard
Nominal size
Unique serial number
Actual inside and outside diameters
Materials of construction
Test pressure
Proof and burst pressure
Electrical continuity tests (if applicable)
Year and month of manufacture
Fire rating

6.3. Marking
End fittings should be marked as specified for fittings and flanges, with the addition of the
manufacturer's name and figure number for proprietary hose couplings. Threaded
connections should be marked with the thread form.
FHAs should have at least the following markings:

Manufacturer's name
Manufacturer's type name or code
Year of manufacture
Latest replacement date (if applicable)
Maximum and minimum (vacuum) working pressure
Maximum and minimum working temperature
Minimum Bend Radius (MBR)
Applicable national document or standard, class and/or type Manufacturer's hose batch
number
Service
Nominal size
Unique serial number

7 STORAGE, TRANSPORTATION AND INSTALLATION

7.1. Storage
All FHAs should be stored in clean, dry conditions and hoses of rubber and composite
construction should be kept in a cool atmosphere protected from direct sunlight. Some hose
linings, if not protected prior to putting in to service, have a finite shelf-life. This should be
considered prior to use. New hoses should be issued on a 'first in first out' basis to minimise
deterioration in storage.
FHAs, except when supplied in coiled lengths, should be laid out straight and flat and
supported along their length to prevent flattening, kinking or twisting. Other equipment
should not be stored on top of hoses.
Coiled FHAs should be end sealed to prevent ozone attack in storage.

7.2. Transportation
Individual hose wrapping should be used to protect braided FHAs without outer protection
from damage in transit.

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7.3. Installation

7.3.1. Safe Handling of FHAs

FHAs should always be handled with reasonable care, and should not be subjected to over-
straining. The design of hose supports and saddles should be to ensure such that minimum
bend radius is not compromised. Single rope slings and wires are not suitable for many
support applications since they can lead to local kinking, abrasion or non-compliance with
minimum bend radius requirements.
FHAs should never be forcefully deformed, crushed, twisted or subject to flow shut-off by
kinking.
Avoid routing or dragging FHAs over sharp or abrasive surfaces.

7.3.2. Installation of FHAs

It is important to consider whether the hose is to be used in static or flexing conditions. The
following points should be noted when planning an installation:

(1) Any piping fittings and couplings used to connect to the FHA shall be to the
same line class as the equipment to which the hose is being connected. This is to
ensure the design duty of the piping fittings is not exceeded with regards to
pressure and temperature. For Hose Selection Guidelines refer to section 7.
Document KPO-50-OPN-SKT-00001-E details the arrangement for piping fittings
and couplings for connecting to the FHA.

(2) It is essential that the mating couplings are completely free from foreign matter,
burrs etc and are otherwise in sound condition.
Damage, corrosion or contamination to the mating surfaces will cause joint failure in
service.

(3) The installed bend radius of the hose must not be less than the minimum bend
radius specified by the manufacturer during any worst-case conditions.

(4) Union nuts should be hand tightened at both ends and the hose allowed to adopt
its natural position prior to tightening.
Excessive force should not be applied when tightening end connections, ie long-
handled spanners/wrenches should not be used. Correct tools should always be
used which will not cause damage that could then lead to degradation or failure.

(5) FHAs should not be installed in a twisted condition, since this puts unbalanced
tension on the hose and reduces the working life of the assembly.
The single or double line indicating the wire braiding strips serve as a guide (or
manufacturer's specific marking system) for installing FHAs correctly.

(6) The FHAs should not be installed in applications where compression could
occur. This can cause the external braiding to 'birdcage'(ie the braided weave
expands and opens) and result in a reduced pressure retaining capability.

(7) The FHAs should not be installed in applications where axial extension could
occur. This can cause the external braiding to be over-stressed and may result in
broken braid wires. This will reduce the pressure retaining capability.

(8) The FHAs should not be installed in applications where torsion of the hose could
occur. This can cause the hose to be subjected to shear stresses for which it is not
designed and can result in premature failure. (Refer to the below figure.)

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RIGHT

WRONG

Figure. Hose Torsion

7.3.3. Minimum Bend Radius (MBR)

When a hose line is installed in to an arrangement where it will be bent, the
recommended minimum bend radius must not be compromised.
Bending beyond the limits of the minimum bend radius is a problem often
encountered during flexing applications. Over-bending can lead to damage to one or
more of the hose construction layers, flow impairment due to kinking, general
overstress to hose and/or fittings. It should be noted that for some hose types, over-
bending could damage the hose (eg deformed wire reinforcement) even though
there is no outward appearance of this. Caution is also needed, therefore, in the
handling of hose prior to installation. Enough hose should be provided to allow for a
movement. Fittings are not a flexible part of the assembly and continuous flexing of
a short hose assembly can tend to wear the hose at the point of connection with the
fitting.
MBR is normally expressed as a ratio of bending radius versus hose diameter and is
measured from the hose centre line.

7.3.4. Temperature
Exposure to high ambient and service temperatures can drastically shorten the hose
life by affecting the outer cover and weakening the reinforcement. Hose line should
be routed away from hot manifolds or other high outside temperature sources
whenever possible. If this is not practical, a protective sleeve or baffle plate should
be installed for protection.
Low ambient or service temperatures can impair the flexibility of the hose.

8 MAINTENANCE, INSPECTION AND TESTING

8.1. Hose Register and Tagging

A complete register of FHAs installed at any Installation should be created and kept
current. This should also include any temporary hoses brought on to the Installation
for specific activities eg shutdowns. Vendors supplying equipment should supply

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current test certificates for any hoses installed on their equipment, or used to
connect to the Plant services.
A suitably competent person should be nominated at each location to be
responsible for maintaining the hose register. It is recommended that the register
should reside within the CMMS. (see Addendum 1.)

The register should, as a minimum, record the following information:

Unique Identification Number

Year of manufacture
Length
Internal diameter
End connections
Location Service
Type of hose
Date of last inspection
Date of next inspection
Status at last inspection (ie satisfactory, scrapped etc)
Latest replacement date

Each FHA should be identified with a unique number applied to the hose. Care
should be taken to ensure that the tag or its fixing does not promote a local
corrosion site, or create a site for chaffing or cutting the hose surface under
operating conditions.

8.2. Inspection Strategy, Criteria and Frequency

FHAs should be routinely replaced with a new certified assembly where any doubt
of the FHAs condition or history exists.
Otherwise the design life defines the replacement date.

8.2.1. Inspection Frequency

The inspection frequency shall be annually until sufficient history is built up in the
hose register which demonstrates that the inspection frequency maybe decreased
or increased.

8.2.2. Periodic Visual Inspection

Prior to submitting a hose for inspection, all chemical / hazardous media shall be
flushed from the hose by Production department.
Hoses should be visually inspected for cuts, kinks, bulges, signs of abrasion,
corrosion products etc. Particular attention should be focused close to the end
fitting for signs of over-bending. Visual inspection should also be carried out on
hose connections, including any static half coupling to which the hose is to be
connected.
A Competent Person should carry out the inspection. The observations should be
logged.

8.2.3. Inspection
Inspection may be delegated to a specialist hose management company as
appropriate; however, the responsibility for the inspection work and resultant
actions lies with the asset management. Whether in-house personnel or specialist
contractors are used to inspect hoses, it is essential that they are competent to
recognise the significance of any defects found.

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FHAs inspection should include both a physical inspection of actual FHA products
and collation of data for the hose register, to provide historical records to enable
periodic inspection routines to be optimised and planned, along with providing an
automatic retrieval of data for re-ordering FHAs.

8.2.4. Rejection Criteria

As a guide, the FHAs should be rejected and removed from service under the class -
dependent failure conditions given in the table below. FHAs displaying developing
signs of these criteria, but judged not yet to warrant replacement, might require
increased frequency of monitoring to provide assurance against unacceptable
degradation.

Defect Action

Over-bending Reject if less than minimum bend radius

Axial extension Reject

Clashes or rubbing Investigate and eliminate

Induced torsion Reject

crushed Reject

Detailed Examination

None of the following defects found are permitted

Missing data markings

Life of hose exceeded
End fitting corrosion
Bulged braid at fitting
Braid damaged
Broken braid wires
Visible leakage
Excessive hardening or softening of the hose (aging)
Excessive cuts, blisters, kinks, abrasion, mechanical damage, elongation under test.

Note: If any doubt exists on the integrity of the FHA, then it should be replaced as
soon as possible.

8.3. Pressure Testing of FHAs

FHAs that pass the visual examination shall be h ydrostatically pressure tested to
110% of the hose design pressure for a minimum of 3 minutes.
No pressure drop or leakage is permissible.

Personnel involved with the control of pressure testing must be aware of the
hazards associated with, and experienced in, the procedures and precautions
required when pressure testing any equipment.
Personnel involved in testing activities of any kind shall be experienced in pressure
testing procedures and shall be fully conversant with the specific requirements,
precautions and procedures specified for relevant tests.

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The most sensitive method for a quantifiable leak test is using nitrogen with a
helium trace. Other methods such as a bubble test and other media such as water,
diesel, air or inert gas are also used.

8.4. Modifications or Change of Service Conditions

8.4.1. Changing Conditions

The user should be aware of changing conditions, which may move the FHAs away
from the original design intent.

Changes can include, but not be limited to, the following:

Process conditions (eg pressure, temperature, flow, fluids)

Functional change
Pipework configuration
Environmental conditions
Alternative hose type

8.4.2. Risk Assessment

If modifications to the system are required or if the process conditions change, a full
Risk Assessment in accordance the use of the hose should be re-evaluated, to
ensure that any proposed changes do not degrade the functionality of the FHAs.

8.4.3. Modifications

Flexible hose assembly construction must not be modified in anyway.

8.4.4. Disposal

FHAs which have been identified as being unfit for purpose should have the end
fittings removed and the main carcass of the hose marked as 'Scrap'. It should then
be disposed after decontaminating any chemicals according to KPO Waste
Management Procedure KPO-AL-HSE-PRO-00212E REV A9. Failure to
decontaminate FHAs that have been in hazardous service will render them special
waste.
The opportunity to test hoses to destruction, after they have been decontaminated,
should be taken to build up operational knowledge. The hose register should be
updated.

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9 APPENDICES

9.1. Addendum 1 – Personnel Competency Requirements

1 General
All personnel that are required to specify, install, maintain or inspect systems
containing FHAs should have training commensurate with their responsibilities.
The content of the training should include the general requirements of safety,
selection, installation and inspection.

2 Authorised Personnel

The content of training should include the general requirements of safety, selection,
installation and inspection.
Each person should be registered and maintain their competency by attending
regular training and have their ability to perform tasks routinely assessed.

3 Competency Matrix

The following matrix provides a typical competence profile:

Activity Maintainer Operator Inspector

Material selection A A A

Material conformance with design S A S

Internal/external conditions S A S

Reduction of joints K A S

Material handling K A K

Material preparation S K S

Basic installation S K S

Complex installation K K S

Conditions of use (restrictions) S S S

Inspection and testing K K S

Re-make limitations S S S

Non-conformance identification S S S

Criteria
S = Skilled K = Knowledgeable A = Aware

4 Competence Assurance, Registration and Training Requirements

The users of FHAs should be formally “competency assessed” to ensure that all
personnel (company and contractor) required for work on FHAs are formally
assessed as being competent to carry out the range of allotted tasks.

Personnel assessed as being competent should be registered as being authorised

to carry out that range of tasks. There should be a formal authorisation process,
including the retention of a current register of authorised personnel.

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It is recommended that vendor personnel employed on short term construction or

maintenance work are competent to carry out the range of work to be undertaken,
and that their competency is recorded in the register of authorised personnel.

5 Personnel Training

Only competent personnel should work with FHAs.

Personnel employed on the installation or maintenance of FHAs should have
appropriate background skills and experience eg instrument or mechanical
discipline technicians with general engineering skills and experience.
Installation or maintenance personnel who have not satisfied the competence
assurance requirements should receive supplementary training and/or be
supervised on the job to meet the competency requirements before being added to
the register of authorised personnel.
Operational personnel should receive training appropriate to their duties.

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9.2. Addendum 2 - Human Factors Associated with Flexible Hose

Assemblies

1 Introduction

Accidents or failures involving Flexible Hose Assemblies (FHAs) can frequently be

traced back, in whole or in part, to a failure in human understanding, action or
response. Operating hoses may pose hazards to personnel, requiring appropriate
control measures such as procedures and use of good practice to minimise risk.
Human failure may frequently be attributed to:
Lack of awareness of hose characteristics, function and limitations
Operator error or a failure to comply with procedures
Lack of adequate procedures
Lack of training or competence

2 Lack of Awareness of Hose Characteristics, Function and Limitations

FHAs are typically complex structures comprising couplings of various designs and
flexible hose comprising of multilayered material and reinforcements. Each layer
serves as a specific purpose that may include chemical or abrasion resistance,
structural strength or physical protection. Only surface layers are normally visible.
Hoses maybe used in flowing fluid service or static pressurised service.
Personnel responsible for specifying, using, maintaining or inspecting hoses should
be aware of the elements of construction of a hose assembly and their contribution
and application to the specific use. This is important if they are to avoid incorrect
use or recognise when a hose no longer meets the required integrity.

The scope for hoses to be used in multiple duties is high. If not properly controlled,
this can lead to failures if hoses are subsequently used in services for which they
were not originally designed or specified in all respects.

3 Hazards to Personnel

FHAs come in a wide range of sizes and are used in both permanent and temporary
duties. Manual handling of hoses either in the free and uninstalled state or in
service needs consideration if weight (including weight of contents) or bulk is
excessive, or if release of pressurised fluids from nozzles etc can cause whiplash
movements causing a loss of control of discharges.
Poorly supported or restrained flexible hose assemblies may present tripping
hazards, or impact hazards from assembly collapse or movement.
The transfer of hot fluids and its potential for operator contact with hot surfaces
needs consideration.
FHAs handled by operators may contain hazardous substances. Care needs to be
exercised to prevent splashes, jets, sprays or other contact with harmful contained
fluids when disassembling or handling hoses. Care is required to ensure that no
residues remain in hoses that could be incompatible with further usage. (Refer to
Paragraph 10.1 of the guidelines.)
FHAs used manually by operators need careful handling since if the hose becomes
blocked, it could suddenly release. A hose should never be looked into that is
connected to a pressure system, even if the system is believed to be isolated.

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9.3. Addendum 3 - Hose Checklist

The following is provided as an example of minimum information requirements.

Where possible, the FHA manufacturer or vendor's specification sheet should be
used to ensure that all relevant information is provided and the correct FHA for the
application is supplied.

KPO’s Responsibility to Define Requirements

Media to be Carried Define fluid composition and phase for all foreseeable operating modes

Working Environment Defines expected minimum and maximum environmental conditions, including
process or environmental contaminants if relevant

Flow Requirements Defines full range of flow conditions (including pulsating flow, multiphase flow,
limiting pressure drop requirements)

Pressure Range Defines maximum and minimum pressures (including vacuum) for all foreseeable
operating modes

Temperature Range Defines minimum and maximum operating temperatures for all foreseeable
operating modes

Volumetric Expansion Ensures that the FHA is installed as per manufacturer's/vendor's

recommendations

Earth Bonding Define requirements

Fire Rating Define requirements

Piping Class Defines materials and pipe rating of connecting pipework or equipment

Erosion and Abrasion Defines any erosion or abrasion issues

Requirements

End Fittings Defines requirements, including materials, thread type and orientation

Other Requirements Specifies any other relevant information which could affect lifecycle performance
If in doubt, CONSULT the manufacturer

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9.4. Addendum 4 - Photographs Showing Good Practice

1 Air hose connected to plant utility station with Crowfoot coupling. Shows
Whipcheck in place to prevent the hose from whipping under pressure should the
coupling disconnect, and blue colour coded identification hose sleeve

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2 Nitrogen Hose connected with Snaptite coupling to plant utility station. Shows
orange colour coded identification sleeve and Whipcheck

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3 Steam Hose Connected with hose clamp and screwed Jaymac Spud coupling
with Whipcheck

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