Dantec Document No: Rev No: Dantec Limited

HHITG1 D Technical Dept

30/10/2019

HOSE HANDLING, INSPECTION

& TESTING GUIDELINES
For Dantec composite hoses installed in service

DANTEC LTD.

Dantec Document: HHITG1 Rev D

Dantec Ltd Head office and works Tarran Way Moreton Wirral CH46 4TL England
Tel: +44 151 678 2222 Fax: +44 151 606 0188 Email: sales@dantec.com

Dantec Document No: HHITG1 Revision: D

Preface
This manual has been prepared to explain the best practice to handle, store, inspect and test
composite hoses in order to prevent potential failure or accidents, and ensure safe, dependable
liquid transfer operations.

Whilst essential to dedicate attention to composite hose once installed and in service, it is
recommended to adopt a proactive approach to pre-purchase selection and develop a functioning
hose management system.

Always wear full PPE (personal protection equipment) when handling composite hose as
appropriate to your company practice. This guide should be used alongside your own SHE and
COSHH regulations.

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Contents:

Part 1 Hose suitability

1.1 Checklist
1.2 Parameters
1.3 Medium
1.4 Working at elevated temperatures/pressures

Part 2 Hose management

2.1 Hose records

2.2 Recording products/parameters of intended use
2.3 Setting Test Intervals
2.4 Dantec Hose Management

Part 3 Hose handling

3.1 Installation and Transport

3.2 Hose handling do’s and don’ts.
3.3 Working at temperature
3.4 Hose support accessories

Part 4 Hose storage

4.1 Draining
4.2 Cleaning
4.3 Infrequently used hoses
4.4 Storage
4.5 Hoses on arms/towers

Part 5 Inspection and testing.

5.1 Regular inspection

5.2 Visual inspection
5.3 Electrical continuity
5.4 Pressure testing
5.5 Final checks/Recording data
5.6 Third party inspection

Part 6 Removing hose from service

6.1 Failed hoses

6.2 Repairs
6.3 Claims and warranty
6.4 Retirement
6.5 Disposal

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Part 1 – Hose suitability/selection

1.1 – Hose suitability checklist

It is imperative that all working parameters and factors are considered before purchasing and/or
using a composite hose.

1.2 – Parameters
General Parameters
Chemical medium
Viscosity of medium
Working pressure
Working temperature
Temperature spikes
Pressure spikes.
Table 1
Other Factors
Simultaneous use of elevated pressure & temperature
Cleaning requirements
Risk of cross contamination
External conditions
Mechanical support available
Environmental/Health and Safety factors

1.3 – Medium

Dantec’s online configurator allows users to search and select the recommended hose for the
media being conveyed. Users can search by media/chemical name or CAS number.
www.configurator.dantec.com

Dantec does not recommend using composite hose for any medium being transferred with a
viscosity above 400 centistokes (cSt).

Hose recommendations are based on available data for media transfers at ambient temperature.
The hoses listed may be suitable for product transfer above or below this. If unsure always check
with the manufacturer or distributor for further guidance.

1.4 – Working at elevated temperatures/pressures.

It is not recommended to use composite hose at any time to its maximum working pressure,
operating temperature and/or minimum bend radius simultaneously.
Doing so could reduce the working life of the hose severely.

Maximum working pressure and maximum working temperature and minimum bend radius are
available on the Dantec website, product data sheet and (if already ordered) on the hose assembly
test certificate.

Working pressure for hoses assemblies may also be reduced due to the rating of the end coupling
attached.
Always rate the hose at the lowest working pressure of the hose or fitting.

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Part 2 – Hose management
2.1 – Hose records

When receiving new hoses it is important to record the hose information, for auditing and for
regular inspections
Dantec recommend recording the following information as good practice:

Table 2
1 Hose Serial number
2 Hose Type
3 Hose manufacturer
4 Bore size
5 Hose length
6 End coupling 1
7 End coupling 2
8 Date New
9 Date tested
10 Tank/Tanker/Area
11 Location (if applicable)
12 Products ordered for see 2.3
13 Test Intervals see 2.4
14 Colour in test see 2.4

Parts 1 to 9 of the above information is available on the manufacturer’s hose Test certificate.
Parts 10-14 will need to be completed by the end user.

2.2 Recording products/parameters ordered for:

By recording what products the hoses were ordered for at time of order, it can help avoid cross
contamination, and give the user the opportunity to check with the manufacturer/supplier when
transferring a new product or changing the general working parameters (see 1.2)

2.3 Setting test intervals

By setting the desired test intervals at the time of receiving the hose, it initiates good hose
management structure going forward. Testing and inspection criteria are covered in section 5 of
this document.

Some users prefer to colour code their hoses with tape or cable ties to show easy visual evidence
the hose has been tested within the current test interval. (See 5.5)
If this practice is to take place, it is best to include the current tagging colour on any new hoses.

2.4 Dantec hose management

Dantec and their distributors offer a hose management system, recording the above data on your
behalf. Please consult your hose supplier for information. It is the end user’s responsibility to inform
the hose manager of any changes to circumstances. Including repairs, relocation, and removing
hose from service.

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Part 3 – Hose Handling
To ensure users gain the maximum working life of their composite hoses, it is imperative that
hoses are handled correctly. Composite hoses over the size of 4” (100mm) nominal bore in
particular must be supported at all times.
All Dantec HD (Heavy Duty) hoses are suitable for both ship to shore and ship to ship (STS)
applications in accordance with OCIMF STS guidelines

3.1 Installation & Transport

Incorrect installation can unduly stress hose assemblies leading to a shortened working life or
premature failure
Table 3
Installation & Transport
Hoses should not be dragged over rough surfaces
For transport make use of equipment such as trollies, rollers or derricks
Do not place your hose on hot surfaces
Do not lift the hose by the couplings, support the hose at numerous points including supporting the end
connection at the ferrules at all times
To assist with lifting; make use of saddles, bridles, slings, bend limiters, and hosebuns

Take care not to bend the hose beyond the minimum bend radius (MBR) during transport and installation
Hose assemblies must not be twisted either in installation or whilst in use
Flanged hose assemblies should ideally have a swivel flange at one end to lessen any distortion
Hose assemblies subject to movement whilst operating should be installed in such a way that flexing occurs
in the same place
In areas such as jetties or hose pits, hoses should be laid out to avoid crossing over each other, allowing easy
disconnection without force to separate
Where possible the manifold should be set/installed at an angle allowing the hose a more natural curvature

3.2 Hose handling do’s and don’ts.

Do’s

Lift the hose near the flange and use a
cradle, web sling or a hose bun
When a string is required, use a shorter
length and a longer length hose to avoid
additional strain. Ensure as much support to
the hose at the termination area using a
bend limiter.

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 Support hose at termination point ideally Avoid over-stressing the hose
using a bend limiter
Adjust supports with tide movements
Support hose with slings
Hose should be long enough to allow for
tide changes and fall and rise of ship

When connecting hoses in a string where

possible use web slings or a hose bun to
support the couplings where they meet

Don’t’s

Never lift hoses from their flanges or end Never support a hose with a single rope
fittings

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 Never use a hose unsupported Never exceed the minimum bend
radius unsupported
Protect against hard edges

Never overbend a hose or allow a hose to

hang between quay and ship

This guide is available to view as an animation download from our website

https://dantec.com/downloads/dantec-web-explainer.mp4

3.3 Working at temperature

Using a hose at elevated temperatures can affect the working pressure and/or reduce the life
expectancy of the hose. This applies to composite hoses, rubber hoses & stainless steel hoses.
Due to the characteristics of the thermoplastics used in composite hose, there can be some
disadvantages associated. The latest standard for composite hose is EN13765/EN13766: 2018
which covers the various requirements of pressure and temperature ratings.
However, whilst the hose can work at its maximum working pressure and maximum working
temperature it is not recommended to operate both in union. Simultaneous use of elevated
temperatures and pressures will severely impact service life. As temperatures rise, thermoplastics
lose rigidity and strength

As a result of plastic deformation under load, particularly at higher temperatures, hoses can
elongate. Hoses will need to be well supported, and this is even more essential in hoses being
operated in elevated temperatures conditions (50°C +). Lack of support can cause over bending,
especially near the couplings resulting in displacement of the helical support wires from their pitch.
This can create the potential for hose collapse and coupling displacement.

3.4 Hose support accessories

As expressed in parts 3.1-3.3

Bend Limiter Hosebun Hose Trolley

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Part 4 Cleaning & Storage

Correct and thorough hose cleaning is essential to avoid contamination of product, and to extend
the service life

4.1 Draining

On completion of a transfer operation and as part of the line clearing procedures, hoses should
be cleared of all product. The transfer hose should be elevated to ensure it is completely drained
before disconnecting.
Once disconnected from the manifold, end flanges should be blanked securely and the assembly
transported for cleaning.

Note: Hoses on ships and barges can been cleaned while connected to the manifold in compliance
with MARPOL regulations.

4.2 Cleaning

For most chemicals cleaning the hose out with fresh water is adequate.
Care must be taken if using hot water not to exceed the working temperature of the hose.
If cleaning with water is an issue, chemical cleaning should take place. Chemicals used should be
on the guidance of your own chemical engineer, and must also be compatible with the hose.

Whilst cleaning via open ended (loose) steaming can be also be undertaken, we recommend that
this is performed for no longer than 15 minutes. Care should be taken not to exceed the working
temperature of the hose, nor expose the hose lining to excessive localised heat

Warning:
Steam lances should never be used and composite hoses should never be pigged.

Hoses must always be cleaned before pressure testing.

4.3 Infrequently used hoses

It has become common practice to blank off hoses which are only used for one dedicated product
and leave ready for the next use.
Long term exposure of the product must be considered, therefore always drain after use and where
approriate clean the hose.

4.3 After cleaning

After flushing/cleaning hoses should be well drained and blanked.

Follow guide 3.1 for transporting hoses to the storage area.

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4.4 Storage

Incorrect short and long term storage of hoses can lead to damage and a shortening of the life
expectancy.
Effects can be immediate such as being hit with objects or vehicles resulting in impact damage.
Slow deterioration due to adverse or incorrect storage conditions may also occur.

Table 4
Storage procedures
Hoses should be stored off the ground horizontally on a solid platform with end fittings in line with the
hose
The hoses should be sheltered from climatic conditions especially direct sunlight
Do not stack hoses as they could damage each other
Ensure the flanges are not hanging, unsupported
Ensure fittings are not in positon to damage the hose body
Storage procedures
Storage procedures

4.5 Hoses on Arms/Towers

When hoses are permanently installed in hose arms, or tower gantries, hoses should be under
suitable shelter from climate and sunlight

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5 Inspection and testing

5.1 Regular inspection

Hose assemblies should be inspected on a regular basis;

 If in constant or frequent use, they should be visually inspected before each

loading/unloading operation
 When this is impractical they should be visually inspected at least once per day
 Hose assemblies used infrequently should be visually inspected each time they are used
 Hoses should be tested for electrical continuity every 6 months.
 If a hose assembly has been stored for over 12 month it is recommended to perform
pressure test before use (see 5.3)
 It is recommended to have all chemical and general purpose composite hoses pressure
tested at 6 month intervals and oil hoses at 12 month intervals.

Note: There are no worldwide official standards for periodic hose testing in service, this guidance
is classed as manufacturer’s best practice. Local legislation, including harbour authority
legislation, may be in place in your location, please check with your relevant local authority.

5.2 Visual inspection

To best understand composite hose, below are the main features.

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As listed in 5.1 hoses should be regularly visually inspected. Any inspection should concentrate
on the following points:

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NB: Providing that the relative position of the inner and outer wires is not compromised, some
shallow denting may be acceptable. However severe indentation may cause lateral wire

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movement, which will lead to the hose collapsing. There may also be internal film and fabric
damage, which could lead to product leakage and severe indentation will create flow restriction in
the hose.

It is recommended that a hose be failed if it has more than a 10% reduction in diameter in 3 or
more areas throughout the hose length. Similarly, if there is serious displacement of the outer
wires, caused by indentation, the hose should be failed.

If in doubt please withdraw the hose and refer to Dantec, a Dantec agent or independent hose
tester.

5.3 Electrical continuity

Prior to pressure tests, all electrically continuous hoses must be tested for electrical continuity.
This should be done regularly within periods not exceeding 6 months. These should be recorded
in your hose management register.
Table 5
Electrical Continuity procedure
Ensure the hose is cleaned, drained and dry
Lay the hose out flat on a dry non-conductive surface
Where possible raise the flanges/fittings off the ground
Ensure you are using a calibrated Ohmmeter
Connect the ohmmeter to each end connection of the hose and take a reading
A reading of 100Ω (ohms) or less per assembly is a pass, and the hose can now be pressure tested (see 5.4)
A reading of over 100Ω (ohms) is a failure and the hose must be taken out of service*

NB: This process will need to be repeated after the pressure test (see 5.4/5.5)
*A reading over 100Ω may be due to corrosion, cleaning of the end fittings may solve this
(NB rust is an excellent insulator).

5.4 Pressure test

Dantec recommends pressure test intervals should be 6 months for chemical hoses and 12
months for oil hoses.

Testing should be done hydrostatically; with water at ambient temperatures being the
recommended medium.
Where this isn’t feasible please consult with Dantec technical team or your Dantec agent.
Testing with air and or other compressed gases is not recommended.

Hoses can be pressure tested individually or bolted together in a hose string.

New hoses will have been initially tested to 1.5 x the working rating of the hose assembly and this
will be stated on the initial test certificate provided by Dantec.
(NB the assembly rating is defined by the lowest rating of the hose body or the hose fitting)

To avoid over stressing we recommend regular pressure test inspections should be 1.5 x the
actual operating (working or AWP) pressure the hose in which the hose is regularly exposed to.
If you are unsure of the regular AWP, testing the hose at the original factory test certificate
assembly rating will suffice (Manufacturer working pressure or MWP).

Customers may test the hose at 1.5 x the manufacturer’s original assembly rating (MWP) at their
own request and risk. (Manufacturers test pressure or MTP)

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Testing procedure is as follows:

Table 6
Pressure Testing
Lay the hose straight and horizontal ,allowing additional space at each end for elongation under
pressure
Flange end should be placed on hose trolleys to allow for controlled movement while under test
Hose ends should be blanked off with blanks which are adapted for testing
One end should be blanked with a vented test adaptor/valve to allow for pressure release
The other end should be blanked with test adaptor that allows for water filling and pressurisation
The end with the vent fitting should be slightly raised to allow for air to be bled from the hose.
Connect the water source to the test adaptor and fill with water, venting all the excess air through the
vented end
When full close off valves and disconnect water source
Connect test pump and fit pressure gauge, raise the pressure to 0.7 bar for hose stabilisation
(Ensure the pressure gauge is within calibration)
Slowly Increase pressure to 1.5 x operating working pressure and hold for 5 minutes
Visually examine the hose for leaks and end fitting movement
After 5 minutes reduce pressure to the operating working pressure for a further 5 minutes
Visually examine the hose for leaks
After 5 minute period of test, perform a controlled release of pressure and drain the water

NB: A Feature of composite hose is elongation under pressure, which is relatively high
compared with rubber hose.
This characteristic of thermoplastic composite hose cannot be used as an assessment of
the condition of the hose or an indication of failure.

5.5 Final inspections/Records

Once pressure test is complete please repeat the electrical continuity test (see 5.3)
Perform visual checks again in line with the visual criteria (see 5.2)

Assuming hose have passed all inspections the hose management records should be updated
and if appropriate the latest colour marking should be applied for easy recognition (see 2.4)

Failed hoses should also be recorded in the database and removed from service.

It is good practice for inspectors to record any signs of wear and tear for hoses that may be
deemed suitable but not in perfect condition (5.2 insert) so operators can take extra care and keep
a closer subsequent inspection of the hose.

5.6 Third party inspectors

Dantec & our agents can perform hose inspections on site, providing test certificates and
maintaining hose management systems. Third parties not nominated by Dantec should follow the
instructions listed in this document.

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6 Removing hoses from service

6.1 Failed hose

If hoses have failed any inspection during the hose inspection they must be removed from service.
Hose management systems must be updated to remove the hose from the system.

6.2 Repairs

Some hose can be repaired which have been damaged in service this will usually result in loss of
length. Kinks and wire displacement cannot be repaired. Only at the stage of repair can
Dantec/Agent advise whether the end fittings can be re-used.
Caution must be taken with hoses being transported and repaired and they must be fully
decontaminated by the end user before doing so. An MSDS for all products transferred must be
provided.

6.3 Claims/Warranty

If the client needs to make a warranty claim on any hose failure or investigation pending claim
they must contact Dantec or the company who supplied the hose. They will be provided with a
form to fill detailing the nature of the claim.
Photographs, videos, working life, operation parameters, and list of products transferred must be
provided.
Never return the hose, until Dantec/supplier has instructed that it is OK to do so.
Caution must be taken with hoses being transported and repaired and must be fully
decontaminated by the end user before doing so.
A completed Dantec returns form and MSDS for all products transferred must be provided.

6.4 Retirement

Composite hose has a long shelf life. Unlike rubber hose it does not degrade quickly. Therefore
composite hose does not need to be retired after x amount of years.
Many clients still include a retirement policy for hoses that have been in service, it is always best
to discuss your operational parameters with your Dantec representative who could offer more
advice.

6.5 Disposal

Hoses that are due to be scrapped must be done so following your own countries/companies
environmental policy.

We hope you have found this document useful for any further information please do not hesitate
to contact Dantec technical team at info@dantec.com or +44 151 678 2222

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Dantec Ltd Head office and works Tarran Way Moreton Wirral CH46 4TL England
Tel: +44 151 678 2222 Fax: +44 151 606 0188 Email: sales@dantec.com

Dantec Document No: HHTIG1 Revision: D