Hose Info Manual - Low Res 2

Hose Information Manual
Dunlop Oil & Marine Hoses
Fluid Technology
2 3
GMPHOM 2009 Hoses. Contents.

A guide to installation & maintenance.
Section 1 - Hose Overview 5 6.4 Hose condition monitoring 38
1.1 Hose Construction 5 6.4.1 Hose system pressure testing 38
Dunlop Oil & Marine, part of the ContiTech division of Continental AG, is recognised as the leading supplier of offshore loading hoses to all 1.2 Hose identification 6 6.4.2 Routine floating hose inspection 38
major oil, gas and petrochemical companies worldwide. 1.3 Hose customisation 8 6.4.3 Submarine hose inspection 39
1.4 Hose electrical properties 9
We have put this guide together to assist users of our GMPHOM 2009 loading hoses in the effective utilisation of the products, as well 1.5 Hose marking 9
as attempting to cover major aspects of hose usage. It has been created as a guide, so is by no means exhaustive. Should you have any Section 7 - Inspection & Test 43
specific questions, then contact our technical team directly. 7.1 Inspection and test intervals 43
Section 2 - Handling & Transport 11 7.2 Facilities 43
The following publications by the Oil Companies International Marine Forum (OCIMF) and/or related organisations may be referred to for 2.1 Delivery methods 11 7.3 Procedures 44
additional appreciation of hose related issues: 2.2 Recommended method of lift for individual hoses 12 7.3.1 Visual inspection 44
2.3 Hose movement around site 12 7.3.2 Hydrostatic pressure test 44
l Guide to Manufacturing and Purchasing Hoses for Offshore Moorings 7.3.3 Vacuum test 46
l Guidelines for the Handling, Storage, Inspection and Testing of Hoses in the Field 7.3.4 Electrical properties testing 46
l SPM Hose Ancillary Equipment Guide Section 3 - Storage 15
l SPM Hose System Design Commentary 3.1 Delivery inspection 15
l Single Point Mooring Maintenance and Operations Guide 3.2 Storage facilities 15 Section 8 - Hose Maintenance 49
l International Safety Guide for Oil Tankers and Terminals. 3.3 Preparation for storage 15 8.1 Repair or retire 49
3.4 Inspection during storage 16 8.2 Repair kits 50
Contact Dunlop Oil & Marine for specific details of any particular hose product or related ancillary connection equipment. 3.5 Ex-service hoses 16 8.3 Hose repair method 51
+44 (0) 1472 359281 8.3.1 Positioning the hose 51
dunlop.sales@fluid.contitech.co.uk 8.3.2 Cover repair technique 51
Section 4 - Installation 19 8.3.3 Floatation repair technique 52
4.1 General precautions for hose integrity 19 8.4 End fitting condition 53
4.2Assembly equipment - tools 20 8.4.1 Flange face damage 53
4.3 Assembly equipment - jointing 20
4.4 Hose string assembly 22
4.4.1 Assembly site 22 Section 9 - Utilisation 55
4.4.2 Hose string assembly 24 9.1 Installation/commissioning spares 55
4.4.3 Making up hose joints 24 9.2 Operational spares 55
4.4.4 Float fitment 25 9.2.1 Delivery time 56
4.4.5 Hose string pressure test 25 9.3 Hose string changeout/rotation 56
4.4.6 Launch & tow 26 9.3.1 Single string operation 56
4.4.7 Offshore assembly 27 9.3.2 Twin string operation 56
4.5 Hose string installation - CALM buoy 28 9.3.3 Multiple hose strings 56
4.5.1 Floating hose string 28 9.4 Retirement indicators 57
4.5.2 Submarine hose string 28 9.4.1 Routine test & inspection results 57
4.6 Hose string installation - FPSO 29 9.4.2 Service incidents 57
4.6.1 Free streaming floating hose tandem loading 29 9.4.3 Residual burst pressure 58
4.6.2 Onshore reel installation 30 9.4.4 Hose life assessment 59
4.6.3 Reel installation on deck 31 9.5 Disposal 59
4.6.4 Offshore reel installation/changeout 31
4.6.5 Other FPSo hose systems 31
Section 10 - Ancillary Equipment 61
10.1 Gaskets 61
Section 5 - Commissioning 33 10.2 Chain assemblies 61
5.1 Post installation checks 33 10.3 Bolting 61
5.2 Pressure test 33 10.4 Butterfly valves 62
5.3 Waiting for first oil 34 10.5 Camlock couplings 63
5.4 Submarine hose system trimming 34 10.6 Battery powered marker beacons 63
10.7 Solar powered marker beacons 63
10.8 Submarine hose floats 64
Section 6 - Operation 37 10.9 Other equipment 64
6.1 Floating hose string hook-up 37
6.2 CBM string hook-up 37
6.3 Bow loading hook-up 37
1 - Hose Overview 4 5
1. Hose Overview
1.1 Hose construction
6 7
5
3
1
4
1. Fittings materials used for the main plies are

The main functions of an end fitting are textile cords, including rayon and purpose
to connect a hose to another hose or designed hybrid combinations depending
manifold, and to secure the components of on application. Careful design choice of
the flexible hose body section at the hose ply application angle and number of layers
ends. Fittings comply with Oil Companies enables the hose to achieve the required
International Marine Forum (OCIMF) and rated pressure with a safety factor of 5:1 and
other client specifications. Standard flange controls other mechanical properties of the
design is to ASME B16..5, Class 150. Class hose. A double carcass hose is essentially
300 flanged fittings can be provided a single carcass hose with an
at client request - this is often to mate 4. Holding Plies additional hose (or secondary
with Class 300 flanged rigid pipework The holding plies provide an additional carcass) built around the outside of
connections. Other flange types (e.g. RTJ) layer of carcass strength and act to prevent the primary carcass (but beneath
may also be accommodated. cover rupture. These may use the same the floatation layer of the Saflote
reinforcing material as the main plies. hose), and is designed to contain
2. Lining any oil that would escape if the
The function of the lining is to carry the 5. Helical Wire primary carcass were to fail.
fluid being transported by the hose and The purpose of the helical wire is to
prevent it from penetrating and damaging provide resistance to external loads such The secondary carcass is
the main reinforcement materials. as tension, external pressure, crush loading, independent of the primary
bending, and to contribute to the internal carcass and consists of a lining,
The lining is usually a nitrile compound pressure resistance. The helical wire reinforcing plies and a cover just
with resistance up to 60% aromatic material is usually carbon steel which is like a normal hose, but with a
content (depending upon other product totally encapsulated in a specially designed reduced safety factor of 2x the
characteristics). This lining grade is rubber compound. rated pressure. The reinforcing
primarily formulated to be resistant to the plies are made of nylon, which has
chemical effects of sweet crudes within 6. Floatation Layer excellent fatigue resistance. This
quite a wide temperature range, whilst For a floating hose, a floatation jacket is important to ensure that the
providing a reasonable level of mechanical consisting of closed cell polyethylene secondary carcass will function
and environmental resistance. However, it sponge is applied prior to the final cover. effectively even after the hose has
is important to guard against unnecessary been in service for many years.
exposure to ozone and UV to prevent 7. Cover
premature ageing. Other linings e.g. The cover primarily provides protection For Saflote hoses, a leak is
Duralon, hydrogenated nitrile, Viton and against abrasion, tearing, weathering indicated by expansion of the
Butyl, are also available to suit a variety (including UV and ozone degradation) and secondary carcass (see p.38). For
of hydrocarbons and other chemical sea water. It also has some resistance to oil. Safgard hoses, a leak is indicated
products. The cover is a synthetic rubber compound when oil is identified at valves
forming a matrix with reinforcing textile situated at each end fitting. See
3. Main Plies ‘breaker’ plies. A high visibility orange section 6 for further details on
The main plies provide the core strength polyurethane (PU) cover finish can be hose operation.
of the hose construction. The principal provided as an option.
1.2 Hose identification Submarine hoses
There are many different arrangements of hoses - all varying with each project and installation,
so it is difficult to define a concise set of standard hoses. The list of hoses below represents the
most commonly supplied by Dunlop Oil & Marine, together with some comments that may be
useful for hose string assembly considerations.
One end reinforced submarine hose (includes types 511L, 551L, Mainline submarine hose (includes types 512L, 552L,
531L, 591L) 532L, 592L)
Floating hoses
In most cases, a reinforced hose is used at each end of a Mainline submarine hoses are often interchangeable within a
submarine hose string. They are often interchangeable within single string, or between adjacent strings in a multi-string, same
a single string, or between adjacent strings in a multi-string, diameter system.
same diameter system. The reinforced hose end is identified
First off buoy half floating hose (includes Fully floating one end reinforced hose Mainline floating hose (includes types by a circumferential band with the words ‘Reinforced End’. End If fitted, float location collars are usually provided along the
types 501, 541, 521, 581) (includes types 501F, 541F, 521F, 581F) 502, 542, 522, 582) reinforced hoses may also be used at mid-water buoyancy tank complete hose length.
connections.
A conventional ‘first off buoy’ hose for Some FPSO tandem loading floating The majority of hoses in a typical
connection to a CALM buoy should hose systems have floatation over the floating hose string will be identical, If fitted, float location collars are usually provided along half the
have the non-buoyant, smaller diameter full length of the FPSO connection hose interchangeable hose lengths. hose length at the non-reinforced end.
end (which is also the reinforced end) as a precaution in case of the need for Occassionally a floating hose string will
connected to the buoy. The reinforced hose emergency disconnect. For such a hose have two or more mainline sections of
end is identified by a circumferential band the reinforced end should be connected to different bore size.
with the words ‘Reinforced End’ clearly the FPSO offtake pipework. The reinforced
legible alongside. hose end is identified by a circumferential
band with the words ‘Reinforced End’
However, be aware there are CALM buoy installations
clearly legible alongside.
that use different off the buoy hose arrangements.
Reduced buoyancy floating hose Tapered floating hose (includes types Tail floating hose (includes types 504, 544,
(includes types 502N, 542N, 522N, 582N) 503, 543, 523, 583) 524, 584)
FPSO tandem loading floating hose strings The link between a mainline hose section The last few hoses before the tanker
may utilise reduced buoyancy hoses and a smaller bore tail section may be connection hose may be smaller bore
for (typically) the 2nd, 3rd and 4th hose made using a hose with an integral taper. than the mainline string section. If they
Catenary loading hose (includes types CAT 571, CAT 572, CAT CBM hose (includes types 511, 512, 514, 551, 552, 554)
positions off the FPSO. They will have The taper may be made within the fitting are indeed of smaller bore, then positive
571DC, CAT 572DC)
smaller outside diameter than mainline at the larger end, or within the bore of identification is straightforward. If they are
floating hoses, but perhaps not obviously the hose itself. The hose outside diameter the same bore size as the mainline hoses, Catenary loading hose string arrangements have historically been A typical CBM hose string has an end reinforced submarine
so. Look for the ‘N’ suffix to the hose type remains constant over the hose length, so then positive identification is by type designed as project specific, and it is particularly difficult to talk of hose connected to the PLEM, several mainline submarine hoses,
number in the hose cover branding for look for different flange diameters to help number on the hose brand covering. ‘standard’ catenary hose constructions. possibly a tapered submarine hose, and then one or more
positive identification. positive identification. submarine tail/rail hoses (including Dunlop types 514, 554, 534 and
However, the same principles of system arrangement apply as for 594).
submarine hose strings - both end reinforced and mainline hose
types can be provided. The tail/rail hose is based on a standard submarine hose, but with
TANKER END
TANKER END
lifting lugs on the end flanges.
Tanker rail floating hose (includes types

505X, 545X, 525X, 585X) Reeling Hoses
This hose has minimal floatation in the Most hose types can also be supplied in a form suitable for reeling. They are identified by
centre section where it bends over the the suffix ‘R’ e.g. 501FR, 542R & CAT572R.
tanker rail, with extra floatation at each
end providing hose buoyancy. The tanker Reeling hose design is often project specific and will depend upon such factors as reel
connection end has a larger buoyancy unit diameter, and number of hose layers on the reel. A reeling hose for one particular reeling
than the outboard end to help support application may not necessarily suit another apparently similar application, so beware of
valve and coupling equipment. The tanker transferring such hoses between projects.
connection end is clearly marked with two
circumferential bands and the words ‘Tanker For a double layer reeled hose string, it is important to ensure that the inner layer hoses
End’ around the hose circumference. are rated for the additional crushing loads compared to the outer layer.
1.3 Hose customisation 1.4 Hose electrical properties

One of Dunlop Oil & Marine’s core capabilities is our ability to provide tailored hose solutions for your system. The below tables highlight All hoses are provided either electrically Typical electrical properties
some of the customisations available from our standard product range. continuous or discontinuous.
Hose Type/Position GMPHOM 2009 OCIMF 1991
Floating hose customisations Both the OCIMF 1991 and GMPHOM First off buoy/FPSO floating Continuous Continuous
2009 guidelines give recommendations
Type no. Double carcass hose type Single carcass hose type Mainline floating Continuous Continuous
for electrical properties of hoses used
Typical variations on CALM buoys, and arrangements for Tail floating Discontinuous Disontinuous
suffix 541 542 543 544 545 501 502 503 504 505
other hose system types can be adapted
Rail floating Continuous Discontinuous
A Increased abrasion resistance (scuff pads) ü ü ü ü ü ü ü ü ü ü accordingly.
End reinforced submarine Discontinuous Discontinuous
B Both ends reinforced (or fully reinforced) ü ü The table to the right summarises common
practice. However, electrical properties
Mainline submarine Discontinuous Discontinuous
D Discharge service only ü ü ü ü ü ü ü ü ü ü can be provided in accordance with client FPSO end catenary Continuous Continuous
requirements too. Mainline catenary Continuous Continuous
F Fully floating ü ü Offtake tanker end catenary Discontinuous Discontinuous
H HNBR lining (Duralon) ü ü ü ü ü ü ü ü ü ü
Flange insulation kits
L Integral float location collars ü ü One method of making a hose string electrically discontinuous is to use a flange insulation kit comprising gasket, bolt shrouds and
N Neutral (or reduced) buoyancy ü ü ü ü ü ü washers made from non-conductive materials such as phenolic resin. A particular application is for Dunlop low temperature product
‘rough bore’ hose strings. Such hoses are manufactured with a helical wire along the hose bore, making direct contact with the end
P Orange polyurethane cover ü ü ü ü ü ü ü ü ü ü fittings. This hose construction has to be made electrically continuous and therefore flange insulation kits are required to provide
discontinuity.
R Reeling service ü ü ü ü ü ü ü ü ü ü
V Viton lining ü ü ü ü ü ü ü ü ü ü 1.5 Hose marking
W Non-standard working pressure ü ü ü ü ü ü ü ü ü ü Each hose is marked individually for information and identification
purposes.
X Extra buoyancy ü ü ü ü ü ü ü ü 1
Our hose marking approach is explained below:
3
Notes:
1.) Type 545X & 505X are standard delivery for Saflote (double carcass) and Selflote (single carcass) barbell rail hoses - for extra floatation 1. Hose type i.e. single or double carcass 2
to support tanker connection ancillary equipment such as chains, valves, couplings. 2. Month and year of manufacture
2.) Hose construction variations can be customised to suit a given application: e.g. Type 541BFP, type 501BFP. 3. Unique hose serial number
4
4. Industry specification standard
5. Nominal bore & rated working pressure
Submarine hose customisations 6. Hose type 5
7. Electrical property (discontinuous hoses only)
Type no. Double carcass hose type Single carcass hose type 8. Length & elongation details
Typical variations 6
suffix 551 551L 552 552L 511 511L 512 512L 9. Dunlop Oil & Marine logo
10. CE brand (Pressure Equipment Directive)
A Increased abrasion resistance (scuff pads) ü ü ü ü ü ü ü ü Additional marking may be provided as required.
7
B Both ends reinforced (or fully reinforced) ü ü ü ü

D Discharge service only ü ü ü ü ü ü ü ü
H HNBR lining (Duralon) ü ü ü ü ü ü ü ü
P Orange polyurethane cover ü ü ü ü ü ü ü ü 8
R Reeling service ü ü ü ü
V Viton lining ü ü ü ü ü ü ü ü 9
W Non-standard working pressure ü ü ü ü ü ü ü ü

Notes: 10
A double carcass hose having branding
1.) There are many other variations of the standard double carcass & single carcass submarine hose ranges. Adaptation for air catenary added during manufacture
service, low ambient temperatures, refined products and non-petroleum products are some examples.
2 - Handling & Transport 10 11
2. Handling & Transport

2.1 Delivery methods
Hose delivery loads arrive at site containerised, on pallets (often secured to flatracks), or by other local delivery method. Hoses are
prepared for delivery by Dunlop Oil & Marine either:
l Wooden packing protected - known as ‘slat packed’

l Palletised
l Individual, free standing
Slat Packed Slat-packed hoses with webbing slings

Slat packed hoses are delivered complete
with webbing slings incorporated by
Dunlop Oil & Marine at time of packing.
There will normally be two such slings

applied at the hose ‘quarter points’ for a
two point lift during transport.
Note: The slings should only be used for

the intended purpose - individual hose
lifting during transport.
Check condition and identification tags

before using such slings for subsequent
lifting.
Palletised Hoses
3-tier pallet stack
Hoses will invariably be delivered on
metal pallets. The Dunlop standard pallet
design is stackable per requirements of
the GMPHOM Hose Guide, although this
is primarily for the purposes of storage on
site.
There are no specific recommendations for

offshore/seagoing pallet transport, although
Dunlop Oil & Marine understand that
practice is to stack pallets to two tiers high
on flat racks for container vessel transit.
Safety precautions at site
l Review stated pallet working loading limit (WLL) and handling information label
before lifting.
l Check security of individual hose lashings before lifting pallet.
l Lift one pallet at a time using a four leg chain sling secured to the pallet lifting
eyes.
l Check supplied pallet legs condition and site securely in their sockets if pallets
are restacked.
l Stack on solid, level ground, with a maximum of three tiers high.
l Refer to Dunlop Oil & Marine’s safe handling and use documentation.
Note: A customised pallet design may be provided for fork lift handling and
airfreight. Such pallets will be appropriately identified. Otherwise do not lift pallets
using fork lift trucks.
2 - Handling & Transport 12 13
2.2 Recommended method of

lift for individual hoses
Recommended method
l For hoses packed on pallets, remove lashings and consider
removing pallet legs if lifting individual hoses from pallets.
l For slat packed hoses, remove wooden packing and safely
discard before lifting hoses
l Where end disks are fitted, consideration should be given to late
removal to avoid possible flange damage during lifting
l Use suitable rated crane and spreader bar
l Sling the hose using minimum 100mm wide textile strops
appropriately rated.
l Sling from three hooks or more spaced over the hose length
l Position slings to take account of local weight concentrations Diagram above shows the quarter point lift method.
Lifting using a hose spreader beam is shown opposite
from the hose end fittings.
l Use the hose ‘quarter points’ if a two-point lift is operationally
unavoidable
Avoid
l Small circumference rope or similar slings
l Wire strop slings
l Lifting by a single sling at the hose mid-point
l Lifting by two slings - one at each flange
l Direct lifting with fork lift truck forks
Do not
l Use any lift method that results in severe local loading and/or
over-bending of the hose
l Use any hose movement method that involves dragging the
hose over unsuitable surfaces such as to damage the cover or end
flanges.
2.3 Hose movement around site

Local site hose movement procedures may consider:
l Spreader bar and mobile crane

l Customised hose towing trolleys
l Trailer with hoses safely stacked and chocked
l Fork lift trucks with specialised attachments
3 - Storage 14 15
3. Storage
3.1 Delivery inspection
Hoses leave Dunlop Oil & Marine’s Remove any wooden slat or crate
warehouse in good condition and securely packaging and check hose cover condition.
For floating hoses laid on pallets,
packed (refer to section 2).
the floatation layer may show some
Remove hose end bungs and use a light
distortion where the hose rests
However, there are intermediate handling source to check hose bore condition.
on the support trays. This is not
points between factory and site, where, for Please retain end bungs and refit for
detrimental to hose performance in
example, packaging may be removed for continued protection during storage.
service, and the distorted floatation
customs inspection. It is therefore advisable
will recover when the hose is
to inspect all new hoses for damage Check flange sealing face for gouges in the
readied for service.
immediately upon delivery. gramophone groove finish.
3.2 Storage facilities

During storage, hoses should be protected
against:
l Sunlight
l Temperature extremes
l Excessive humidity
l Ozone
l Mechanical damage
l Chemicals
l Pests
Dedicated hose storage facilities are

recommended - a climatically controlled
or otherwise cool, spacious warehouse
with overhead craneage is ideal.
Suitable ventilation to allow air flow is
recommended.
If stored outside, hoses should be held on

Hoses in storage at the Dunlop warehouse an area of solid, level ground, with separate
protection against the environment.
3.3 Preparation for storage

Site the hoses in suitable facilities or on a prepared area of ground
as per the instructions in section 3.2 above. Hoses in storage
Retain hoses in original delivery pallets (if provided).
Replace end bungs to protect flange faces and prevent ingress

of foreign bodies etc. However, ensure bung ventilation holes are
unrestricted.
Stack pallets to maximum height of three tiers, taking due account

of section 2 - Handling & Transport.
Alternatively lay individual hoses out straight and level, supported

by several wide wooden timbers or similar e.g. railway sleepers.
3 - Storage 16 17
3.4 Inspection during storage

At appropropriate intervals, check for:
l Sundry mechanical damage

l Rodent attack
l Insect attack
l General rubber degradation (cracks)
3.5 Ex-service hoses

Perform cover repairs and apply flange surface protection, if
required, following routine cleaning, inspection and testing - see
Section 7.
Consider removing any excess bore residue using a soft foam

‘plug’ on a fibre rope or similar.
Use the same principles of storage as for newly delivered hoses.
Take due account of any sequence of planned future utilisation

when siting a given hose in the storage area. Bore cleaning procedure using soft foam plugs
4 - Installation 18 19
4. Installation
A series of suggestions and recommendations follow to assist the user in the preparation of
formal hose system installation procedures for a given terminal.
4.1 General precautions for hose integrity

Dunlop Oil & Marine experience is that two essential criteria exist to
keep hoses fit for operation during the installation process. The two
main criteria are:
Minimum bend radius (MBR)
l Avoid over bending (see table)
l Avoid mechanical damage Nominal Floating Submarine &
bore hoses tanker rail hose
The table to the right highlights the minimum bend radius (MBR)
values that are recommended for both OCIMF 1991 and GMPHOM (mm) (inch) (m) (ft) (m) (ft)
2009 hoses as per the OCIMF Hose Guide. The recommendations
state the MBR for floating hoses is 6D - six times the nominal hose 150 6 0.9 3 0.6 2.0
bore diameter - whereas submarine hoses and tanker rail hoses
have an MBR of 4D. 200 8 1.2 4 0.8 2.7
250 10 1.5 5 1.0 3.3
It is probable that hoses are occasionally bent to within the MBR
due to the practicalities of some installation operations - especially 300 12 1.8 6 1.2 4
with submarine hose systems. However, at some point of over- 400 16 2.4 8 1.6 5.3
bending, the hose may kink. Furthermore, since bend radius during
installation is invariably a subjective, visual assessment, then best 500 20 3.0 10 2.0 6.7
practice would be for the 6D MBR to be maintained for all hose
600 24 3.6 12 2.4 8.0
types wherever possible.
Cover/carcass damage
A certain amount of scuffing of hose covers is possible during
most installations.
Ensure that there are no sharp protrusions, deck fittings and so on

that might cut through the hose cover; an obvious precaution, but
one which, if not rigorously followed, could result in delay during
hose damage assessment and repair or replacement.
Some users benefit from a system of hose support trolleys to move

hoses and hose strings around the assembly site.
Flange faces
Keep flange face protection in place for as long as possible during
individual hose handling before string assembly.
Flange face protection on hoses ready for installation

4.2 Assembly equipment - tools

Good joints have historically been achieved by systematic Bolt diameter Torque Torque
manual bolt ‘flogging’. Torque wrenches are now generally (in) (ft-Ib) (N-m)
used, but deciding an appropriate torque setting is not always
0.75 157 213
straightforward. The following table of torque values is
Listed below are suggested items of tooling: pressure and fitted with small bore delivery pipe to match the valve recommended by a supplier of PTFE coated alloy steel stud bolts 0.875 250 339
in the test plate. for 50% yield stress. 1.0 373 506
l Spreader lifting beam. At least 10m long x6 tonne WLL with 5 l Fluorescein dye to detect flange leaks during pressure test of 1.125 538 730
lifting hooks and fabric type strops of 100mm minimum width completed string Note: Theoretical calculation for such values assumes a specific 1.25 740 1003
l Suitable craneage l Good supply of wire strops and rope value of friction coefficient which is itself theoretical, and no
l 350mm tapered podger for aligning flange bolt holes l Several hand operated come-along ratchets, tirfor or equivalent 1.375 1000 1356
responsibility is offered for their utilisation.
l Two combination spanners to suit each nut size being tightened 1.5 1307 1772
l Torque wrench and square drive sockets to suit Optional tooling:
l Pressure test plate to suit hose flange and fitted with a large bore
valve for fill line and small bore valve for pump connection l Multi headed hydraulic torque machine with power pack
l Pressure test plate to suit hose flange at other end of string fitted l Steel tube section for rollers Normal practice is to use a recognised employed, particularly for critical hose
with an offset valve to bleed air from the system l Small wheeled bogies tightening pattern of diametrically opposed string connections to solid pipework sub-
l Water pressure pump capable of achieving the rated hose test bolt pairs, with minimum two passes. sea. 11 1
7 15
Additional passes are often considered. 14 5
Double nutted, long stud bolts and nut 3 9

Single or multiple tool hydraulic joint retainers may be considered for sites with a
10 4
tensioning equipment is occassionally history of bolt loosening.
6 13
16 8
2 12
Bolting technique
Typical 4 pass tightening pattern (for
16 hole flange joint):
Fluorescin dye Torque wrench Hand operated ratchets
1.) Tighten nuts to 30% of

recommended torque in forward
cross-tightening sequence.
2.) Tighten nuts to 60% of
4.3 Assembly equipment - jointing recommended torque in reverse

cross-tightening sequence.
3.) Tighten nuts to 100% of torque in
forward cross-tightening sequence.
A commonly utilised hose sealing system that normally performs Standard bolt sizes assumed by Dunlop for ASME B16.5 Class 150
4.) Control pass at 100% of
successfully is: and 300 flange joints connections.
recommended torque in a clockwise
Hydraulic torquing tool being used during installation direction on adjacent fasteners.
l Non-asbestos fibre gasket with nitrile binder, 3mm thickness (full Flange Class 150 Class 300
face or inside bolt circle to suit flange) size No. Bolt Length No. Bolt Length
l PTFE coated, alloy steel stud bolting (in) holes dia (in) (in) holes dia (in) (in)
- ASTM A193 Grade B7 stud material
- ASTM A194 Grade 2H nut material 4 8 0.625 3.75 8 0.75 4.5
Note: Stud bolting options include stainless stell and monel. 6 8 0.75 4.0 12 0.75 5.0
Rigid, spiral wound gaskets are often preferred for hose string end 8 8 0.75 4.25 12 0.875 5.5
connections to hard piping, with some projects specifying spiral 10 12 0.875 4.75 16 1.0 6.25
wound gasket joints throughout.
12 12 0.875 4.75 16 1.125 6.75
Successful joints have also been achieved with a rubber ‘O’ ring
16 16 1.0 5.5 20 1.25 7.5
sealing system utilising pre-machined grooves in the flange
face (although such a technique is not included in the OCIMF 20 20 1.125 6.25 24 1.25 8.25
recommendations).
24 20 1.25 7.0 24 1.5 9.25
NAF full face gasket
Spiral wound gasket

(PTFE filler & st inner ring variant
4.4 Hose string assembly Examples of general project arrangement drawings
Most hose string assembly is performed onshore for subsequent installation offshore, and this is the assumption made in the following
section.
In some instances, hoses are both assembled and installed onshore e.g. taken onto a reel for subsequent installation on an FPSO. See
section 4.6 for some particular issues relevant to hose strings for FPSO service.
Occassionally, hose string assembly takes place offshore - see section 4.4.7.
4.4.1 Assembly site

Dedicated facilities would ideally include a long, dry, clean, solid and
flat working area with ample space for craneage and other hose
Whatever facilities are available, the principal aims are:
assembly aids, terminating in a shallow launch ramp, perhaps using
rollers or trolleys to reduce friction and minimize cover damage
during launch. l Arrange the hoses in the correct order
l Make up sound hose flange joints
Some operators have such dedicated facilities available, otherwise l Protect hoses from damage
typical locations for hose string assembly and subsequent launch l Launch and tow hoses safely
are:
l Dock-side/jetty l Dry dock

l Foating dock l Beach
Slipway Floating dock
Dry dock Beach

4.4.2 Hose string assembly 4.4.4 Float fitment

Floats may be fitted to individual submarine hoses prior to hose string assembly, or after hoses have been bolted together.
Refer to the hose identification information in section 1.2 in Consider orientation of the hose string ready for launch and
conjunction with project general arrangement drawings or other tow with respect to installation method, and provide sufficient Refer to the submarine hose system general arrangement drawing or other document, and identify float location collar positions
documents to help determine the correct string arrangement. supplementary float fitment at hose ends for additional support requiring float fitment.
during towing operations and possible standby at site.
Some hose positions will only have one hose item available, e.g.
first off buoy, whereas there will be multiple mainline hoses to For floating hose strings, it is usual to tow from the CALM buoy or Fitment procedure - hinged float range
choose from. FPSO connection end. l Open up the float by unhooking the hose float location collar (see Fig 2) deciding where the clamp should be
clamp from its float securing pin. The clamp l Ensure that the clamp hook and eye are positioned (see Fig 5)
Consider pre-assigning hose serial numbers to each position in the For submarine hose strings, there are further considerations tensioner is a 0.75” diameter threaded bar located equi-distant from the tensioner l Tighten the tensioner to 40N-m torque
hose string to assist subsequent hose identification in service, and such as whether there will be a seperate vessel to take control for with 30mm A/F central tighening nut (see central nut using a torque wrench with open ended
possible hose positional rotation after routine onshore inspections. installation. Fig 1) l Place clamp hook over float securing pin adaptor, or with an open ended spanner
l Lay the float flat and lift the hose over and tighten fastener to a nominal torque to until the float makes a good grip onto the
the float (alternatively slide the opened hold in position (see Fig 3) location collar
Submarine hose string alignment float under a suitably raised and supported l Orientate float such that clamp position
Submarine hose alignment stripe
& flange identification letter
hose) will suit any subsequent diver intervention Note: Consider marking the floats, for
Submarine hoses are provided with a longitudinal white stripe l Lower the hose onto the float, and work in service (see Fig 4) example, with sequential numbers from
as an aid for divers to prevent twisting of the hose string when manually guide the float into position such l The submarine hose longitudinal white top to bottom of string to assist in possible
making up PLEM and under buoy flange connections. It would be that the float keyway sits properly onto the stripe can be used as a reference when subsequent diver intervention work.
advisable to ensure that the stripes of individual hoses are adjacent
to one another on assembly, rotating the hose on make up if
required to achieve this. White circumferential rings on submarine
hoses refer to ends with extra reinforcement, and typically are the
ends which are atached to hard piping.
Flange identification
Hose end flanges have the hose serial number welded on the rim,
followed by the letter ‘A’ or ‘B’. This is a recommendation of the
OCIMF Hose Guide related to traceability and identification. Fig 1 Fig 3
4.4.3 Making up hose joints

Fig 2 Fig 4 Fig 5
Ensure that the flange faces are undamaged and clean. Use a wire
hand brush to remove sand, dirt and paint.
Refer to section 4.3 for information on jointing materials, bolt

torque values etc. 4.4.5 Hose string pressure test
Position marker beacon brackets at appropriate hose joints, and fit It is good practice to perform a hydrostatic pressure test with the may continue to ‘creep’ whilst on hold. Some reduction in pressure
using longer bolts supplied. hose string assembled, but still onshore. Even if limited working with time during a 3 hour hold period can therefore be expected,
space means the hose string has to be part launched during but this should be nearly stable by the end of the test. If pressure
Connect bolt-on anodes (if used) at appropriate hose joints using assembly, such a test is advisable since any bad joints can be more loss seems to be continuing in a linear fashion, then suspect
anode securing kits supplied. easily corrected than with the hose string installed. equipment leakage and investigate.
Take particular care when including a wafer butterfly valve at the A recommended procedure is: l Tighten or re-make joint(s) if necessary and re-commence test
end of a hose string. Such a valve is sandwiched between the
hose end flange, and some other piece of flanged equipment e.g. l Fit blinds c/w filling and vent valves to each end of the hose Note: Butterfly valves are not suitable for pressure testing against
short spool camlock coupling. Damage to the valve integral rubber string the closed disc. The lightweight blind flange normally supplied
gaskets must be avoided. l Use a high volume, low pressure pump to fill the string with for camlock coupling flange protection is not rated for pressure
water, raising the string as necessary to ensure no air entrapment. testing, so a proper rated test blind must be utilised, with a means
Note: It may be preferable to attach floating hose string end gear l Pressurise to hose rated pressure of venting or releasing pressure in the hose string.
once the string is installed, rather than during hose string assembly. l Examine joints for leaks
l Monitor locked in hose string pressure
Butterfly valve Note: Hoses will elongate appreciably whilst being pressurised and
4.4.6 Launch and tow 4.4.7 Offshore assembly

A floating hose string assembled on a good having a conventional first off the buoy Assembly offshore is based on the stowing the hoses in sequence such that
concrete jetty surface and then launched hose, additional support buoyancy is principles of onshore assembly outlined unnecessary handling is avoided
down a shallow slipway should have few typically provided at the reinforced (non- earlier in this guide, and due account of l Safety - equipment/fittings must be
problems. Likewise, floating and submarine floating) end using 2 or 3 suitably sized this should be taken when considering the provided to prevent inadvertent hose
hoses assembled in dry or floating docks. submarine floats or other buoyancy aids. following procedures. movement/rolling during assembly or
installation
Additional care is needed for submarine Note: Some submarine hose constructions The vessel/barge chosen for assembly l A support vessel may be needed to
hose strings with floats when dragged for gas service are deliberately ballasted of hoses offshore should ideally have the assist and control launch.
overland, and when launching off the side during the manufacturing process to following minimum characteristics:
of a jetty where ample craneage will be ensure that they will submerge when Procedures will vary depending on vessel(s)
needed. empty. Supplementary buoyancy is l A flat work area, long enough to and facilities available. These may range
therefore needed for the complete string if accommodate at least 2 hose lengths from a large barge with a substantial crane,
Always lift the string with strops positioned towed. l Work area free of sharp edges or roller beds, launch ramps etc operating in Anchor handler
around the hose body, never around the projections that may cause hose damage calm seas, to a relatively small, open stern
floats. The hose string should be fitted with a l Sufficient storage area on deck for the workboat/anchor handler having to work
purpose-designed towing flange. hoses being assembled in poor weather and sea conditions using
Beach launch activities may require the l A suitable crane capable of lifting hose stern posts and deck winches to assist
assistance of, for instance, tractors or The towing vessel may also double as an lengths into position on deck and then launch.
JCB’s, but such procedures have been installation vessel. Alternatively, the towing to help move assembled lengths into the
successfully undertaken at a variety of vessel may need to pass control of the water In any event, and certainly for a free
locations. string to an installation vessel at site. l Low freeboard and a stern roller to streaming floating hose string, it will usually
facilitate hose entry to the water be necessary to be able to retain the final
Some launch procedures may require Maximum recommended towing speed section of the launched hose string on
prior experience of and confidence in hose for hose strings is 5 knots. A lower towing Additionally: deck for up to several hours to perform a
string behaviour during the launch process, speed of 3 knots is recommended for pressure test.
as in the example to the right. submarine hose strings fitted with floats. l Consideration should be given to
Actual achievable speed will depend upon
For all hose strings, it is preferable to tow tow rope snatch loads and hose string
the hoses empty, and blanked off against behaviour in prevailing sea conditions.
water ingress. A submarine hose string will
float when empty, even without any floats Dunlop Oil & Marine do not know of any
on, and can therefore be towed to site cases of float loss from towed submarine
provided no sea water ingress during the hose strings, but reduce speed if float
tow. If water ingress is identified, this must security is in question.
be rectified.
A long floating hose string may need the
Note that if all floats are similarly aligned on assistance of a second vessel to control the
the hose, then the hose string will want to trailing end during river or dock navigation.
float with the float hinges uppermost (i.e.
clamps to the bottom). Consideration can be given to bringing
the leading hose onto deck for a tug or
Deck handling
Floats or other buoyancy aids are workboat with an open stern and roller/ Dockside roll in
recommended at the hose string ends. bolster.
Failure to do this in certain conditions,
could result in the hose string auto Note: Seek advice when including non-
submerging. Dunlop Oil & Marine supply equipment e.g.
breakaway couplings in the hose string.
For CALM buoy floating hose strings
Hoses ready for installation

4.5 Hose string installation - CALM buoy l Continue to draw flanges together until close enough for standard stud bolts to be fitted
l Fit studbolts over lower half of bolt circle removing guide wires and draw bolts - consider using skillets at 3, 6 and 9 o’clock positions to
assist gasket fitment
l Insert gasket (rigid, IBC spiral wound type) from 12 o’clock position and check location
4.5.1 Floating hose string l Insert remaining studbolts over upper half of bolt circle and remove skillets (if fitted)
l Tighten bolts in recognised sequence to required torque
The floating hose string is usually installed once any associated subsea hose installation has been completed. The typical installation
Buoy connection
sequence that follows assumes a floating hose string towed to site following onshore assembly per section 4.4, removal of any towing
l Run guide wires through buoy centre well/inspection hatch to buoy connection flange, and then through corresponding bolt holes of
aids and fitment of temporary flange face protection. Attachment of such protection needs to allow for running of guide wires through
buoy connection flange and buoy end hose flange
selected bolt holes and detachment at an appropriate point during the installation.
l Double check hose string alignment stripe lines up with expected buoy connection flange orientation, and that hose string does not
have 360 degree twist
l Pass winch or Tirfor wires through 3 and 9 o’clock bolt hose positions of both hose and buoy flanges
l Pull hose string up to buoy until flanges are approximately 150mm apart and fit draw bolts
l Pull hose string up to buoy until flanges are approximately 150mm apart and fit draw bolts
l Continue to draw flanges together until close enough for standard stud bolts to be fitted
l Continue to draw flanges together until close enough for standard stud bolts to be fitted
l Fit studbolts over lower half of bolt circle removing guide wires and draw bolts - consider using skillets at 3, 6 and 9 o’clock positions to
l Fit studbolts over lower half of bolt circle removing guide wires and draw bolts; consider using skillets at 3, 6 and 9 o’clock positions to
l Insert remaining studbolts over upper half of bolt circle and remove skillets (if fitted)
l Insert remaining studbolts over upper half of bolt circle and remove skillets (if fitted)
4.5.2 Submarine hose string 4.6 Hose string installation - FPSO

Installation vessel deck space and available facilities such as winches and craneage will Submarine hose
Procedures for installation of hose strings on CALM buoys will be generally similar from terminal to terminal, whereas FPSO’s on the other
need to be taken into account when devising a specific installation plan. string installation hand utilise a variety of loading hose string arrangements.
A typical installation sequence as follows, assumes that the hose string has already been
assembled, leak test completed and all of the bead floats have been attached securely to
the hoses in accordance with the positions indicated on the system design drawings.
4.6.1 Free streaming floating hose tandem loading
There are numerous tandem loading systems where
Blind flanges with vent valves or alternative assemblies should be fitted at each end of environmental conditions allow a floating loading hose string to be
the string for control of flooding and venting and/or as flange face protection to suit. left free streaming (usually from a stern manifold) at all times. Hose
Attachment of such equipment needs to allow for running of guide wires through selected string assembly considerations are similar to those of a CALM
hose flange bolt holes, and detachment at appropriate points during the installation. buoy.
The hose string should be arranged so that the buoy connection hose is overboarded first. However, the connection to the FPSO is usually made vertically at
deck level, with an installation lifting spool piece often included as
Orientation of the hose string on deck needs to account for the preferred position of the part of the FPSO connection equipment.
hose string’s white alignment stripe relative to the PLEM and buoy connection flange
orientations. Hoses are manufactured to ensure that the bolt holes are aligned from one to Assembly of the hose string may need particular care in terms
other end of the hose. of hose arrangement sequence, and various pieces of ancillary
equipment such as restraint tether and spoolage.
Usual practice is for the white alignment stripe to run along the outside of the major
curve for a ‘Chinese lantern’ configuration, and along the top of the hump of an ‘S’ type of The hoses at the waterline - sometimes termed ‘the FPSO hose
configuration. loop’ could be floating hoses with reduced buoyancy to standard,
or submarine hoses with floats.
It is advised to mark the PLEM and buoy connection hard piping flange rims accordingly
to assist diver operations.
The detailed installation plan may need to account for a partially launched submarine hose
string that is initially floating full of air, and/or buoyancy support provided by metal tanks,
or other large concentrated point buoyancy device.
PLEM connection
l Ensure hose string ends are readied for flooding and venting operations
l Run guide wires through PLEM end hose flange down to PLEM connection flange, selecting bolt holes for the lower part of the flange
joint
l Restrain hose string buoy end using deck equipment - winch, crane etc
l Overboard hose string with the aid of support vessel or other launch technique
l Monitor and control descent of hose string down to PLEM, flooding and venting as required
l Check hose string approach angle to PLEM flange - adjust using clump weights and/or buoyancy e.g. air bags
l Double check hose string alignment stripe lines up with expected PLEM connection flange orientation
l Pull hose string down to PLEM until flanges are approximately 150mm apart and fit draw bolts
4.6.2 Onshore reel installation 4.6.3 Reel installation on deck

For FPSO’s where the hose string is In some cases, the reel may be located on board the FPSO prior to hose string installation. Here, the hose string could be assembled
held onboard between loadings, the onshore, launched into the dock, and then reeled on as a complete single string.
usual mode of stowage is on a reel. If an
original equipment supply hose string is
installed onto the reel before the reel is
sited onboard the FPSO, then the hose
4.6.4 Offshore reel installation/changeout
installation operation will typically be done Once an FPSO is deployed in the field, any intervention to a reeled
on a dock-side adjacent to where the FPSO hose string will need to be performed offshore.
is being kitted out.
Some FPSOs have work space and facilities to allow onboard hose
Irrespective of where the onshore reel changeout. However, in many cases, hose string removal and
installation is performed, refer to relevant changeout has to be done with the assistance of an installation or
parts of section 4.4 for guidelines other support vessel.
concerning the work area, facilities and
hose string assembly method.
A particular consideration with reel 4.6.5 Other FPSO hose systems

installation is the method for connecting
the first hose to the reel. It is probably best Some FPSO loading hose strings are stowed on deck trays
to connect the first hose to the reel on its between loadings, with the hose string winched onboard over
own. a stern roller chute. Installation is normally performed for a
The hose can either be lifted into position completely assembled hose string. A close visual inspection of
with the reel connection flange part way hose condition after installation should be an integral part of the
round the reel, or the reel connection detailed procedure.
flange driven round under the reel such
that the first hose can be connected Other loading hose systems include the hose string stowed as a
horizontally. The actual sequence used will free-hanging catenary.
need to be determined to best suit project
logistics. The example shown below is for Some FPSOs use low pressure submarine loading hoses as import
a 20” double carcass floating hose string and export risers. Whatever the hose string arrangement, detailed
where a heavy quick connect/disconnect installation procedures should utilise appropriate aspects of hose
(QC/DC) coupling was installed along with handling and assembly given throughout this section.
the first hose.
It may be beneficial to perform a separate

pressure test for the first hose to reel
connection joint with the first hose only
Connetion of first hose to reel
connected, especially if it is not easily
accessible when the complete string is on
the reel.
The remainder of the hose string can then

be attached, with a few hose lengths at a
time being successively assembled and
wound on to the reel. The reel may have
a hose string guide rail across the drum,
and other structural steel work could also
be potential sources of hose damage, so
careful monitoring is needed as the string
is reeled on.
Finally, the outboard end of the hose string

should be securely lashed to the reel.
For a double layer reeled hose string, it is

important to ensure that the inner layer
hoses are rated for the additional crushing
loads compared to the outer layer.
Double layer reeled hose string

5 - Commissioning 32 33
5. Commissioning
5.1 Post-installation checks
A post-installation check of hose string condition should be Typical abrasion damage
performed prior to commissioning.
For surface hose strings, this will include the following checks:
l Cover and floatation damage

l Flange joint security
l Condition of ancillary equipment - tanker connection end gear
etc
l Marker beacon function at night (floating hoses)
For submarine hose strings, checks (as appropriate) are:
l Cover damage
l Joint security
l Float positions & security
l Double carcass manually operated hose valves are closed
l Function of double carcass remote pressure monitoring system
l Hose string alignment - ensure string is not installed twisted
l Initial configuration - ensure no tight bends
l Proximity to other objects - buoy mooring chains, sea-line
pipework, seabed protrusions etc
l Multiple strings are not interfering with each other
A video record of installed submarine hose string condition by

divers or remote operated vehicle (ROV) is recommended.
Intervention may be needed to correct any problems found. There

are known instances of submarine hose strings under CALM
buoys being installed with several bolt hole misalignment between
buoy and PLEM flange connections.
A submarine hose string configuration checking method by divers for CALM buoys in low water depths is included in section 6 of this
guide. Deeper water systems may only have depth information from an ROV survey to work with.
Dunlop Oil & Marine will endeavour to assist in resolving any post-installation problems found, but resolution of such problems will usually
be the responsibility of the installation contractor rather than the hose manufacturer. The preparation of a list for post-installation checks
would be useful for future routine maintenance.
5.2 Pressure test

Installed hose strings should be hydrostatically pressure tested
before being taken into service. Refer to section 4.4.5 of this guide
for a suggested pressure test regime.
Fluorescein dye can be included to help check for flange joint

leaks.
The hose string(s) may be required to be included in a complete

system test which includes the sea bed pipeline. Such a test may
require a system pressure above the hose design rated pressure.
Dunlop Oil & Marine will consider any such requirement and advise
accordingly.
Fluorescin dye
5 - Commissioning 34 35
5.3 Waiting for first oil

A hose string may be installed for some considerable time before being taken into product loading service.
For hoses installed on CALM buoys this waiting time should be considered as part of the expected hose lifetime, with inspection and
maintenance procedures applying per section 7 of this guide. This also applies to other installations where the hoses see day to day
fatiguing conditions.
For installed hoses stowed onboard FPSOs etc the waiting time does not necessarily need to be included within the expected hose
service life. Precautionary protection from sunlight - a tarpaulin over hoses on a reel, for instance, is recommended.
For hoses that are to remain filled with sea water for an extended period, consider coating the bores of the hose end fittings with a
suitable glass flake epoxy paint system or similar. GMPHOM hoses are supplied hot dip galvanised as standard. Epoxy paint can be offered
as an alternative protection method against corrosion. This can be done at the Dunlop Oil & Marine factory prior to delivery if included in
the hose order.
Any projected change to the handled product which could affect the lining performance or buoyancy of the hoses should be relayed
back to Dunlop Oil & Marine who will be able to advise whether or not the hoses would still be suitable.
5.4 Submarine hose system trimming

Some float supported submarine hose systems will have one float distribution recommended for installation when the hoses are full of
water, and a different float distribution when they are full of product, If this is the case, and assuming that any problems seen in the initial
post-installation check are resolved, then normal procedure would be to remove one or more pre-identified floats immediately before
introducing the product, or as soon as possible after the first product loading.
It is strongly advised that the configuration should be monitored routinely until confident that it is within the design parameters of the
system. Dunlop Oil & Marine engineers can offer assistance, should it be so desired, in the form of computer modelling based on the data
provided from the monitored measurements, and recommend possible positional changes to the buoyancy modules if so required.
Subsea PLEM with submarine hoses installed

6 - Operation 36 37
6. Operation
6.1 Floating hose string hook-up
Refer to the OCIMF publication Single Point Mooring Maintenance A single hose snubbing chain is used in many instances, although
and Operations Guide (latest edition) for general advice on twin snubbing chains with intermediate tie-off chains terminating in
handling floating hose strings ready for conventional tanker pelican hooks may also be used.
berthing.
Note: For twin snubbing chains, an additional chain attachment
Whatever procedure is adopted at a given terminal, a major eye should be specified for the rail hose flanges.
consideration is to ensure that there are no tight bends induced
when the work boat is towing the floating hose string(s) out of the The snubbing chain needs to be tied off such as to at least partially
way ready for tanker approach. support the weight of the tail hoses attached to the rail hose, with
the rail hose itself adopting a smooth curve above the tanker rail.
Occassionally, multiple floating hose strings cross over each other Additional support to the rail hose may be provided by the tanker
in particular sea conditions. Use work boat(s) to disentangle the derrick using a wide fabric strop on the centre hose body section.
strings by carefully pulling from either the free hose string end(s),
or from one of the hose strings looped position. A close eye should For floating hose strings stowed onboard a FPSO (usually on a
be kept on the hose string as it is being pulled back to ensure the reel), a project specific deployment and recovery procedure should
MBR is not exceeded. be available, although conventional hook-up to a mid-ships tanker
manifold would still proceed as above.
Check hose strings for damage, especially if hose line marker
beacons are involved.
Check condition and security of the hose string lifting and

snubbing chains, and the chain attachment lugs on rail hose
flanges or incidental spoolage before tanker lifting operations
commence. In the absence of local acceptance criteria, Dunlop
Oil & Marine suggest maximum 10% allowable reduction in chain
link diameter or other component part through wear or corrosion.
Likewise, 10% reduction in thickness of parent metal forming the
Hose strings crossed over
hoses or spool attachment eye.
6.2 CBM hose string hook-up

CBM hose string hook-up follows the same principles as for floating hose strings to conventional tankers. The pick-up chain has a series of
master links or rings at approximately 5m intervals for successive capture by the tanker derrick.
However, an assessment of the subsea hose lay path should be made before commencing lift operations, especially for multiple strings
side-by-side. Ensure that the strings are not crossed over, and cannot be caught under the tanker keel when lifted.
Likewise, hose string lay down at the end of cargo operations should follow a well defined procedure to minimise the chance of a loop
occurring in a single string, or cross-over of multiple strings.
6.3 Bow loading hook-up

Procedures for installations that utilise dedicated tankers with
bow loading are assumed project specific. A heavy quick-connect/
disconnect(QC/DC) device is often used at the bow connection
end of the hose string, and the condition of any additional
floatation on the hose to support the hardware should be
monitored.
The QC/DC equipment is usually a universal joint type of

arrangement sited at or below deck level, and no additional
snubbing chain type support is needed.
6 - Operation 38 39
6.4 Hose condition monitoring

Auto-submergence
Example of auto submergence
Auto-submergence is an effect whereby submergence of part of a floating hose string
results in successive submergence of adjoining hose sections, with the complete
6.4.1 Hose system pressure testing floating hose string eventually submerging. This effect is driven by sponge floatation
compression with depth, and it is important to maintain reserve buoyancy of individual
hose sections at or above minimum design level to minimise the chance of local
In the absence of any project specific requirements, precautionary system pressure testing is recommended at maximum 6 month submergence in the first place.
intervals to hose rated pressure, or operating pressure +50%, whichever is the lower, for a period of 3 hours. After an initial fall due to hose
elongation, pressure should start to stabilise after about an hour. If pressure continues to fall in a linear fashion, then suspect a leak and It is rarely caused by a single event. Some possible contributory factors are:
investigate.
l Hose changeout where extra buoyancy has been omitted from the disconnectd first
Visual inspection of the floating hose strings can be made throughout the test. Look for expansion of the secondary carcass - which off buoy hose
would indicate primary carcass failure. Carcass expansion, if present, will be emphasised either side of the hose central restrictor band. l The support buoy has been removed from the rail hose
Submarine hose string inspection would not normally be expected to be undertaken at this time. l Crossed hoses in a heavy, choppy sea
l Floatation aid missing from marine breakawawy coupling.
6.4.2 Routine floating hose inspection The same effect could occur if a heavy piece of equipment is connected to the string,
or if part of the string is forced under the water e.g. by a vessel running over it. The
Floating hose strings should be visually inspected prior to tanker configuration of a tanker rail hose with buoyancy concentration at the tanker connection
arrival or as regularly as possible within practical operating end is a deliberate provision to account for the weight of butterfly valve and camlock
constraints. coupling etc normally connected. Nevertheless, it will still tend to submerge, and the
integral buoyancy of the pick-up buoy is a useful provision.
For surface hose strings a similar sequence as for pre-
commissioning checks applies. A workboat and diving team are If you believe auto-submergence has occurred to your hoses(s), bring the hose to the
needed for proper assessment. Floating hose damage below the surface asap and consult Dunlop Oil & Marine for advice.
water line might, for instance, be expected from propeller cuts.
l Check for cover/floatation damage

6.4.3 Submarine hose inspection
Example of hose wall damage
l Check for excessive marine growth and overbending/kinking
l Check for hose wall damage from mechanical impact or over
bending
l Check floating hose strings not wrapped around CALM buoy hull Submarine hose system checks are reliant on diver services avail-
Safgard tap valve in open position
l Check flange joint security ability, but should include (as appropriate):
l Check condition of ancillary equipment - breakaway coupling
and associated floats l Check for cover damage
l Check marker beacon function l Check for hose wall damage from mechanical impact or over-
l Replace any hose section or ancillary equipment item if safe bending
operation is in doubt l Check flange joint security
l Visually monitor floating hose strings during tanker loading l Open and close double carcass hose manually operated valves
operations to check for presence of product in secondary carcass
l For double carcass floating hose strings, look for expansion of l Check function of double carcass remote pressure monitoring
the secondary carcass - which would indicate primary carcass system (if applicable)
failure. Carcass expansion, if present, will be emphasised either side Hose string wrapped around CALM buoy hull l Check general configuration shape - ensure no tight bends
of the hose central restrictor band. or obvious deviation from normal expected attitude (see
‘Configuration Shape Measurement’ section on following page)
l Check that there has been no contact with mooring chains, in-
Double carcass floating hoses before and after secondary carcass expansion
line weights or umbilicals
l Check multiple strings are not interfering with each other
A normally operating Saflote hose.
A Saflote hose indicating a leak by expansion of the secondary carcass.

6 - Operation 40 41
Configuration shape measurement
Diver depth readings taken at each flange joint and mid-hose

length can give an initial indication as to whether a configuration
is in the expected position. Dunlop Oil & Marine submarine hoses
have a circumferential stripe in contrasting colour to the hose
cover at their mid-length, although this may coincide with a hose
float location collar, and be obscured by an attached float.
Additional information concerning configuration shape requires

a team of divers to take both depth and centre-line offset
measurements at various points along the string. If practicable
for the system location, this more detailed measurement method
should be performed at approximately monthly intervals.
The resulting data pairs can be used to produce a simple two-

dimensional representation of configuration shape using standard
spreadsheet graph plotting tools, or other routine.
It will not give a completely accurate picture (especially for

complex hose system end geometry) but should allow reasonable
monitoring of configuration behaviour over time, and to identify
the possible need for further investigation/action if significantly
deviating from the design or normal operational configuration
shape.
‘Dummy’ points can be included within the hose string

configuration plot at a short distance away from surface and
seabed manifold flange connection points to reflect the rigid
pipework take-off angles, and the fact that there is a rigid length of
hose end fitting (up to 1m long) that will not be expected to bend.
Some factors that may affect configuration shape are:
l Water depth
l Change in top connection position (e.g. through loss of a CALM
buoy mooring chain)
l Product density
l Trapped air or gas - vacuum
l Float loss/damage
l Mid-water tank buoyancy change
l Marine growth
l Pressurised system (through increased bending stiffness)
l Hose properties change with time (e.g. reduction in bending
stiffness)
l Kinked hose
l In-line weight
A system comprising multiple hoses supported by a single, high

buoyancy mid-water tank should not be expected to change
configuration from day to day - or indeed over its service life
- provided that the tank remains watertight with no deliberate
buoyancy trimming change or marine growth build up.
A long length ‘Chinese lantern’ or float supported ‘S’ shape

hose string configuration is somewhat more susceptible to the
influences listed above, and indeed, by experience, prone to day to
day configuration changes that cannot always be easily explained.
It is therefore important to review the complete configuration
history when deciding whether to intervene with adjustment of the
float distribution.
7 - Inspection & Test 42 43
7. Inspection & Test

Best assessment of individual hose condition requires removal from service for full external and internal visual inspection, hydrostatic test
and vacuum test.
Some of the inspection activities require subjective judgements to be made, especially in terms of visual inspection of the hose bore.
It is therefore preferable to maintain continuity of inspection personnel from year to year, or to have a programme of training in place
using experienced hose inspectors.
it is also important to keep detailed records of hose inspection findings to assist in evaluation at subsequent inspections.
7.1 Inspection and test intervals

Practice varies. Some operators perform full onshore inspection and test exercises Position Initial test interval
annually. In other cases, such inspection and test frequency is much lower and/or a
modified inspection and test regime is followed. First off the buoy 6 months - 1 year
Mainline floating 1 - 3 years
Recommended maximum intervals for full inspection and test of various hose types after
first installation on a CALM buoy are given in the OCIMF Field Test Guide, and summarised Rail 6 months - 1 year
in the table to the right. Submarine 1 - 3 years
The table should be considered as the basis of a best practice approach to hose test and
inspection intervals for all types of systems. It acknowledges the expected additional
problems that might be expected in ‘critical’ hose positions.
Annual full inspection and test is recommended on floating hoses if operational circumstances allow. Plan for absolute maximum of 3
year interval for first full inspection and test of all hoses, but 1 year maximum for first off buoy floating hoses and rail hoses. Individual sites
may then modify inspection intervals with experience.
For submarine hoses full inspection and test intervals should be planned for 3 yearly intervals as a minimum. Monthly checks should be
undertaken by divers to assess the configuration and external condition of the hoses.
In the case of a surge event, refer to section 9.4.2. All accidents or incidents should be thoroughly investigated and, if necessary, the
affected hoses should be withdrawn from service and be subjected to a thorough inspection and test before determining whether or not
they can be returned to service.
In case of incidents such as surge event, contact Dunlop Oil & Marine for advice.
7.2 Facilities
Ideally, the hose test facility would be sited within a purpose built utilities and test equipment available as required.
hose storage warehouse (see section 3.2) close to the hose string
assembly/disconnection area and include:
l Electric supply
l Water supply and drainage
l Compressed air supply
l Hose bore inspection lamp and good general lighting
l Roller bed(s)
l Pressure test equipment
l Vacuum test equipment
l Hose electrical properties test equipment
Otherwise a large, flat, solid outside work area with all necessary
7.3 Procedures Procedure:
i.) Filling
The following procedures are based on the OCIMF publication ‘Guidelines for the handling, storage, inspection & testing of hoses in the l Lay hose out straight on rollers
field’ (2nd ed. 1995), and our own extensive field experience. l Fit test blinds to hose, ensuring outlet (vent) position to top
l Fill hose using water supply (leave vent valve open until steady
flow of water achieved, then close off)
7.3.1 Visual inspection l Stop mains water fill once all air is vented
Equipment needed: ii.) Test

Visual inspection of hose bore lining l Apply pressure to 0.7 bar (10psi)
l Water jetting equipment or brushes (for marine growth removal) l Measure overall hose length and record as L1
l Good natural light and/or inspection lamp l Increase pressure to half hose rated pressure over a 5 minute
l Hand-held mirror (to reflect direct sunlight into hose bore) interval
l Hold for 30 minutes
Activities: l Reduce pressure to 0 over a 5 minute interval
l Raise to full hose rated pressure over a 5 minute interval
l Check general hose appearance for evidence of kinking or l Hold pressure for 10 minutes
severe impact l Measure overall hose length and record as L2
l Check fitting condition for excessive corrosion, both externally l Reduce pressure to 0 over a 5 minute interval
and internally l Wait 15 minutes, then apply pressure to 0.7 bar (10psi)
Hydrostatic pressure test
l Check cover/floatation condition for cuts, gouges, tears etc l Measure overall hose length and record as L3
l Check hose bore lining for blisters, bulges, gross deformation,
separation from the fitting Elongation assessment
l Check secondary carcass security (including detector devices)
l Check rail hose lifting lug condition Rejection criteria
Rejection criteria: L2-L1 l Excessive temporary or permanent elongation

Temporary elongation = x 100% l Twist
L1
l Excessive cover/floatation damage l External leakage
l Crushed or kinked hose wall L3-L1 l External bulge appears
Permanent elongation = x 100% l Inability to stabilise test pressure with no indication of an
l Local reduction in bore diameter (may suggest excessive tensile L1
load in service) equipment malfunction
l Distinct circumferential ‘ribbing’ (indicating fatigue) Example
l Mechanically damaged lining
l Lining exhibiting product attack (multiple hoses could be Compare the above field test percentage elongation values with
Factory test elongation = 0.8%
affected) those recorded in the original manufacturing factory tests. If either
Field test temporary elongation = 2.9%
l Movement of end fitting nipple relative to flexible hose section temporary or permanent elongation values from the field test
- REJECT - increase more than 2%
l Bulges/blisters (other than air pockets or local delamination in are more than 2% above the respective factory test elongation
cover) percentage values, then this is a criterion for rejection.
Factory test permanent elongation = 0.2%
l Product seepage from beneath hose termination at flange weld Field test temporary elongation = 2.0%
neck - ACCEPT - increase less than 2%
l Secondary carcass activation (double carcass hoses)
l Excessive fitting corrosion
l Excessive wear to lifting lugs
For larger bore hoses, consideration may be given to an internal

bore inspection over the full hose length by inspection personnel.
A safe procedure of work is essential if such a practice is adopted.
7.3.2 - Hydrostatic pressure test

Equipment needed:
l Pressure test flange blinds with inlet and outlet valving

l Bolting and gaskets
l Pressure pump with hose design rated pressure capability
l Pressure test gauge (and/or other pressure monitoring method)
l Roller bed for free hose elongation
l Water delivery hose(s) to suit
Hose being filled with water

Hose pressure test being carried out
7.3.3 Vacuum test Example of a hose inspection sheet
Equipment needed:
l Transparent acrylic plates for each end of the hose, one with
vacuum suction port
l Rubber gaskets
l Vacuum pump
Hose Inspection Sheet Serial number:
Rated pressure:
Manufacturer:
l Vacuum suction hose to suit
Type:
l Good light source (flashlight/reflected sunlight) Diameter:
Length:
Procedure: 1.) Visual Inspection
l Clean flange faces General condition
l Clean hose bore to remove all excess water Rejection Criteria
l Locate rubber gaskets loosely on hose flange sealing faces using Fittings End A End B
bolt studs l Lining collapse/delamination check for:
l Offer acrylic blanks up to flanges and hold in place - wear (especially to lugs)
l General reduction in hose bore - corrosion (ext & int)
l Start vacuum pump l Appearance of blisters/bulges - flange face damage
l Release hold on acrylic flanges once sufficient vacuum l Water/product pulled out of lining (may be indicated by - leak detector condition (double
established carcass hoses)
pool of water collecting at bottom of hose bore)
l Attain 680 mbar gauge vacuum and hold for 10 minutes l Water/product pulled back from lining to fitting nipple Bore
l Examine hose bore from both ends using a good light source interface area check for:
and check for all things listed under rejection criteria - flattening/kinking/necking
- lining tears/blisters/bulges
- lining wear - ‘ribbing’
- fitting separation
7.3.4 Electrical properties testing Cover/Floatation

check for:
- lost floatation/cover
The equipment needed for testing is the same whether the hose(s) - cuts/tears
- product seepage (especially
are electrically continuous or discontinuous. Equipment needed is at fitting join)
as follows:
l 500 volt electronic resistance meter and hose flange connection

leads or hand cranked ‘megger’ and hose flange resistance leads 2.) Hydrostatic test
Start Length @ Test Length @ End Length @ Temporary Permanent 2nd carcass status
0.7 bar, L1 rated pressure L2 0.7 bar, L3 elongation (%) elongation (%)
Procedure:
l Ensure all dry hose and flanges are held clear of the ground by Original factory elongations (%)
insulated materials
l Select and operate appropriate test equipment, making good
electrical contacts with the end flanges
3.) Vacuum Test
For an electrically continuous hose, a very low resistance reading End A fitting interface
will be found (probably less than 10 ohms) using the multi-meter. (pull back/blisters)
End B fitting interface

The resistance measured between flanges should be greater than (pull back/blisters)
25,000 Ohms for an electrically discontinuous hose.
Rubber lining
(blisters/fluid/delamination)
4.) Electrical properties test Continuous / Discontinuous ........................................................... ohms
Recommendation Tick box Comments
Fit for service
Fit for service after repair

Unfit for service Inspector ............................................................................................. Date ........................................................
8. Hose Maintenance 48 49
8. Hose Maintenance
Little or no hose maintenace is usually possible in service, and would normally be assumed to take place during or after the routine
onshore inspection and test programme - detailed in section 7.
Hose maintenance is effectively limited to both cover and floatation damage repair, as well as providing surface protection to exposed
metal fitting surfaces in the event of deterioration in service.
8.1 Repair or retire

The decision as to whether to repair a
damaged hose or not is often subjective,
taking account of extent of damage, hose Visual inspection
age, time in service, general condition and
operational risk etc.
Some relevant considerations are: Any yes no

Repairable Retire
l A hose usually needs to be removed defects?
from service for a successful repair
l The economics of repair may not be no yes
justified for a hose with extensive damage
(especially an old hose approaching the
end of its expected service life)
Hydrostatic test
l The material layers beneath the rubber
cover and/or sponge floatation cannot
be repaired, and if damage is of sufficient
severity to expose these underlying layers Elongations no
then this should be considered a reason for Retire
retirement OK Original factory
l Damage into the tapered sections down test elongations
towards the flange neck may be particularly yes
difficult to evaluate and repair successfully
l It is difficult to know how fitting integrity Vacuum test
may be compromised under conditions of
excessive metal loss
l The source of external hose damage
should be established in case the
damaging mechanism could also have no
over-stressed the hose wall reinforcement Bore OK Retire
components (e.g. a vessel riding over a
floating hose string) yes
l A floating hose with significant sponge
floatation damage or loss could lead to
auto-submergence of a complete floating Electrical properties
hose string test
For an externally damaged hose taken from

service, the decision to retire or repair takes
the path in the diagram to the right.
Property as no Retire/consider
Dunlop Oil & Marine can offer the services alternative use
expected
of an engineer to examine suspect hoses
and offer training in the use of repair
yes
materials should it be required.
Fit for service

8 - Hose Maintenance 50 51
8.2 Repair kits 8.3 Hose repair method

Dunlop Oil & Marine can provide materials for cover and floatation repairs should the decision to repair be made.
8.3.1 Positioning the hose
Repair of damage to hose covers, and to floatation layer in floating hoses may be considered, but repair of damage to the underlying
hose wall layers should not be attempted. Hose repairs are best performed onshore in dry, controlled conditions. Offshore repairs may be attempted, but with the relevant hose
section(s) recovered/secured to a work barge or similar, and the hose repair area kept dry.
Three standard repair kits are available:
The hose should be positioned such that the damaged area is towards the top. It may help repair personnel if the hose is supported clear
1.) 0.75 litre cover repair kit - providing materials for production of sufficient polyurethane elastomer to cover an area of approximately of the ground using strong, wide timbers or similar.
0.1m2 to a depth of 5mm. Includes an adhesive for bonding the cover repair compound to the original rubber or polyurethane cover, or to
exposed sponge floatation. The hose should be ‘chocked’ in position to prevent rotation during the repair exercise.
2.) Sponge repair kit - comprising a roll of closed cell sponge plus adhesive to provide approximately 0.07m3 volume of replacement
floatation.
8.3.2 Cover repair technique
3.) Accessories kit - comprising 5 litres of cleaner/priming fluid, plus knives, brushes and trowel.
The cover repair compound is deliberately provided in relatively small quantities based on experience in the field. A 0.75 litre batch can Examples of when to repair
be mixed by hand using the supplied spatula and mixing container. Larger batch quantities are available, but require a mechanical mixing
tool operated by an electric drill for good consistency of mix. The mix has a limited working time (only a few minutes in hot climates)
before it starts to harden so mixing large quantities can be counter-productive.
The sponge repair kit is based on a single roll of closed cell sponge for treatment of a localised damaged area. It is probably uneconomical
to attempt to replace a large, deep section of lost floatation, remembering that a final cover repair will also be needed over the affected
area. Indeed, a cover repair itself becomes a very awkward task if it is over a large area both in length and circumference.
The accessories kit contains primer fluid which must be spread over the hose bonding surface before applying the cover repair
compound adhesive. It can also be used as an alternative to a general ‘cleaning’ solvent such as MEK. Standard supply of the primer is in
5 litre tins.
Other items in the accessories kit are to help prepare the damaged hose area and to then apply repair materials.
A single accessories kit can service up to four or five cover repair kits.
If requested, Dunlop Oil & Marine can help to source suitable repair material locally.
Health and Safety
Some repair materials supply is in original component manufacturers’ containers, which should therefore be received un-opened. No repair Repair
Do not use materials from containers which are received open. Cover split through foam and carcass down to embedded helix. Abrasion. Cover abraided down to breaker fabric.
Some of the materials used in the repair kits are flammable and/or toxic. Warnings are provided on the relevant containers. Cover repair process
Read all data provided on the relevant containers before opening. l Cut away any remaining loose areas of cover damage using the cobbler’s knife and/or stanley knife from the accessories kit (consider
using adhesive to bond down a flap of torn cover to sound underlying rubber or sponge material)
Refer to manufacturers instructions enclosed with the cover repair compound carton and the compound adhesive container. l Wire brush (from the accessories kit) the damaged cover surface extending approximately 100mm onto the undamaged cover all
around the damage
Refer to Dunlop Oil & Marine if further data is required by local health and safety rules. l Apply bonding agent UU56 (from the cover repair kit) to the prepared area and allow to dry for approximately 30 minutes, and in
accordance with the enclosed instructions
Appropriate health and safety precautions should be taken for personnel protection and for preparing the repair working l Mix the two part polyurethane compound components (from the cover repair kit) in accordance with the enclosed instructions, and
environment. These should be determined in accordance with local safe working practices and may include, but not be limited apply with the spreader provided (the trowel from the accessories kit can also be used for this)
to: l Ensure that there is a thin layer over the complete damaged cover surface, extending approximately 50mm onto the prepared,
undamaged cover, before building up the damaged area with more compound
l Use the gloves provided for mixing the cover repair compound and adhesive l To strengthen a thick repair, apply a cut-to-size layer of breaker fabric (from the cover repair kit) after application of about 3mm
l Wear protective goggles thickness of cover repair compound
l Wear overalls to protect repair personnel clothing l Mix successive 0.75 litre batches of repair compound as required to complete the repair
l Do the repair outside, or in a well ventilated warehouse l Lightly brush the repair cover surface with RU80 primer/cleaner after 3 to 5 minutes for a smoother repair finish if required
Dunlop Oil & Marine can provide training for operators in the use of repair mediums commonly used on rubber and PU covered hoses.
8 - Hose Maintenance 52 53
8.4 End fitting condition

Hose wall design improvements and the adoption of regular hose
inspection and testing programmes have resulted in operators
seeing improved hose lifetimes. Attention to hose end fitting metal
surfaces will probably therefore become an increasingly important
issue.
The standard external fitting surface protection method for newly

manufactured hoses delivered by Dunlop Oil & Marine is hot
dipped galvanising. A marine grade epoxy paint system may be
alternatively specified by clients.
It is important to remove all marine growth even if the flange and

any out-of-hose nipple section seems otherwise in good condition.
Occasional instances of local severe pitting beneath marine Epoxy paint coated fittings
Example: Before cover repair Example: After cover repair
growth have been reported. Consideration could be given to weld
or other metal repair method in such an instance, but this must
be considered under separate specialist advice rather than as a
8.3.3 Floatation repair technique routine method.
Of particular concern are deep pits externally at the flange weld

l Remove marine fouling etc from in and around the damaged area. neck, or internally along the nipple tube extending inboard
l Remove sponge from the damaged area using the cobblers knife (from the accessories kit) until a sound layer of sponge or the from the weld neck. Nominal metal thickness in these areas
underlying carcass rubber cover is exposed at the base of the damage. approximately relates to that of standard wall line pipe, in the
l Cut out a hole, forming sides of sound sponge which taper outwards to the full depth of the damage. region of 10mm for larger bore hoses. Refer to Dunlop Oil & Marine,
l Cut to size sections of sponge from the roll (from the sponge repair kit) such that they will snugly fit the edges of the tapered hole, and if necessary, for more detailed guidance.
finish approximately 5 to 7mm beneath the level of the outer hose cover.
Note: The idea is that when the successive layers of cut sponge are bonded together within the hole, they will act as a single plug of For fittings that have seen excessive loss of galvanising in service,
sponge which cannot fall out if the repaired cover is subsequntly damaged again. reinstatement of the zinc layer by zinc spraying is a possibility,
l Apply a thin layer of S708 adhesive (from the sponge repair kit) to the sponge or rubber layer at the base of the hole, and to the mating although this is unlikely to provide really good long term Bolt-on zinc anodes
surface of the appropriate piece of repair sponge section. protection. A proprietary marine grade epoxy paint system is
l Allow both surfaces to ‘tack dry’. possibly the best option for such rectification work. Contact with
l Fit the prepared sponge section into the hole. local marine painting experts is advised.
l Apply hand pressure to expel air, and to promote adhesion of the mating surfaces (a wooden mallet or similar implement can
alternatively be used). Additional protection in the form of bolt-on zinc anode kits is also
l Repeat step 4 for successive layers of the repair sponge sections. available - refer to Dunlop Oil & Marine for further details.
l Refer to the cover repair technique (previous page) to complete the job.
Consideration should be given to protecting the inside fitting
Dunlop Oil & Marine can provide engineers to repair the hose, but encourage operators to undergo training in repair techniques. surfaces if there is evidence of corrosive attack. There have been
particular instances of such occurence where hose strings are
Note: The repair methods above may need to be adapted to suit particular circumstances. Refer to Dunlop Oil & Marine for further flushed through and left with ballast water in the bore after loading.
information on materials and procedures. Sulphate reducing bacteria are thought to be the main culprits,
initiating distinctive pits several milimetres deep.
A glass flake epoxy paint system, such as Rigidon, has proven

Rigidon painted bore
successful in providing long term, internal surface protection
in such circumstances. Note that GMPHOM 2009 hoses are
galvanised internally as standard.
8.4.1 Flange face damage

The gramaphone groove finish on the flange face is vulnerable to
accidental damage. If the face is excessively scored (which itself is a
somewhat subjective matter), then a poor flange joint seal may be
expected.
If in doubt, do not use the hose until the finish has been re-made
with the proprietary tooling. There are specialist companies with
appropriate portable equipment, but this is unlikely to be a viable
proposition in remote locations.
Hose repair demonstration
Flange face repair tool
Reference to the ASME B16.5 flange standard should also be made.
9 - Utilisation 54 55
9. Utilisation
9.1 Installation/commissioning spares
In most cases, new hose string installations progress safely, with
Suggested hose system installation contingency
little or no hose damage. However, it is still advisable to have a hose
system spares contingency for installation. Hoses 20%, with minimum 1 of each type
Gaskets & bolts 100% for hose string end connections

In particular, flange joints may need to be re-made, with new bolts
& 10% intermediate connections
and gaskets used.
Camlocks, valves, chains,
50% with minimum 1 of each item
See the table to the right for Dunlop Oil & Marine’s pick up buoys, spools etc
recommendations for spares.
Marker beacons c/w battery 25% with minimum 1
Floats 10%
9.2 Operational spares

The OCIMF publication Single Point Maintenance and
Submarine & floating hose system
Operations Guide (2nd ed, 1995, section 9 ‘Spare Parts’) gives
recommendations for operational spares for a single SPM: Hose couplings, spreaders, spool pieces & gaskets 100%
Hoses, both submarine & floating 100%
The recommendations are summarised in the table to the right.
Buoyancy tanks or floats 100%
This is a useful starting point for individual terminal stockholding Tanker rail hoses & first off the buoy hoses 200%
considerations, although a leaner approach is often adopted.
Valves & flanges 200%
Lifting chains, shackles etc 200%
Hose lights, battery packs etc 100%
Associated bolts 200%
Pick up buoys 200%
Additional considerations
Consideration Implication
Risk to operations of an event leading to

At least 100% spares of all system hoses and ancillary items always required
complete hose system write off
Risk to operations of an event leading to
At least one full floating and/or submarine hose string and ancillaries always required
single hose string write off
Multiple hose strings with common hoses Possible reduced stockholding
Regular hose string tanker handling Increased stockholding of rail and tail hoses, in particular rail hose, together with tanker
operations connection end gear - butterfly valve, camlock coupling, pick up buoy, chains etc
System with adverse response at particular Increased stockholding of critical position hoses e.g. first off the buoy
points
Good historical hose performance data

available, and routine retirement criteria Confidence to work with reduced stock levels of one or more hose types
established
Poor storage facilities Short turn round of hose stock needed to avoid early cover and lining degradation
9.2.1 Delivery time for different products. In such cases it is still recommended to dedicate individual hose useage to a single product line. This is because the
hose lining will establish a ‘chemical balance’ with an incident product that will dictate lining performance with time. Introducing a different
product will create a new balance with a lining that has already changed its original nature. This has potential increased risk of adverse
Delivery time will depend upon the hose type, quantity and on current factory loading. Please seek advice from Dunlop Oil & Marine for lining performance, and complicates assessment of expected hose lifetime.
latest delivery time estimates. In an emergency, Dunlop may be able to offer an improved level of assistance. Air freighting could also be
considered in an emergency situation.
Shipping could take up to 8 weeks to port of destination remote from the UK. Customs clearance and overland transport issues etc all
add to the delivery time to site. Early submission of hose requisitions is therefore strongly recommended whatever stock-holding policy is
9.4 Retirement indicators
adopted.
There are no hard and fast rules for retiring hoses from service. Expected lifetimes for various hose string positions are established
through operational experience which tends to be terminal specific. A good hose inspection and maintenance schedule will help in
building up a statistical database of wear, damage and failure frequency (per OCIMF Field Test Guide recommendations), with selective
9.3 Hose string changeout/rotation burst testing also assisting in hose lifetime evaluation.
Changeout of hoses individually offshore can be more of a problem than removal and replacement of a complete hose string. The Many operators have developed hose lifetime assessment policies based on the above general approach, and have subsequently
need to change out a single hose suggests an unplanned, operational occurence. The risk of this can be reduced by appropriate early succeeded in safely extending hose service life. Double carcass hose designs are now widely used, and this has added to user confidence
assessment and intervention as part of a planned hose inspection and test regime involving removal of the complete hose string from when extending hose service life. Dunlop Oil & Marine have worked with a number of operators in setting up hose lifetime assessment
service, with sufficient stock available for hose string rotation without operational interruption. programmes, with considerably longer service lifetimes achieved in some instances.
Hose life expectancy will differ from one installation to another. It is imporant to emphasise that local environmental conditions and
9.3.1 Single string operation resulting system behaviour, loading frequency, handling practices and inspection and maintenance procedures all influence actual
lifetimes that may be achieved. However, retirement after just 2 or 3 years might still be expected for critical hose positions such as the
The simplest case to consider is a single string system, and an tanker rail and first off buoy hoses.
annual (or other regular) onshore inspection and test schedule.
Components for a complete hose string are held onshore ready

to replace the installed hose string should it be returned to shore 9.4.1 Routine test & inspection results
following an adverse service incident or for routine hose inspection
and test per section 7. Refer to section 7 for routine inspection
criteria that lead to rejection of individual In summary, the usual reasons for retirement are:
Once the originally installed string has been removed from service, hoses for further use in service.
the second string is immediately assembled, tested and installed l External degradation due to environment (ageing in sunlight or due to ozone)
for minimal interruption to loading operations. Ideally, site facilities In some cases, hoses rejected on the l External mechanical damage
will allow safe storage of a complete hose string ‘ready to go’. basis of the above criteria are stand alone l Kinking
decisions resulting from specific service l Hose bore lining anomalies (may be emphasised in vacuum testing)
Any hoses, spoolage, valves etc from the originally installed string incidents or conditions that only affect one l Corrosion
that are found to be damaged or unserviceable are then repaired or two hoses in isolation. In other cases l Elongation under pressure beyond industry specification
or replaced, together with new bolting and gaskets, such that a there may be indications of a wider issue or
complete hose string is then available onshore again. issues affecting a number of hoses.
9.3.2 Twin string operation 9.4.2 Service incidents

A terminal with twin loading hose strings sharing single product
transfer has more flexibility in terms of devising a rolling hose string Occasionally there are accidental service incidents that affect many or all hoses in a string, and where retirement of all affected hoses
changeout routine that allows continuous operation at a busy should be considered.
terminal. Essentially, oil transfer can continue through one string -
Tanker breakout
albeit with reduced throughput - whilst the other is removed from
If a loading tanker moves sufficiently off station (e.g. through hawser parting) such that the floating hose string becomes very taut, then
service. One scenario is where operational logistics and experience
hose damage through excessive tension may occur. This may be indicated by necking of one or more hoses where the helical wire locally
allows planned inspection and test of 1 hose string per year over a
deforms, creating restrictions in the hose bore. Even if this is seen in just one or two hoses in the string, all hoses should be considered as
2 year cycle.
‘suspect’. The submarine hose system may also be affected.
The main reinforcement plies and adhesion levels between the hose wall layers may also be compromised to varying extents from hose
9.3.3 Multiple hose strings to hose.
Many floating hose strings include breakaway couplings that part at some pre-set tension with minimal pollution in such an event. This
The principle of successive hose string inspections can be extended for those terminals with several operating strings, assuming the will generally help protect the hoses against accidental over-tension. However, the coupling may be set above the normal safe working
same product is used in both. However, it is more likely that hose string changeout logistics may need to take account of different hose load of the hose, and the possibly complex nature of a breakout event still makes close review of likey hose condition advisable.
string bore sizes, and/or products.
Storms
An example of this is crude stock import for a refinery, and refined products export. It is important to separate these activities in terms of Although new terminal installations are invariably analysed for survivability in, say, 50 or 100 year storm design conditions (including
hose utilisation. the loading hose strings) it is still recommended to check both floating and submarine hose string condition after storms. There are
occasional incidences reported of kinking etc which may be due to unexpected system response effects (for whatever reason). Failure
In some cases, different hose constructions will apply for different products. In other cases, the same hose construction could be utilised pattern may be apparently random in such circumstances.
Auto-submergence
If a floating hose string sinks (see section 6.4 for initiating mechanisms), the following situations may arise: 9.4.4 Hose life assessment
l Mechanical damage to floatation and/or hose wall carcass due to initiating cause
l Mechanical damage due to contact with sub-sea structures
Burst testing a hose following service life provides some indication
l Mechanical damage/kinking at sea bed contact
of the hose condition but not a full picture. Dunlop offers support
l Kinking at surface connection(s)
to our clients by providing a full suite of inspection and test
l Permanent loss of buoyancy on recovery to surface
services at our factory in Grimsby to establish hose condition
Always treat hoses that have been involved in such an incident with caution. Recover the hose string for full onshore inspection and test,
following service life. We work with our clients to try and optimise
and individual hose dimensional checks for residual buoyancy assessment. If several hoses have obviously been affected, then prepare to
the service life of the hoses at a particular installation. Programmes
retire all hoses involved.
of work are customised to the clients needs but may include any
or all of the following: visual inspection, hydrostatic , vacuum and
Surge event stiffness testing, dynamic fatigue testing, tensile testing, burst
Very high pressures can be generated over short periods of time during cargo transfer operations due to upset conditions, for instance testing, material testing in the laboratory.
unexpected valve closure. This is known as surge pressure and is considered an event outside the normal operating condition. It should
be ensured that pressures in normal operating conditions do not exceed RWP of the hose. Refer to GMPHOM 2009 for recommendations Close examination and test of the individual components of the
on what to do in a surge event. hose wall by specialist laboratory equipment is particularly advised
for life assessment work as rubber compound degredation and
loss of hose wall adhesion are signs of ageing and the extent of this
can act as a retirement indicator. A comparison of reinforcement
9.4.3 Residual burst pressure cord tensile strength, rubber compound properties and hose wall
layer adhesion levels is made between the ex-service hose wall
Extracting reinforcing cords for testing
section and a new-build hose sample.
For hoses that have been in service, some
level of fatigue will be expected. The extent
to which a given hose fatigues will depend
upon such factors as position in system,
environmental conditions, time in service,
9.5 Disposal
handling operations, product ageing etc,
and will vary from site to site. Hoses have been used for a variety of purposes after completion of their normal service life. Field drainage, fendering, pontoon support
and limited use in a dredging line are examples of practical applications.
Destructive burst testing of selected hoses
over a period of hose string operation can Safe disposal should otherwise be in accordance with applicable local authority rules.
help in deriving expected hose service life
for various hose positions.
Although burst testing should not be

regarded as indicating a simple pass/fail
situation, safe practice would be to base
retirement criteria on the minimum 5:1
design pressure safety factor given in the
GMPHOM hose guide for proof testing of
prototype hoses.
For double carcass hose burst tests the

same 5:1 design pressure safety factor can
be applied for primary test burst. and a
2:1 design pressure safety factor can be
applied to the secondary carcass test burst.
For instance, a hose with 15bar design

pressure will be expected to burst at 75bar
Hose prepared for burst test
or above when in ‘as new’ condition. A
burst pressure of 69bar would suggest
some loss of strength due to fatigue
unless there has been a specific damaging
incident.
Although such a 69bar value might seem

to indicate fairly good residual strength,
this needs to be considered alongside the
fact that there have been many instances
of hoses bursting well in excess of the 5:1
minimum pressure safety margin, even
after many years in service.
10 - Ancillary Equipment 60 61
10. Ancillary Equipment

Guidelines for use and maintenance of the major supply items are as follows:
10.1 Gaskets
Storage
l Store in cool, clean, dry atmosphere away from direct sunlight
Installation
l Use each gasket once only - use a new gasket if re-making a joint
l Carry carefully - avoid bending, face damage and contamination
l Ensure flange faces are clean and undamaged
l Do not use jointing compounds or release agents
l Carefully align and centralise gasket with flanges
l Ensure gasket is not pinched or damaged during joint tightening
Maintenance
l Check flange joints for leaks in routine hose string inspection
10.2 Chain assemblies

Storage
l Store on wooden pallets in clean, dry atmosphere
Installation
l Ensure intended use is within chain assembly components’
working load limits
l Check condition before bringing into service
l Ensure safety bolts, split pins and connector links are secure as
appropriate
Maintenance
l Check component security before any service lift
l Check for corrosion and wear at regular intervals
l Adhere to any specific legislation applying
10.3 Bolting
Storage
l Retain in boxed packaging in dry location until needed
Installation
l Use each bolt set once only
l Hand run nuts onto stud thread evenly either side of flanged joint
l Tighten to pre-established torque valve using cross-tightening pattern (see section 4.3)
l Check effect of lubricant (if used) on recommended torque value
l Do not lubricate PTFE coated bolts
Maintenance
l Check condition and tightness during routine hose string inspection
10.4 Butterfly valves 10.5 Camlock couplings

(standard supply lever operated, rubber lined wafer type) Storage
l Store on wooden pallets in clean, dry environment
Storage
l Store on wooden pallets in a cool, dry, dark place Installation
l Open the valve to approximately 100 (long term) l Ensure cams rotate freely and are undamaged
l Treat rubber liner with talcum powder or silicone spray (long l Use an appropriate gasket at non-cam jointing face (or fit directly
term) to rubber faced butterfly valve)
l Use hardboard or plastic protectors to rubber lined faces l Ensure camlock flange face ‘O’ ring is in good condition and
correctly seated
Installation l Rotate cams to flange rim clearance position
l Remove residual talc etc with damp cloth
l Ensure disc is fully closed or towards the closed position within Operation
the protection of the valve body l Offer camlock flange face to mating flange
l Fit valve with shaft horizontal such that the lower half of the disc l Locate 15mm steel bar (supplied as standard) in cam cut-out slot
will move in the direction of flow during opening (if operationally and rotate to lock, or use special camlock locking wrench
practicable) l Operate all cams for full security
l Support valve - offer up to adjacent equipment flange Note: do not use hammers or similar
using valve body bolt location holes to assist alignment and
centralisation, ensuring no damage to rubber lined faces Maintenance
l Do not use separate gaskets with the rubber lined valve faces l Check ‘O’ ring after each operation - replace as necessary
l Ensure bolting has sufficient extra length to account for valve l Check cam bolt tightness and security to cam block
body width l Grease shoulder bolts every 2 to 3 months
l Insert bolts, hand tighten nuts and check free movement of disc l Complete cam assemblies can be replaced, but must be
l Ensure valve is in partial or fully open position and fully tighen accurately re-sited and set
bolts l Sub-components of the cam assemblies are also available
l Return valve to fully closed position and lock l Make good body surface coating damage with a marine grade
epoxy paint system or similar
Operation
l To open valve - remove locking bolts, insert lever into housing,
turn actuator housing through 90 degrees in correct direction and The standard supply lever operated, rubber lined wafer
butterfly design is for ease of handling and operation
10.6 Battery powered marker beacons
lock open
l Close valve back through same 90 degree quadrant offshore at the tanker end of a loading hose string where Storage
usual service is just to retain product in the hose string l Store on wooden pallets in clean, cool, dry place
Maintenance between loadings.
Preparation for service
l Act of dismantling valve from the line may damage rubber faces l Remove top light assembly fixing bolts
- take care It is designed to seal against approximately 3 bar internal
l Carefully lift top light assembly away from stanchion
l Shaft, disc and bearings can be replaced, but the need to do so pressure only.
l Push top light and stanchion battery bullet connectors together
suggests an underlying operational problem l Replace top light assembly on stanchion (including rubber
l The lining is not replaceable Other valve configurations - double flanged, gearbox
gasket)
l Make good surface coating damage with a marine grade epoxy actuator for pressure service etc are available.
paint system or similar Installation
l Site upright in pre-determined hose string positions using extra
long bolts to secure flange connection plate
Open/close direction and locking
Operation
l Top light will automatically activate in low light conditions, and
The valve actuator housing and valve body top flange include
switch off when sufficient ambient light returns
bolt sets and bolting holes for positive locking of the disc in open
and closed positions. The disc is only meant to operate over one
Maintenance
quadrant of the potential full turning circle defined by the two
l Remove miscellaneous deposits from lens
possible alignment positions of the bolting holes.
l Replace battery when exhausted - typically up to 12 months life
(beacon can be removed from hose string by unbolting stanchion
from flange connection plate if required)
Do not attempt to send the disc beyond its normally l Spares are also available for flasher unit and lens assembly
closed position since it may subsequently be unable to be
freed and possibly result in rubber lining damage.
10.7 Solar powered marker beacons
Solar powered beacon lights have a number of features that may or desk lamp
affect initial activation for service. If the standard supply SB202 unit 3. Use a 12 volt DC source to charge up the internal battery through
does not self-activate in low light conditions, then try the following: the underside lugs for 24 hours.
1. Check that the on/off switch (fitted to base) is on
2. Leave under a bright light source for 24 hours e.g. direct sunlight Refer to supplied operating instructions for further details.
10.8 Submarine hose floats

Storage
l Retain in original packing (usually wooden slats) for protection
l Store in cool, clean, dry location away from direct sunlight
l Thoroughly clean ex-service floats before re-storing
Installation
See section 4.4.4
Maintenance
l A kevlar strap with super duplex tensioner is available for
supplementary float security if required
l Minor damage repair to polyurethane skin and floatation may
be attempted onshore using foam insert (if needed) and suitable
moisture curing adhesive
Metalwork is also replaceable. Retro-fittable zinc anodes are

available in case the stainless steel clamp mechanism is
susceptible to corrosion in the local environment.
10.9 Other equipment

Items such as spools and blind flanges, and the exposed metalwork of floating surface equipment such as floating concentric reducers
and Y-pieces should generally be inspected and maintained in a similar fashion to hose end fittings. Checks for excessive external and
internal corrosion, and reinstatement of surface protection will be the primary issues.
Lifting lugs or eyes, where fitted, should also be checked for corrosion and wear per legislation applying. Dunlop Oil & Marine suggest a
maximum 10% reduction in bearing metal thickness.
Repair of minor damage to the floatation units of floating surface equipment (including pick-up buoys) can be affected as for submarine
floats. Extensive damage is often not easily repairable.
Contact Dunlop Oil & Marine for any specific issues concerning supplied ancillary equipment.
Contact www.dunlop-oil-marine.co.uk
Market segment The ContiTech division of the Continental Corporation
Fluid Technology is a development partner and original equipment
supplier to numerous industries for high-quality
Dunlop Oil & Marine Ltd functional parts, components and systems. With its Learn more about
Moody Lane, Grimsby know how in rubber and plastics technology, the contents of this
N.E. Lincolnshire, DN31 2SY ContiTech contributes significantly to industrial brochure.
United Kingdom progress and mobility that is safe, comfortable and
Phone: +44 1472 359281 eco-friendly.
Fax: +44 1472 362948 The content of this publication is not legally binding
Email: dunlop.sales@fluid.contitech.co.uk and is provided as information only. The trademarks
displayed in this publication are the property of
Continental AG and/or its affiliates. Copyright © 2014
ContiTech AG. All rights reserved. For complete
information go to: www.contitech.de/discl_en

Hose Info Manual - Low Res 2

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Hose Info Manual - Low Res 2

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Hose Information Manual

Dunlop Oil & Marine Hoses

GMPHOM 2009 Hoses. Contents.

1. Fittings materials used for the main plies are

1.2 Hose identification Submarine hoses

lifting lugs on the end flanges.

Tanker rail floating hose (includes types

1.3 Hose customisation 1.4 Hose electrical properties

B Both ends reinforced (or fully reinforced) ü ü ü ü

W Non-standard working pressure ü ü ü ü ü ü ü ü

2. Handling & Transport

l Wooden packing protected - known as ‘slat packed’

Slat Packed Slat-packed hoses with webbing slings

There will normally be two such slings

Note: The slings should only be used for

Check condition and identification tags

There are no specific recommendations for

Safety precautions at site

2.2 Recommended method of

2.3 Hose movement around site

l Spreader bar and mobile crane

3.2 Storage facilities

Dedicated hose storage facilities are

If stored outside, hoses should be held on

3.3 Preparation for storage

Retain hoses in original delivery pallets (if provided).

Replace end bungs to protect flange faces and prevent ingress

Stack pallets to maximum height of three tiers, taking due account

Alternatively lay individual hoses out straight and level, supported

3.4 Inspection during storage

l Sundry mechanical damage

3.5 Ex-service hoses

Consider removing any excess bore residue using a soft foam

Use the same principles of storage as for newly delivered hoses.

Take due account of any sequence of planned future utilisation

4.1 General precautions for hose integrity

Ensure that there are no sharp protrusions, deck fittings and so on

Some users benefit from a system of hose support trolleys to move

Flange face protection on hoses ready for installation

4.2 Assembly equipment - tools

Double nutted, long stud bolts and nut 3 9

1.) Tighten nuts to 30% of

4.3 Assembly equipment - jointing recommended torque in reverse

Spiral wound gasket

4.4 Hose string assembly Examples of general project arrangement drawings

4.4.1 Assembly site

l Dock-side/jetty l Dry dock

Slipway Floating dock

Dry dock Beach

4.4.2 Hose string assembly 4.4.4 Float fitment

4.4.3 Making up hose joints

Refer to section 4.3 for information on jointing materials, bolt

4.4.6 Launch and tow 4.4.7 Offshore assembly

Hoses ready for installation

4.5.2 Submarine hose string 4.6 Hose string installation - FPSO

4.6.2 Onshore reel installation 4.6.3 Reel installation on deck

A particular consideration with reel 4.6.5 Other FPSO hose systems

It may be beneficial to perform a separate

The remainder of the hose string can then

Finally, the outboard end of the hose string

For a double layer reeled hose string, it is

Double layer reeled hose string

l Cover and floatation damage