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SEAFLEX MARINE HOSE

Maintenance & Repair 22 Apr. 2014 Masuo KURODA Engineer The Yokohama Rubber Co., Ltd. Hitoshi INDO Engineer Yokohama Industrial Products Asia-Pacific Pte. Ltd.

OUTLINE 1. Handling 2. Installation 3. Towing & Leakage Test 4. Storage 5. Appearance ( Visual Inspection ) 6. Testing 7. Repair

Handling

Hose Rack Handling Lifting by crane to avoid damaging rack and hose

Forklift truck may cause damage

Hose Handling

Spreader Bar

At least 3 lifting points Flat Nylon Straps Strap over nipple area at each end

Risk of kinking Damage to integral flotation

Hose Transportation – Dry Container Four hoses (20”x35ft) in one container

40-feet Dry Container

ADVANTAGES • Higher Frequency of Vessels • Easier and safer Transportation

Easy transportation to Customer’s Site

Installation

Hose Installation Connecting of hoses is recommended to be carried out on a jetty or a workboat.

Connecting the flanges, check the position of the gasket, then insert all of the bolts and tighten the nuts using an air-impact wrench. Then finish tightening all the nuts in a symmetric pattern using a torque-wrench under the values of torque on Table 1 and Table 2.

Hose Installation Hose connecting is in accordance with the applicable hose arrangement drawing. In case of double carcass hoses, to assist hose connections, the hose has an orange stripe parallel to the longitudinal axis of the hose and in line with the oil pot detector. The oil pot detector shall be located at the top of the hose.

After tightening flange bolts, the first hose hands into the sea by crane. And then the second and third hoses should be connected. Repeat in the same way.

Hose Installation Some hoses such as first off buoy hose (FOB), tanker rail hose (TRH) and so on has different ends. Connecting the hose, distinguish the right and left of the hose in accordance with the applicable hose arrangement drawing. The reinforced end of FOB, identified by a white circumferential line and bearing the words “REINFORCED END” should face SPM buoy and in case of TRH the side to be connected to a tanker is identified by a double white circumferential line and bearing the words “TANKER END”. Some hose has lifting lug(s) on the flange, the lifting lug should be located in accordance with the applicable hose arrangement drawing. Incase of TRH Lifting lugs on the tanker manifold side should be located at the top and the bottom Lifting lug on the connection to the Tail hose side should be located at the bottom. First Off Buoy hose

SPM buoy side

Tanker Rail Hose

Tanker Manifold side

Hose Installation End Gear

The tanker rail hose should be provided the end gear set which includes the butterfly valve, camlock with short spool piece, hang-off chains, pick-up chain, pick-up rope, small marker buoy and light weight blind flange. Pick-up chain should be connected to the pad eye of the taker rail hose.

Hose Installation Butterfly Valve The butterfly valve should be inserted between the flanges of the tanker rail hose and the spool piece of the camlock. The top position of the butterfly valve leans to 45 degrees of clockwise or anti-clockwise to be convenient operation. The butterfly valve has the directions such as the upstream side and the down streamside. The upstream side is identified by an arrow on the body of the valve. Lifting lug

Spool Piece If spool piece would be used between hose and hose it should be located in accordance with the applicable hose arrangement drawing. Lifting lugs be located at the top and the bottom.

Hose Installation Winker Light 1. Body shall be put between adaptors with bolt & nut. 2. Winker Light shall be set to the top side of flange with bolt & nut. Guard

Lantern

Body

Adaptor

Towing & Leakage Test

Towing Hose on Shore Towing with casters Do not drag on the ground

Casters

Towing to site - Avoiding premature sinking or damages

Blind flange with Towing Eye

Blind flange with Towing Eye Maximum towing speed 5 knots Floating Hose line

Full of air or water Additional support for hose parts with no integral flotation Subsea Hose line Full of air Blind flange with bleed valve

Additional flotation

Leakage Test The leakage test shall be conducted after connecting the flanges in order to confirm no leakage from the flange connections. The following is the procedure for the leakage test. (1) Blind flanges for the leakage test shall be provided to both ends of the hose string with pressure gauges. (Please note that the lightweight blind flange is not suitable for the leakage test.) (2) The hose string shall be elongate freely. And the butterfly valve should be opened during the test. (3) Fill with water, venting to remove all air, and apply a pressure of Maximum operating pressure. (4) Raise the pressure to the rated pressure and hold for 3 hours. (5) Before releasing the pressure, all flange connections shall be confirmed to be no leakage. (6) Release the pressure and water for the test should completely drain from the hose string for the towing.

Storage

Hose Storage Outdoor Storage

Indoor Storage Store in a cool, dark, dry area Store on steel pallets Wooden blanks at both ends

Cover to protect from Ozone and Sunlight (Temperature: -29oC to 60oC) Cover Sheet

Wooden Blanks

DO NOT Do not store close to equipment generating heat or Ozone

Do not store directly on ground

Hose Storage Laid out straight to avoid hose bending Use wide support to prevent deformation

Narrow Supports Permanent deformation caused by Narrow Supports

Visual Inspection

Periodic Inspection In-Situ Submarine Hose Lines

Frequent routine visual Frequency inspection outer surface, end fittings, & joints.

Items to check for

Others

Kink, Body Damage, Oil seepage, Heavy marine growth, Scuff. Check for any change in configuration.

Floating Hose Lines Visual inspection of outer surface of hose (especially the 1st off the buoy hose & tanker rail hose) prior to each loading operation. Damages caused by contact with vessels, crossed lines, Kinking, Oil seepage. Check for any change in line sinking.

Replace the hose having critical damage before operation.

Inspection Testing of Hoses on Shore Building up a database of wear, damage and failure frequency rates to establish retirement criteria and on-shore inspection & testing cycle Type of Hose

Initial Test Interval

Floating Hose Except T.R & F.O.B Hose

1 to 3 Years

Submarine Hose

1 to 3 Years

Tanker Rail Hose (T.R hose)

6 Months to 1 Year

First Off the Buoy Hose (F.O.B Hose)

6 Months to 1 Year OCIMF 1995 Section 4.5

Cleaning & Inspection of Hoses on Shore Inspection of Hoses on Shore Cover

Carcass

Cuts Gouges Tears Abraded spots

Crushed or Kinked areas Broken Reinforcement Permanent Distortion Longitudinal Ridges Bulges

Liner

Fittings

Blisters Cracks Bulges Excessive Corrosion Tube Separation Tear

Cover - Cleaning Marine Growth

After cleaning Hose

Marine Growth, Barnacle

Cover - Cleaning & Further Inspection Cleaning: To detect reinforcement or flotation damage, cuts, tears and abraded spots. almost as usual

Damage Before cleaning

After cleaning

Sharp object Small Cut

Outer Cover Aging Small cracks due to ozone and sunlight are not normally cause for retirement.

Deep cracks reaching breaker plies – Hose to be necessary checked details.

Damaged Cover of Submarine Hose - Retirement Criteria REPAIRABLE

Breaker

Cover

NON REPAIRABLE

Reinforcement Cord

Tube Lining

Helical steel Wire Exposed Helical steel Wire Scratches – No Exposed Breaker Plies

Damaged Reinforcement Cord

Breaker Plies Exposed Breaker Plies

Cord Damage

Oil Leakage

Damaged Cover of Floating Hose Retirement Criteria Cover

REPAIRABLE

NON REPAIRABLE Sponge

Reinforcement Cord

Base Hose

Tube Lining

Damage

Damage under Sponge

Scratch & Small Cut

Oil Leakage

Extensive Damage

Permanent Deformation on Helical Wire (Kinking)

NON REPAIRABLE

NON REPAIRABLE NON REPAIRABLE

Inner Liner Inspection - Bulge Minor defects: Re-examine bulge area during vacuum test Major defects: Retire Hose

h

Inside of Hose

H >15mm Retire Hose

W

Liner

Bulge

L

L×W > 30cm2 Retire Hose

NON REPAIRABLE

Inner Lining Inspection - Cracks Inside of Hose

NON REPAIRABLE Crack Cut

Lining Breaker

NON REPAIRABLE Cracks grow rapidly under bending during operation that will lead to oil leakage though the lining.

Examples of lining cracks

Inner Liner Inspection – Separation & Tear

NON REPAIRABLE

NON REPAIRABLE

Any separation (Hose should be retired)

Any tear reaching hose breaker layer (Hose should be retired)

Inner Liner Inspection – Gap & Step between Nipple End and Lining Lining

Nipple Nipple Gap

Nipple End

> 5mm RETIREMENT > 5mm RETIREMENT

Lining

Nipple End

> 5mm RETIREMENT

Nipple End

> 5mm RETIREMENT

Nipple

Step

Fitting Inspection - Corrosion Clean up and examine for cracks or excessive corrosion Inside of Fitting

RETIREMENT

RETIREMENT Excessive Corrosion influence nipple thickness (Hose should be retired) Deep tipping (Hose should be retired)

Excessive corrosion on flange face (Hose should be retired)

Testing

Pressure testing of Hose In-Situ Frequency of pressure testing in-situ ・ Every six months or more ・ After a very severe period of bad weather Pressure testing ・ Raising the internal pressure to the rated pressure or operating pressure plus 50%, whichever is lower. ・ Holding it for a period of 3 hours. ・ Visual Inspection : Oil seepage ・ Pressure stabilization ・ Leak detection system : Non activating (In case of Double Carcass Hose)

Testing of Hoses on Shore Type of Hose

Initial Test Interval

Floating Hose Except T.R & F.O.B Hose

1 to 3 Years

Submarine Hose

1 to 3 Years

Tanker Rail Hose (T.R hose)

6 Months to 1 Year

First Off the Buoy Hose (F.O.B Hose)

6 Months to 1 Year OCIMF 1995 Section 4.5

Building up a database of wear, damage and failure frequency rates to establish retirement criteria and on-shore testing cycle • Serial Number • Manufacturer • Type/Model • Size/Length • Delivery Date • Service Records • Test Data • Visual Inspection • Comments

Testing of Hoses on Shore - Hydrostatic Test Time - Pressure Diagram

Pressure

Rated Pressure

L2

½ Rated Pressure

L1

5 min.

L3

30 min. 5 min.

30 min.

Time

Temporary Elongation

L3 − L1 P .E . = L1

Permanent Elongation

L2 − L1 T .E . = L1

15 min. 5 min.

To be compared to original test

T . E . situ − T . E . factory ≥ 2%

P . E . situ − P . E . factory ≥ 2%

RETIREMENT

OCIMF 1995 Section 4.5.1

Hydrostatic Test Unit 3

1

2

PRESSURE HOSE

4 2

QUICK COUPLING FEMALE

QUICK COUPLING FEMALE

20000

SUCTION HOSE

3

3

WATER TANK

STRAINER

3000

2

6 7

7

SURPLUS HOSE

4 4

3000

HOSE

5

5 1

PUMP 5

CONNECTION PIPE WITH VALVE QUICK COUPLING(SUS) FEMALE VALVE

PRESSURE GAUGE WITH VALVE

6 6

VALVE

PF 3/4" FOR SURPLUS HOSE

740

100

1/2" QUICK COUPLING (SUS) MALE

PF 1" FOR SUCTION HOSE

500

1000

100

7

200

BLIND FLANGE FOR 16"

Testing of Hoses on Shore - Vacuum Test Test Requirements: A vacuum of 680 millibar for 10 minutes C-Clamp Vacuum Pump

RETIREMENT Separation RETIREMENT Clear Plastic Blind Flange

Inspect for & retire hose if any of the following is found: • Tear • Blisters • Cut • Bulges • Separation • Gouge

Tear OCIMF 1995 Section 4.5.3

Vacuum Test Unit 1

VACUUM PUMP

VACUUM GAGE 300

1

314

CLEAR PLASTIC BLIND FLANGE WITH SOFT GASKET

HOSE QUICK CONNECTOR MALE

HOSE

2

3

6

CLEAR PLASTIC BLIND FLANGES WITH SOFT GASKET

3

552

6

PIPE WITH CONNECTOR HOSE QUICK CONNECTOR MALE

SOFT GASKET

3

5

2

FLANGE CLAMP

VACUUM HOSE

QUICK CONNECTOR

QUICK CONNECTOR 2

FEMALE 6000

FEMALE

Testing of Hoses on Shore - Electrically Continuity Test Measure Electrical continuity to confirm hose satisfies original requirements Dim Light

Resistance < 25,000 ohms

Test Unit

Continuous Hose OCIMF 1995 Section 4.5.2

Test Lamp: (4 Volt, 0.3 Amp) Battery 4.5 V, Electrical cord

Discontinuous Hose 500 volt hand cranked Megger, Electrical cord

Electrically Continuity Test Unit Electrical Tester

Resistance Tester

Alligator Clip

Test Unit Assembly

Test Pin

Hose

Tester

Hose Repair

Hose Repair - Repair Kit

Repair Kit Wire Brush with Spare Wire for Roughing Surface of Rubber

SC4000 with Hardener Adhesive for Fabric Reinforced Rubber Sheet

Special Cement Primer for Compound (A+B)

Compound A (Black)+ B (White) For Filling Compound

Hand Roller For Pressing Rubber Sheet

Brush Coating

Measuring Cup For Mixing SC4000 and Hardener

Fabric Reinforced Rubber Sheet For Repairing Outer Cover Sponge For Repairing Sponge Wrapper For Wrapping Rubber Sheet

Repair Procedure (1)

Damage

Cut the outer cover around the damaged area with a knife.

Buff well the damaged area and adjacent area with a wire brush. Clean the buffed area with a solvent.

Repair Procedure (2) Mix Compound-A and Compound-B at a ratio of 1: 1.

Caution: Mix well and use within 2 hrs after mixing Apply two coats of Special Cement. Apply the second coat after the solvent in the first coat has evaporated.

Fill the damaged area with the mixed Compound and spread it approx. 5mm thick. Leave it for 3 days.

Repair Procedure (3) Mix SC4000 and Hardener at a ratio of 1000: 40 in measuring cup. (4% of total weight)

Take off plastic film covering green color side of the Rubber Sheet.

Apply two coats of mixed SC4000 over the mixed Compound (A+B) and Rubber Sheet. Allow the first coat dry completely for 30 minutes, and then apply the second coat.

Repair Procedure (4)

Put the rubber sheet over the area.

Press the Rubber Sheet firmly using the hand roller. Roll from the center to the edges so as to remove the air between the layers completely.

Apply the wrapper with maximum tension around the repaired area.

Hose Repair - Example (1) Cut on Outer Cover

Scratch on Outer Cover

Hose Repair - Example (2) Damaged Sponge Layer

Thank You for Your Attention ! Terima kasih atas perhatian Anda!