Revision 2.4 11/11/02

Flexible Hose ManagementGuidelines

Issue No. 1January 2003

Co-sponsored by

The Health and Safety Executive

The Institute of Petroleum

TABLE OF CONTENTS

FOREWORD...................................................................................................................................................4

ACKNOWLEDGEMENTS............................................................................................................................5

1.0 INTRODUCTION..............................................................................................................................61.1 Objective..............................................................................................................................................61.2 Scope....................................................................................................................................................61.3 Introduction..........................................................................................................................................61.4 Application...........................................................................................................................................61.5 Responsibilities....................................................................................................................................71.6 Personnel Competence.........................................................................................................................81.7 Definitions............................................................................................................................................9

2.0 LIFE CYCLE MODEL AND MANAGEMENT CONTROLS.................................................12

3.0 PERFORMANCE STANDARDS...................................................................................................15

4.0 CONCEPTUAL DESIGN................................................................................................................164.1 Objective............................................................................................................................................164.2 Use of A Flexible Hose......................................................................................................................164.2.1 Safety..................................................................................................................................................164.2.2 Vibration / Movement........................................................................................................................174.2.3 Misalignment......................................................................................................................................174.2.4 Remote Mounting...............................................................................................................................174.2.5 Temporary Applications.....................................................................................................................174.2.6 Degradation Issues.............................................................................................................................184.2.7 Applicability.......................................................................................................................................184.2.8 Life-cycle Analysis............................................................................................................................184.3 Consultation with Vendors.................................................................................................................18

5.0 RISK ANALYSIS.............................................................................................................................195.1 Objective............................................................................................................................................195.2 New Applications...............................................................................................................................195.3 Existing Flexible Hose Assemblies......................................................................................................195.4 Risk Evaluation Process.......................................................................................................................205.4.1 Method...............................................................................................................................................205.4.2 Actions following Risk Assessment...................................................................................................225.4.3. Recording...........................................................................................................................................23

6.0 DETAILED DESIGN.......................................................................................................................246.1 Objective............................................................................................................................................246.2 Background........................................................................................................................................246.3 Selection Guidelines...........................................................................................................................256.3.1 Responsibilities..................................................................................................................................256.4 Hose Length Calculations..................................................................................................................276.5 Certification........................................................................................................................................286.6 Marking..............................................................................................................................................29

7.0 CONSTRUCTION, INSTALLATION & COMMISSIONING...................................................30

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7.1 Objective............................................................................................................................................307.2 Storage and Transportation................................................................................................................307.2.1 Storage................................................................................................................................................307.2.2 Transportation....................................................................................................................................307.3 Installation..........................................................................................................................................307.3.1 Safe Handling of FHA’s.....................................................................................................................307.3.2 Installation of Flexible Hose Assemblies...........................................................................................317.3.2 Fixed Applications.............................................................................................................................327.3.3 Flexing Application............................................................................................................................337.4 FHA Routing......................................................................................................................................357.4.1 General...............................................................................................................................................357.5 Commissioning...................................................................................................................................37

8.0 OPERATIONS, MAINTENANCE, INSPECTION and TESTING............................................388.1 Objective............................................................................................................................................388.2 Tagging and Documentation..............................................................................................................388.3 Inspection Strategies..........................................................................................................................398.3.2 Inspection Criteria & Frequency........................................................................................................398.3.4 Inspection Documentation/Reporting................................................................................................418.4 Replacement Strategy.........................................................................................................................428.5 Rejection Criteria...............................................................................................................................428.5.2 Detailed Examination.........................................................................................................................438.6 Pressure Testing of Flexible Hose Assemblies..................................................................................44

9.0 MODIFICATIONS OR CHANGE OF SERVICE CONDITIONS.............................................459.1 Objective............................................................................................................................................459.2 Changing Conditions..........................................................................................................................459.3 Risk assessment..................................................................................................................................459.4 Change Control..................................................................................................................................459.5 Modifications.....................................................................................................................................45

10.0 DECOMMISSIONING....................................................................................................................4610.1 Objective............................................................................................................................................4610.2 Disposal..............................................................................................................................................4610.3 Transportation....................................................................................................................................4610.4 Change Control..................................................................................................................................4610.5 Partial Decommissioning...................................................................................................................46

11.0 REFERENCES.................................................................................................................................48

12.0 APPENDICES..................................................................................................................................49

Appendix 1 Personnel Competency Requirements..................................................................................51Appendix 2 Legal Requirements.................................................................................................................53Appendix 3 Human Factors Associated with Flexible Hose Assemblies.................................................55Appendix 4 Hose Construction..................................................................................................................58Appendix 5 Hose Failures...........................................................................................................................60Appendix 6 Hose Checklist...........................................................................................................................62

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FOREWORD

The purpose of these guidelines is to provide operators of Offshore Installations, Drilling Facilities and Onshore Plants with a reference framework of management, technical controls and procedures necessary to ensure the continued integrity of flexible hose assemblies throughout their lifecycle. These guidelines have been primarily written to address the needs of Offshore Installations operating in the UK Continental Shelf, but the principles may be widely applied to many onshore applications.

These guidelines provide an outline approach to lifecycle activities relating to these components, including management, and sets out issues to be considered, but does not provide a comprehensive check list or procedure nor state in detail how to design, operate or maintain Offshore Installations or Onshore Plants.

These guidelines provide the user with information to assist in the development of a robust technical solution. Economic issues are not necessarily addressed within this document and the user should use their own internal evaluation processes for the consideration of any economic factors.

It is considered that these guidelines will be of use to managers, design engineers, operators, technicians, contractors and consultants and all parties concerned with the safety and environmental issues associated with operating Offshore and Onshore facilities.

Although it is envisaged that the adoption of these guidelines will help to reduce the risk of incidents, the authors or publishers of this document cannot accept any responsibility of whatsoever kind for loss or damage or alleged loss or damage arising or otherwise occurring in or about premises, areas or facilities to which these guidelines have been applied.

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ACKNOWLEDGEMENTS

This guidance document was instigated by the Hydrocarbon Leak Reduction Committee of UKOOA and is supported by the Health and Safety Executive and the Institute of Petroleum. A small working group was formed to develop this document and to collate responses from the industry, hose suppliers and manufacturers.

We acknowledge the contributions made by all those involved in developing or reviewing this guidance document, and in particular, the members of the working group ( listed alphabetically ).

Ken Beattie Phoenix BeattieSteve Bowers MarathonRon Boyd Shell Expro ( Chairman )Michael Forster Amerada HessRon Hindmarch RAPRAColin Honeyman Hydrasun Rick Kirk Instrumentation Safety ServicesJohn Nairn WitzenmannAlan Thompson Health and Safety ExecutiveAlan Thomson Step Change in Safety

We wish to thank the manufacturers and suppliers for the use of their documentation and illustrations.

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1.0 INTRODUCTION

1.1 Objective

To ensure the integrity of Flexible Hose Assemblies ( FHA ) on Offshore Installations, Drilling Facilities and Onshore Plants is maintained throughout their lifecycle.

1.2 Scope

This document describes the engineering design, construction, operations, maintenance and inspection management controls necessary to ensure the continuing technical integrity of flexible hoses.

1.3 Introduction

Flexible Hose Assemblies are complex components used extensively for delivery of products or hydraulic power on a wide range of process, drilling and service/utility systems. Failures in their integrity can create hazards such as, leakage of flammable or toxic substances. Failures or potential defects can compromise the operation of safety and control systems and impact on the safety of personnel. In addition environmental burdens may be placed on management through pollution issues.

Flexible Hose Assemblies are often an integral part of pressurised systems carrying hydrocarbons (liquids and gases), high pressure water, chemicals, fuels, high-pressure power fluids and are also used in many Drilling / Well Engineering applications. Flexible hoses are also used extensively during bulk loading and unloading operations.

Effective management, in particular the assurance of personnel competency, is key to ensuring the quality of the whole lifecycle management of FHA’s. To ensure the integrity of Flexible Hose products, it is necessary to establish a performance based maintenance and inspection strategy in accordance with approved guidelines and inspection practices.

This guidance has been developed for all personnel involved in the lifecycle of FHA’s such as asset owners, manufacturers, vendors, etc. It will enable them to define safe technical solutions whilst satisfying regulatory obligations.

1.4 Application

This Guidance Document is applicable to Flexible Hoses and their accessories at all Offshore locations and its principles are similarly applicable at Onshore applications.

For guidance, the following hose service and types are typically covered by this document, (this list is not exhaustive and is included for information only);

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Service

Instrument Impulse hoses Hydraulic hoses Chemical transfer Bulk loading Hydrocarbon Process ( fluids and gases ) Compressed gases ( bottled gas installations ) High pressure fluids ( chemicals, water etc ) Temporary hoses ( including utilities ) Sampling hoses Steam hoses Packaged units ( e.g. drilling, generators, fire-pumps, cranes )

Type

The following types of hose are included in this guidance document;

Rubber construction – textile and wire reinforced Thermo-plastic constructions Stainless Steel Braided – without outer covers Convoluted ( metallic and non-metallic )

Exceptions

The following hoses are largely excluded from this document, as management systems already exist to ensure their integrity. However, where relevant, examples are used in the document as illustrations and it is considered that the guidance should be taken into account as appropriate when working with the following;

Proprietary hoses integral with vehicles Fire hoses Aviation fuel hoses Breathing apparatus hoses Offshore floating and submarine hoses, including large diameter cargo off-

loading hoses Subsea umbilicals Subsea jumpers Flexible Risers, flowlines and pipelines as defined in the Pipelines Safety

Regulations (PSR) 1996

1.5 Responsibilities

It is the responsibility of the Asset Owner in the offshore sector or the Duty Holder of an onshore installation to ensure that the maintenance and integrity management requirements of these guidelines are developed and implemented within the engineering design, construction, operations, maintenance and inspection process and other relevant management systems. The responsibilities include personnel competency assurance, the

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development, implementation and review of maintenance strategies and controls, the correct execution of the work and the appointment of responsible personnel.

1.6 Personnel Competence

The integrity of flexible FHA’s is very dependent on the correct selection of hose product and adherence to the installation procedures. Personnel competency is therefore a key issue and should be considered at all stages of the lifecycle.

The following strategy regarding personnel competence should be applied to ensure the integrity of FHA installations.

- All personnel required to install, inspect and maintain FHA’s should be formally authorised, and registered to do so and be fully conversant with the appropriate installation and maintenance procedures, failure criteria etc.

- All personnel required to test FHA’s should be formally authorised and registered to do so and be fully conversant with the relevant test procedure.

Refer to Appendix 1.

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1.7 Definitions

ALARP

As Low As Reasonably Practicable

Delivery Hose

A hose or FHA, which has a service duty to convey fluids or gases throughout its useful life.Examples would include, bulk handling systems, mud, rotary and utility hoses.

Flexible Hose Assembly ( FHA )

A complete hose with end fittings and any associated accessories.

HAZOP

A systematic review of an activity to identify the HAZardous OPerations

Hose

A flexible conduit normally of circular cross-section and usually have an inner lining, reinforcements and an outer cover.

Hose Assembly

A hose complete with end fittings and bonding wires (where relevant)

Hydraulic Power Hose

A hose, which has been designed to transmit hydraulic power from a source to an actuator.Examples would include hydraulic power hoses on cranes, valves, engines, and umbilicals.

LSA

Low Specific (radio)Activity

Minimum Bend Radius ( MBR )

The minimum radius of curvature, measured from the straight hose centre line ( or other manufacturer defined datum ), which the hose can tolerate without sustaining damage, distortion, excessive load or impaired performance.

Modification

A change in service or use from that for which the FHA was originally specified. Change may include function, internal environment, external environment, operating limits,

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installation arrangement, flowing versus static conditions etc. Replacement components must be fully matched ( like for like ) to the original specification in all respects ( including length ) if it is not to be regarded as a modification.

Temporary Flexible Hose Assembly.

A FHA, which is used for a specific short duration activity, and is covered by a local risk assessment and normally controlled by the Permit to Work system.

Temporary Equipment.

Equipment including packaged units hired from a supplier to carry out a specific short-term task. Hoses integral to packaged equipment are the responsibility of the Vendor who should provide current documentary evidence of hose condition.

Working Pressure

Maximum Working Pressure (MWP)

The maximum working pressure at any given temperature, confirmed by the manufacturer, to which the flexible hose assembly may be submitted.

Minimum Working Pressure ( Vacuum )

The minimum working pressure ( vacuum ) at any given temperature, confirmed by the manufacturer, to which the flexible hose assembly may be submitted.

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2.0 LIFE CYCLE MODEL AND MANAGEMENT CONTROLS

Figure 1 represents a model of the complete life cycle of a flexible hose assembly and provides the basis for design procedure and the retention of the design integrity. This document has been structured to comply with this format.

The user of this guidance document should be aware of all sections to enable the continuing integrity of FHA’s.

Table 1 summarises the key aspects of the safety management life cycle objectives and activities. For each component, the guidance sets out responsibilities, competencies, development of a maintenance and inspection strategy, documentation and reporting requirements to achieve lifecycle management.

The model is a simplified representation of many inter-dependant activities and does not attempt to fully depict the iterative nature of some of them.

The management controls in Table 1, are specific requirements necessary to ensure the integrity of the FHA’s over their life span.

The operations and maintenance element of the lifecycle is included for completeness and should be implemented by the operations and maintenance teams. However, the maintenance strategy may initially be developed in the detail design phase.

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Figure 1: Lifecycle management

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LIFE CYCLE PHASE OBJECTIVES / DELIVERABLES

ACTIVITIES DOCUMENTS

Conceptual DesignTo ensure that the use of a flexible hose assembly can be justified as the optimum technically safe solution, and that all lifecycle aspects are considered.

Safety assessment

Technical evaluation

Lifecycle cost analysis

Identification of alternative methods

These Guidelines

ISO 8331

Risk Analysis To identify and evaluate any risks posed by the use of FHA in any specific application, that the FHA’s are classified by risk category, and to ensure that risk reduction measures have been fully considered.

Risk assessment

Identification of opportunities for risk reduction

These Guidelines

Detailed Design Detailed design, material specification, operating conditions, procurement and storage.

Hose performance

Compatibility

Operating parameters

Procurement criteria

Certification

These Guidelines

ISO 8331

ISO 10380

Construction / Installation / Commissioning

To ensure that Flexible Hose Assemblies are transported, stored, installed to design, and that commissioning is satisfactorily completed.

Installation & testing

Storage and transportation

Hose routing

Commissioning

These Guidelines

ISO 8331

Operations, Maintenance, Inspection & Testing

Development of a Maintenance and Inspection Strategy for FHA’s. The strategy should ensure that Inspection frequencies align with the FHA criticality and risk assessment.

Tagging and documentation

Inspection strategy

Pressure Testing

Rejection criteria

These Guidelines

Modification To ensure that the integrity of FHA’s is retained both during and after modification or change of service conditions.

Risk analysis

Detailed design

Change management

These Guidelines

All of the above

Decommissioning The integrity of the FHA is retained during decommissioning

Risk analysis

Decommissioning/ Removal

Change management

Documentation and close-out

These Guidelines

Table 1 : Flexible Hose Assembly Safety Management Life Cycle Objectives and Activities

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3.0 PERFORMANCE STANDARDS Performance standards for Flexible Hose Assemblies are not normally required, but may be necessary, where a hazardous situation may arise or be intensified in the event of failure of a FHA. In some systems the FHA may be considered a critical component, which could compromise the safe operation of the entire system.

The requirement of a performance standard would normally be applied to the entire system, of which, the FHA is one contributory component. When quantifying risk, the normal procedure is to design out the hazard wherever practicable, therefore, demonstrating ALARP.

A typical performance standard for a system containing FHA may be required to specify the following;

- the role of the installation ( role statement )

- what the installation is required to do under stated circumstances ( functional specification )

- what integrity level is required in these circumstances ( integrity specification )

-any requirements for survivability after a major incident ( survivability specification )

Example;

The flexible hose assemblies used on a diesel fire pump to deliver cooling water should be assessed to ensure that they do not impact on the overall performance requirements of the fire pump. A maintenance and inspection strategy will have to be developed to ensure that the hoses are capable of delivering in all expected operational cases.

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4.0 CONCEPTUAL DESIGN

4.1 Objective.

To ensure that the use of a flexible hose assembly can be justified as the optimum technically safe solution, and that all lifecycle aspects are considered.

4.2 Use of A Flexible Hose

Due to the additional management controls required to ensure the safe continued operation of flexible hose assemblies, a full Risk Assessment, should be carried out to fully identify all the issues relating to a hose in any particular application and to justify the use of this component.

Where applicable, life cycle cost analysis should also be carried out using internal procedures.

NOTE: A flexible hose assembly should normally only be selected if fully justified considering the criteria set out in 4.2.1 – 4.2.8 and any other relevant criteria;

4.2.1 Safety

Consider the following issues, which have safety implications;

FHA’s should not be used where it is safer to install permanent pipe work / instrument tubing Appropriate fire rating of the application must be considered Compatible with the piping class of the system and the equipment design pressures and

temperatures. Compatible with the application, in particular FHA’s used in suction applications should be

capable of withstanding a negative pressure. FHA’s should only be used which have been assembled and tested by the vendor / competent

person and for which supporting documentation has been supplied. Hose assemblies will only be used for duties, for which they are approved, taking due

consideration of the environmental conditions in which the hose is to be used or stored. Dependant on the application, all metallic or conductive components may be required to be

electrically continuous and in some cases bonded to earth Hoses should be firmly attached to their end fittings by the hose manufacturer / approved

supplier. FHA’s should be adequately supported and installed to the manufacturer guidelines as

applicable and consistent with the best practice principles contained in this guidance document.

FHA’s should be identified with a suitable unique numbering system FHA’s should be installed, tested and inspected by competent personnel Length should be kept to a minimum, consistent with flexibility and required function. Internal and external effects of chemicals on all components associated with the FHA. Electrical continuity requirements must be considered.

4.2.2 Vibration / Movement

Flexible hose assemblies may eliminate the transmission of vibration or movement in a specific application.

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FHA’s will only efficiently eliminate the transmission of vibration, movement or noise if the adjacent pipe work is properly anchored on downstream side of the hose. In the worst cases, failure to ensure this can lead to uncontrolled movement of the FHA and premature failure.

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

4.2.3 Misalignment

FHA’s should not be used as a remedy for poor design or installation, e.g. to correct misalignment of rigid components.

4.2.4 Remote Mounting

When it is necessary to have instrumentation or other equipment mounted in convenient locations/ positions remote from the point of measurement, the use of FHA’s should only be considered if the movement couldn’t be safely achieved by alternative engineering solutions.

The use of hard pipe should be maximised. Therefore, the length of any flexible hose should be kept to the minimum, commensurate with proper installation, and should be adequately supported to prevent mechanical damage.

4.2.5 Temporary Applications

Flexible Hose may be used where it is necessary to carry out specific temporary tasks associated with normal process production, supported by a risk assessment i.e.:

process sampling process diversion to closed drain or vent connection of a process line to import or export point, e.g. boat or vehicle loading or

offloading

hydrotest hook-up for installed system testing

Flexible hose may also be used as a temporary method to transport fluids, after a suitable risk assessment has been completed, ensuring that the hose is correctly specified and tested for the application.

Hoses should be clean before use to prevent mixing of dissimilar chemicals within the hose, especially if the hose has been used in previous applications.

Where FHA’s are initially installed as a temporary arrangement, this should normally be for a pre-defined short period. If periods of use become extended, then the application should be subject to a critical review process. Use of temporary FHA’s for longer periods should be subjected to a risk review and a suitable permanent solution sought which demonstrates risks are ALARP. The change process should manage this.

It is incumbent on the user to ensure that the flexible hose assembly is fit for purpose prior to each application.

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4.2.6 Degradation Issues

Degradation of FHA’s can be accelerated due to heat, environmental conditions or contamination of the outer coverings and braids due to chemicals, ultraviolet light, ozone, salt, water etc. A competent corrosion engineer and the Manufacturer should be consulted as necessary, taking due regard to the predicted working environment, and fluid composition. It should be noted that the fluid composition could change over the expected lifecycle.

NOTE: Heat tracing and insulation can considerably accelerate any corrosion mechanisms

4.2.7 Applicability

Only if the hose application can demonstrate risks are ALARP, and a suitable hose is available, that meets all the functional specifications, may a hose then be used. Otherwise, an alternative engineering solution should be applied.

4.2.8 Life-cycle Analysis

It is incumbent on the user to assess if an economic evaluation is required. If considered applicable, prior to using Flexible Hoses for a specific application, the following may be considered to enable a total lifecycle cost to be calculated;

(a) Cost of using a FHA alternative against existing accepted materials and methods (e.g. rigid pipe work)

(b) Cost savings derived by quicker installation by using a FHA..

(c) Cost of an ongoing maintenance and inspection programme for FHA in comparison with existing maintenance.

(d) Increase or reduction in risk ( see Section 5.4 )

(e) Potential cost associated with FHA failure

4.3 Consultation with Vendors

Having carried out a conceptual design study to clearly specify the full service conditions expected, the input and support of FHA suppliers or vendors should be solicited to ensure that they tender and supply FHA’s with the capability of delivering throughout the service life. Failure to provide the vendors with a full operational specification could result in a sub-optimal, or inappropriate hose being supplied.

See section 6.3 for additional information.

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5.0 RISK ANALYSIS

5.1 Objective

To identify and evaluate any risks posed by the use of FHA in any specific application, that the FHA’s are classified by risk category, and to ensure that risk reduction measures have been fully considered.

FHA’s are used to transmit power or convey fluids that may have toxic, corrosive or potentially explosive properties, in most cases at elevated pressures. Failure of hoses poses a potentially serious threat to the safety of personnel, damage to the process plant and harmful impact to the environment if loss of containment occurs. Therefore, a robust risk assessment is required.

5.2 New Applications

All new FHA applications should be assessed to ensure that all risks associated with the component have been identified using an appropriate risk evaluation technique. For new applications, this should ideally be carried out during the project HAZOP phase. Where FHA’s are required as new applications on existing plant, assessment may be carried out exclusively on the FHA’s, taking account of the impact on the operating system in its entirety. Competent personnel should perform the risk assessment with expertise in typically the following areas;

Process control / engineering Production operations Corrosion management Production chemistry ( as required ) Piping Maintenance / Inspection Technical safety

A formal Risk Assessment will;

remove uncertainties regarding the safety integrity and cost effectiveness ensure that designs are to a suitable technical standard. form a basis for maintenance strategies such as inspection frequencies provide an audit trail

If a FHA has been identified as the optimum technical solution based on Section 4, then, it should be classified as detailed in section 5.4.

5.3 Existing Flexible Hose Assemblies

It is recommended that all existing hoses currently in service should be assessed in accordance with the risk evaluation process detailed in section 5.4 and the results recorded.

5.4 Risk Evaluation Process

Each FHA should be classified based on the consequence of failure. The following outlines a method that can be used to apply a structured approach to evaluating risks derived from using FHA’s in potentially hazardous services.

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5.4.1 Method

Assess each FHA application against the criteria detailed below and plot the resultant position on Table 4. If doubt exists between hose classes, then the higher class should be selected. For example, if failure of the FHA could have consequences affecting both Production & Equipment (L) and Environmental Impact (E), the higher class rating resulting from plotting each consequence against human potential injury (S) should be used to select class. The resultant classification should be recorded and used to determine the maintenance & inspection strategy as defined in Section 8

To assist in this risk assessment process the following guidelines on interpretation of personnel safety, production and environmental consequences should be used.

1. Potential extent of human injury if the hose fails, taking into account the duration that personnel are in the location;

S0 = No injuryS1 = Slight Injury, non-permanentS2 = Severe injury, death of one personS3 = Several fatalities (2-10 fatalities)S4 = Catastrophe, multiple fatalities (> 10 fatalities)

2. Potential production and equipment loss if the hose fails

L0 = No operational upset, no damage to equipmentL1 = Minor operational upset, minor damage to equipmentL2 = Moderate operational upset, moderate damage to equipmentL3 = Major operational upset, major damage to equipmentL4 = Damage to essential equipment causing major operational loss

major loss of containment

For guidance the following table identifies assumptions used in this guide for defining production and equipment loss.

Production and equipment loss

Consequence Factor (L)

Cost (Replacement of equipment and production loss)

Additional Guidance

L0 < £1K < 3 hour production lossL1 £1K - £100K Up to 3 hours lost productionL2 £100K - £1M Up to 1 days lost productionL3 £1M - £10M Spared equipment that will reduce

production by 30% or production loss up to 10 days

L4 > £10M Non spared equipment essential to production or loss of production > 10 days

Table 2 : Production and Equipment loss estimations

3. Potential environmental consequences

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For guidance the following table identifies assumptions used in this guide in defining Environmental Consequence Factors E0 – E4 based on offshore environmental releases.( Alternative onshore criteria may be substituted for Onshore releases as applicable ).

The Control of Major Hazard Regulations (1999) (COMAH) applies to many onshore major hazard installations. The regulations specify criteria for reporting major incidents to the European Union which could provide a basis for defining consequence factors for injuries to persons, property damage, and damage to the environment.

E0 = No release or release with negligible damage to environmentE1 = Release with minor damage to the environment which should be reportedE2 = Release with significant damage to the environmentE3 = Release with temporary major damage to the environmentE4 = Release with permanent damage to the environment

Environmental Consequence Factor

(E)

Release of Oil, Fuel, NGLs, Drilling Fluids or Gas

E1 Liquids < 1 tonne, <7.5 bbl, < 1 m3

Gas < 0.04 mln scf, < 0.001 M m3

E2 Liquids 1 – 100 tonnes, 7.5-750 bbls, 1 – 100 m3

Gas 0.04 – 4 M scf, 0.001 – 0.1 M m3 (st)

E3 Liquids 100 – 1000 tonnes, 750-7500 bbls, 100 – 1000 m3

Gas 4 – 40 M scf, 0.1 – 1 M m3 (st)

E4 Liquids > 1000 tonnes, > 7500 bbls, > 100 m3

Gas > 40 M scf, >1 M m3 (st)

Table 3 : Environmental Consequences (st) = standard conditions(scf) = standard cubic feet

Note that E2 is approximately equivalent to the amount of gas from the blowdown of a large oil/gas installation in the Northern North Sea. 20Kg/s for 1000 seconds = approximately 20000 m3 (st)

The Environmental impact of any chemical that could be released should be taken into consideration using factors such as its toxicity and release quantity.

Hose Classification Table

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Table 4: Flexible Hose Assembly risk classification

5.4.2 Actions following Risk Assessment

The hose classification derived by applying the risk assessment method will enable the appropriateness of the FHA to be determined, and whether any additional risk reduction measures are required. Where possible, lower Class applications should be sought to demonstrate ALARP.

NOTE: Class 5 FHA’s:

Other than in exceptional or specialised circumstances any FHA in existing plant, which has been assessed as Class 5, should be removed from service immediately, and an alternative method sought which demonstrates risks are ALARP.

During new plant design, proposed hoses assessed as Class 5 should not be used and an alternative solution sought which demonstrates risks are ALARP.

Where exceptionally a FHA is demonstrated to be the technically superior and safest solution, a rigorous monitoring and testing regime is required to ensure integrity. ( Section 8.3 )

Class 4 Hoses:

It is recommended that any existing hose, which has been assessed as Class 4, should preferably be withdrawn from service and be subject to a detailed challenge process to identify a suitable alternative method, which demonstrates risks are ALARP. Alternatively, a rigorous monitoring and testing regime is required to ensure integrity. (Section 8.3)

It is recommended that FHA’s assessed as Class 4 for use in new installations should not be used and an alternative solution sought which demonstrates risks are ALARP. Where exceptionally, a FHA is demonstrated to be the technically superior and safest solution, a rigorous monitoring and testing regime are required to ensure integrity is maintained. ( Section 8.3 ).

5.4.3. Recording.

The resultant classification should be documented against the relevant FHA tag number in the hose database, where applicable. ( See Section 8.2 )

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6.0 DETAILED DESIGN

6.1 Objective.

To ensure that the design achieves the required performance criteria by application of sound engineering practice, appropriate material procurement and the development of lifecycle strategies.

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6.2 Background.

In order to optimise the service life of a hose it is important that all the interested parties; user, manufacturer, buyer and distributor, agree on the full specification, expected life and working conditions of any hose being considered; it is not reasonable for one party to take responsibility for, or to dictate to the others. The general requirements for a hose are as follows:

a) able to meet and be resistant to all the expected service conditions;

b) manufactured to a standard so that no early failures occur;

c) robust so that no random unexpected failures occur;

d) able to meet a predicted and agreed service life and

e) competitive in price with equivalent products.

With regard to resistance to the service conditions the manufacturer has to know the products being carried, pressures and temperatures with possible excursions outside the basic ‘envelope’.

To gain this the buyer and user must communicate so that all relevant information is given otherwise the material choice for the lining, in particular, may not be adequate for the application and service life may then not be achieved.

Early service failures of any product are usually attributable to manufacturing faults. It is therefore essential that the manufacturer not only provides a valid design for the hose but also maintains a consistently high standard of production so that faults in manufacturing do not occur.

Some service conditions are onerous e.g. in North Sea oil and gas operations. It is important here that external elements of weather, abrasion or fluid spillage do not adversely affect the protective properties of the outer cover. The manufacturer has therefore to choose carefully the cover compound and the thickness to mitigate against these operational requirements.

It is in the ‘useful life’ of the hose that random failures occur. With hoses these typically arise from ‘abuse’ e.g. abraded cover not repaired; inappropriate storage conditions, insufficient inspection, and hose not installed correctly. A healthcare programme would require a very regular inspection by competent inspectors who are well acquainted with hose problems. The inspector should advise, remedy or change out so that unexpected failures would be avoided.

Finally, the agreed service life, established by laboratory or long term testing, must be adhered to with hoses taken out of service as soon as that period has elapsed. It should be understood that this is a “notional service life “ which could be reduced by service conditions ( see Section 8.3.2 )

It is incumbent on the FHA manufacturers and vendors to supply their products to recognised International Standards that are able to perform in the specified service conditions. It is not the responsibility of the user to define materials and construction to the manufacturer or vendor, but rather to ensure that all service conditions likely to be encountered are specified.

The following selection guidelines should be used as a checklist for the provision of a detailed specification to the FHA manufacturer or supplier.

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6.3 Selection Guidelines

6.3.1 Responsibilities

When evaluating the performance and safe operational requirements of a FHA, it is important that a dialogue is established between the Manufacturer/Vendor and the prospective customer. FHA’s should be chosen for their suitability with the proposed service conditions, by means such as;

(a) Referring to a manufacturers compatibility chart, (b) Consulting with the manufacturers or vendors representative.(c) Consultation with a material specialist and/or relevant engineering documents.

The initial parameters are illustrated in Figure 2.

The following parameters should be considered prior to selection:

Customers Responsibility Manufacturer / Vendor Responsibility

Media to be carried Defines fluid composition and phase for all foreseeable operating modes

Ensures compatibility of all components

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Dialogue

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

Ensures compatibility of all components with all specified fluids.

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

Defines construction requirements and hose bore size

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

Ensures compatibility of all components with specified range

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

Ensures compatibility of all components with specified range

Installation Geometry Provide details of the proposed geometry

Assess geometry and advise customer on feasibility, including lengthening, torsion etc

Flexibility Ensures the Flexible Hose Assembly is installed as per Manufacturers /Vendors recommendations.

Advises minimum bend radius and other installation limitations ( e.g. creep )

Weight Ensures the Flexible Hose Assembly is installed as per Manufacturers /Vendors recommendations.

Defines weight and support requirements

Volumetric expansion Ensures the Flexible Hose Assembly is installed as per Manufacturers /Vendors recommendations.

Advises expansion performance and installation requirements based on specified function and hose properties.

Earth bonding Defines requirements Ensures electrical continuity of all componentsFire rating Defines requirements Ensures compatibility of all components or

advises on fire resistancePiping class Defines materials and pipe rating of

connecting pipework or equipment.Ensures compatibility of all components with connected system

Erosion and abrasion requirements

Ensures the Flexible Hose Assembly is installed as per Manufacturers /Vendors recommendations.

Ensures compatibility of all components

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

Ensures compatibility of all components

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

Ensures other measures are compatible or advises user of consequences.

Figure 2 : Customer / Manufacturer / Vendor Interfaces

6.4 Hose Length Calculations

In the majority of installations a hose is required to have at least one bend in its length. It is essential that to obtain maximum expected life from a hose assembly, undue tension at the end fittings due to bending must be avoided. The following information is intended to provide a guide to ensure that the correct hose length is calculated for both static and flexing conditions.

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To avoid tension on end fittings a short length of straight hose is required at each end of the unit so that the bend starts away from the end fitting.

When establishing optimum FHA length, the following factors should be considered; motion absorption, flexible hose length due to pressure, hose and machining tolerances.

The following figures explain how the optimal hose length should be calculated.

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The hose immediately adjoining the coupling should remain un-flexed for a length at each side of not less than 6 times the outside diameter of the hose.

The formula for calculating the effective length of the hose assembly is;

L = 2A + B + C + R

Where;

R = minimum bend radiusA = 6 x O.D.B / C = Effective length of attached coupling

L = Overall Length

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Extra length needs to be added to the hose to allow for the flexing operation, therefore the extra length of the hose to be allowed in assembly = M

The formula for calculating the assembly length is

L = 2A + B + C + R + M

6.5 Certification

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

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

Fire rating

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6.6 Marking

End fittings should be marked as specified for fittings and flanges, with the addition of the manufacturers name and figure number for proprietary hose couplings. Threaded connections should be marked with the thread form.

FHA’s should have at least the following markings;

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

7.0 CONSTRUCTION, INSTALLATION & COMMISSIONING

7.1 Objective

To ensure that Flexible Hose Assemblies are transported, stored, installed to design, and that commissioning is satisfactorily completed.

7.2 Storage and Transportation

7.2.1 Storage

All FHA should be stored in clean dry conditions and hoses of rubber and composite construction should be kept in a cool atmosphere protected from direct sunlight. Some hose linings, if not protected prior to putting into service, have a finite shelf life. This should be considered prior to use. New hoses should be issued on a first in first out basis to minimise deterioration in storage

FHA, except when supplied in coiled lengths, should be laid out straight and flat and supported along their length to prevent flattening, kinking or twisting. Other equipment should not be stored on top of hoses.

Coiled FHA’s should be end sealed to prevent ozone attack in storage.

7.2.2 Transportation

Individual hose wrapping should be used to protect braided FHA’s without outer protection from damage in transit.

7.3 Installation

7.3.1 Safe Handling of FHA’s

FHA’s should always be handled with reasonable care, and should not be subjected to over-straining. The design of hose supports and saddles should be designed to ensure minimum bend radius is not compromised. Single rope slings and wires are not suitable for many support applications since they can lead to local kinking, abrasion or non-compliance with minimum bend radius requirements.

FHA’s should never be forcefully deformed, crushed, twisted or subject to flow shut off by kinking.

Avoid routing or dragging FHA’s over sharp or abrasive surfaces.

FHA’s should not be allowed to hang between equipment, or between vessels, plant and installations or flotels that can move and cause the FHA to become over-bent or trapped.

7.3.2 Installation of Flexible Hose Assemblies

When designing equipment where FHA is to be used, it is important to consider whether the hose is to be used in static or flexing conditions.

The following points should be noted when planning an installation;

(a) It is essential that the mating couplings are completely free from foreign matter, burrs etc. and are otherwise in sound condition.

Damage, corrosion or contamination to the mating surfaces will cause joint failure in service.

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

(c) Union nuts should be hand tightened at both ends and the hose allowed to adopt its natural position prior to tightening.

Excessive force should not be applied when tightening end connections i.e., long handled spanners/wrenches should not be used. Correct tools should always be used which will not cause damage that could then lead to degradation or failure.

(d) FHA should not be installed in a twisted condition, since this puts unbalanced tension on the hose and reduces the working life of the assembly.

The single or double line indicating the wire braiding strips serve as a guide, (or Manufacturers specific marking system), for installing FHA’s correctly.

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

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

(g) The FHA should not be installed in applications where torsion of the hose could occur. This can cause the hose to be subjected to shear stresses for which it is not designed and can result in premature failure. ( See Figure 3 )

Figure 3 : Hose Torsion

7.3.2 Fixed Applications

a) Sufficient slack hose should be provided to compensate for any contraction in length, (when subjected to pressure, braided hose may reduce in length). Clamps of the correct size should be used to support the FHA where necessary. ( See figure 4 )

Figure 4 : Hose Length

b) Excessive hose lengths should not be used, since this often results in the FHA being severely bent into confined spaces. ( See figure 5 )

Figure 5 : Excessive hose length

c) Should there be a risk of abrasion to the FHA from rough or sharp edges, moving parts etc. FHA should be re-routed or clamps used where necessary to keep it clear from the obstruction.

d) Where sharp changes in direction are required, elbow couplings should be used, as this avoids space congestion and does not stress the assembly. ( See figure 6 )

Figure 6 : Use of elbow couplings.

7.3.3 Flexing Application

(a) Sufficient FHA length should be allowed to permit required movement. ( See figure 7 )

Figure 7 : Flexing applications

(b) FHA’s should not be bent to less than its minimum bend radius at any point during flexing.( See figure 8 )

Figure 8 : Minimum bend radius

c) Avoid hose bends in two planes whenever possible. Where this is impossible the use of clamps should be employed. ( See figure 9 & 10 )

Figure 9 : Bends in two planes

Figure 10 : Bends in two planes

7.4 FHA Routing

7.4.1 General

FHA routing should have a good appearance, since this will probably ensure good technical installation, better service functionality, use of less hose, fewer connections and fewer potential leak sources.

(a) Route FHA’s in straight lines following the contours of the equipment on which they are used.

(b) Use brackets and clamps to secure them in position and to prevent excessive rubbing and abrasion, whilst still allowing the intended movement of the hose.

(c) Use FHA’s of the correct length.

(d) Use elbow couplings to provide more direct routing thus reducing the overall length and associated bends in the system.

(e) Consider the effects of mechanical loads, such as twisting, kinking, tensile or side loads, bend radius and vibration, which can significantly reduce FHA life. Use of swivel type adaptors may be required to ensure that no twist is put into the hose during installation. Unusual applications may require a special test program prior to final FHA selection.

(f) Avoid routing hoses ( especially temporary hoses ) where they would introduce additional hazards. Hoses laid across walkways or traffic routes pose tripping hazards and damage could occur to the hose. If such routing is unavoidable, particular care needs to be paid to the impact on Emergency Escape Routes or necessary emergency mitigation measures. Hoses

containing flammable or toxic materials should not be routed through safe areas.

7.4.2 Minimum Bend Radius (MBR)

When a hose line is installed into an arrangement where it will be bent, the recommended minimum bend radius must not be compromised.

Bending beyond the limits of the minimum bend radius is a problem often encountered during flexing applications. Over bending can lead to damage to one or more of the hose construction layers, flow impairment due to kinking, general overstress to hose and/or fittings. It should be noted that for some hose types, over bending could damage the hose (e.g. deformed wire reinforcement) even though there is no outward appearance of this. Caution is also needed therefore in the handling of hose prior to installation. Enough hose should be provided to allow for a movement. Fittings are not a flexible part of the assembly and continuous flexing of a short hose assembly can tend to wear the hose at the point of connection with the fitting.

MBR is normally expressed as a ratio of bending radius v. hose diameter and is measured from the hose centre line.

7.4.3 Bends & Clamps

To prevent twisting, the hose should be bent in the same plane as the motion of the item to which it is connected. This cannot be achieved in a situation where a flexing hose is bent in intersecting but different planes. At least one bend will be in the wrong plane and the hose will tend to twist. To correct this the intersecting planes can be separated by using a longer hose length with a clamp positioned at the point where the planes change. Care must be taken to ensure that there is sufficient hose length in the flexing portion of the hose to allow the intended movement. In effect the clamp serves to divide the hose into two assemblies. Provided the section of hose is bent in the same plane as the movement, the bend will absorb the movement and the hose will not twist.

7.4.4 Abrasion

Abrasion is a problem encountered in hose installations, constant abrasion at the same point on a hose may wear through the outer cover and weaken the reinforcement to point of failure.

Abrasion is caused by contact with sharp edges, contact with moving parts, overlapping of hoses and the improper use of clamps.

To avoid contact with sharp edges, or contact with moving parts, clamps can sometimes be moved to different locations or attached to different points to move hoses away from the abrasion area. Note: Any change in clamping arrangement should be assessed as part of a formal design change procedure before implementation.

7.4.5 Temperature

Exposure to high ambient and service temperatures can drastically shorten the hose life by affecting the outer cover and weakening the reinforcement. Hose line should be routed away

from hot manifolds or other high outside temperature sources whenever possible. If this is not practical, a protective sleeve or baffle plate should be installed for protection.

Low ambient or service temperatures can impair the flexibility of the hose.

7.5 CommissioningThe technical requirements for commissioning, (ranging from pre-installation checking through to commissioning of various types of mechanical equipment and associated systems) or recommissioning, are dealt with in the subsequent sections under the headings listed below;

7.5.1 Cleaning & Flushing

All components used in a system should be cleaned and flushed prior to use, to prevent debris being carried to other parts of the system and causing damage.

7.5.2 Pressure Testing

The preferred method of pressure testing ( see section 8.5 ) should be identified, to demonstrate the integrity of the system prior to the introduction of any process fluids.

Owing to their complex compound structure 'Composite Flexible Pipes' demonstrate unusual structural characteristics when being hydrostatically tested. Very slight growth, brought about by relative movement of the various circumferential layers comprising the pipe, takes place with respect to time, producing a distinct pressure time decay trend.

The volume of test fluid added to maintain test pressure should be accurately measured to differentiate 'Composite Flexible Pipes’ characteristics from genuine leakage. Detailed information should be obtained from the relevant manufacturer or vendor.

7.5.3 Electrical

The installation should be checked for electrical continuity or earthing if applicable.

7.5.4 Loss of Containment

Care should be exercised during commissioning activities, in particular with personnel working in close proximity to un-tested joints, or joints that have been previously disturbed.

A risk assessment should be carried out prior to commencing commissioning activities to ensure mitigating actions are in place and that all relevant personnel are fully conversant with the activities to be performed.

8.0 OPERATIONS, MAINTENANCE, INSPECTION and TESTING

8.1 Objective

Development of a Maintenance and Inspection Strategy for FHA’s using these guidelines or other equivalent basis. The strategy should ensure that Inspection frequencies align with the FHA criticality and risk assessment.

8.2 Tagging and Documentation

The inspection and maintenance strategy developed in accordance with section 8.3 below should be documented and retained current. It is recommended that historical inspection and failure data be recorded in a structured format to allow ready retrieval, as this will influence the inspection and maintenance strategies.

A complete register of FHA’s installed at any Installation should be created and kept current. This should also include any temporary hoses brought onto the Installation for specific activities e.g. shutdowns. Vendors supplying packaged units should supply current test certificates for any hoses installed on their equipment, or used to connect to Installation/Plant services.

A suitably competent person should be nominated at each location to be responsible for maintaining the hose register. It is recommended that the register should reside within the locations Maintenance Management System.

The register should as a minimum record the following information:

Unique Identification Number Year of manufacture Length Internal diameter End connections Location Service Criticality rating Type of hose Date of last inspection Date of next inspection Status at last inspection ( i.e. satisfactory, scrapped etc ) Latest replacement date

Each FHA should be identified with a unique number applied to the hose. Care should be taken to ensure that the tag or it’s fixing, does not promote a local corrosion site, or create a site for chafing or cutting the hose surface under operating conditions. The tag should align the hose with the register.

8.3 Inspection Strategies

8.3.1 Strategy

A strategy should be applied jointly by the inspection and maintenance authorities to ensure the integrity of FHA’s and associated fittings installed on critical services such as flammable or toxic fluids, high pressure water, chemical and high pressure fluid power systems.

The preferred strategy should include routine replacement of FHA’s with a new certified assembly where any doubt of the FHA condition or history exists. Otherwise the design life defines the replacement date.

The responsibilities for implementing the requirements of this document are detailed below:

It is the responsibility of a competent person e.g. the Head of Maintenance or the Plant/Installation Senior Maintenance Engineer, to ensure that a risk assessment has been carried out ( see Section 5.0 ) and that the following criteria are met:

- FHA’s are classified as applicable. ( Section 5.4 and Table 4 )

- All FHA’s are recorded in a centralised register

- Periodic inspection routines are in place and reviewed routinely in consultation with the Inspection Department.

- The maintenance strategy is reviewed periodically.

- Only authorised, competent personnel are permitted to install, inspect and maintain flexible hose lines.

- Accurate informative records are kept. ( Section 8.2 )

8.3.2 Inspection Criteria & Frequency

The inspection frequency and criteria should be developed from the risk assessment derived from the classification system in Section 5.4.

The expected rate of degradation and the nature of the contents should govern the frequency and type of inspection of registered systems. This implies a local judgement and in this regard note should also be taken of the history to date and of the associated scale of activities. Inspection and replacement cycles are based on a bandwidth, and therefore, providing sufficient documentation exists local judgement should be used to identify the frequency within the band limits. Consultation may be made with the appropriate manufacturer/vendor.

The factors to be considered include:

(a) Deterioration rates based on knowledge and experience with the actual FHA, or with the process or materials of construction on similar systems.

(b) Materials, method of construction and sophistication of design generally, including novel or unusual features.

(c) Support, expansion, contraction characteristics with changes in temperature.

(d) Line contents at a temperature in excess of the atmospheric boiling point (note also cryogenic materials).

(e) Line contents in excess of their auto ignition temperature.

(f) Line contents, which include toxic or corrosive material.

NOTE: In service, FHA’s are subjected to a wide variety of conditions dependent on the equipment and environment and overall, a general estimate of hose life is not possible. Consequently it can only be recommended that records be kept with a view to establishing a working life for each application.

For guidance Table 5 may be utilised to determine Inspection frequency. However, users have a responsibility to ensure that inspection periods take full account of actual service conditions and operating history for each FHA and consequence of failure, which may change the general recommendations contained in this table. Manufacturers advice should be taken into account as appropriate. Use of inspection frequencies significantly in excess of manufacturers recommendations should be critically reviewed and justified by the user.

Flexible Hose Inspection Frequency Recommendations

Table 5: Inspection Frequencies

NOTE; * Maximum frequencies as detailed in Table 5, can only be achieved if justified by sufficient historical evidence of the hose condition. Asset Teams should inspect and replace hoses more frequently if abnormal failure rates are detected.

Temporary Hoses.

All FHA’s in temporary service should be inspected and tested before use and regularly monitored during service.

In general temporary FHA’s should be inspected on a regular on-going basis, as recommended in these guidelines. The frequency and degree of the inspection should follow the guidelines.

Periodical Visual Inspection

Visual inspection of the hose body for cuts, kinks, bulges, signs of abrasion, corrosion products etc. Particular attention should be focused close to the end fitting for signs of over-bending. Visual inspection should also be carried out on hose connections, including any static half coupling to which the hose is to be connected.

A competent person should carry out the inspection. The observations should be logged.

The interval between inspections is dependent upon criticality of service, environment the FHA is operating in, consequence of failure and hose use (service duration)

8.3.3 Inspection

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

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

FHA’s should be physically located and visually examined for defects, see Section 8.5.

8.3.4 Inspection Documentation/Reporting

Inspection results should be recorded according to company and/or local site arrangements and would typically comprise;

Raise Job Card ( as applicable ) to local site procedures for remedial/correcting action for defective FHA’s.

An Inspection Field Summary Report should typically be raised detailing defects and any issues of immediate concern, and submitted to the local responsible person for action.

An Inspection Technical/Close Out Report should be raised detailing the overall inspection. This would typically include recommendations to alleviate problems or defects found and contain the register of the FHA’s inspected in the form of data sheets or drawings.

8.4 Replacement Strategy

Where it is considered uneconomic or excessive plant downtime would occur, a replacement strategy can be adopted where the FHA is exchanged on a like-for-like basis. The hose register should be consulted to identify if any common mode failures are occurring. Root cause analysis should be carried out to identify the failure mechanism. This strategy should only be adopted where it does not increase risk.

Should an alternative FHA be selected, this constitutes a modification and a full risk analysis should be carried out with reference to sections 5.0. and 9.0 of this document

8.5 Rejection Criteria

As a guide, the FHA should be rejected and removed from service under the class dependant failure conditions given in Table 6. FHA’s displaying developing signs of these criteria, but judged not yet to warrant replacement might require increased frequency of monitoring to provide assurance against unacceptable degradation.

8.5.1 Installation Geometry

Initially the FHA should be visually inspected for the installation geometry;

Defect Action

Over bending Reject if less than minimum bend radius

Axial extension Reject

Axial compression Reject

Clashes or rubbing Investigate and eliminate

Induced torsion Reject

Table 6 : Visual Examination - Installation geometry

The first four of the above defects are all the result of either a flexible hose assembly of the wrong length for the installation, or of a poor design.

Induced torsion is normally due to poor installation practices or of a poor design where torsion is induced into the hose during movement.

8.5.2 Detailed Examination

This is followed by a more detailed examination of the flexible hose assembly as detailed in Table 7.

Defect found Acceptable Levels

Class 1 Class 2 Class 3 or 4 Class 5

End fitting corrosion Moderate – not affecting safe function

Slight – not affecting safe function

Not permitted Not permitted

Bulged braid at fitting≤ 10% of hose diameter

≤ 5% of hose diameter

Not permitted Not permitted

Braid damage Slight dents or local disruption of pattern

Slight dents Not permitted Not permitted

Broken braid wires≤ 10% of total number – evenly distributed – and with no more than 2 in any one carrier

≤ 5% of total number – evenly distributed – and with no more than 2 in any one carrier

Not more than 5 wires in total and not more than 1 in any one carrier

Not permitted

Visible leakageNot permitted Not permitted Not permitted Not permitted

Lack of electrical continuity

Not permitted Not permitted Not permitted Not permitted

Excessive hardening or softening of the hose ( aging )

Not permitted Not permitted Not permitted Not permitted

Excessive cuts, blisters, kinks, abrasion, mechanical damage, elongation under test

Not permitted subject to judgement on extent and consequence of failure

Not permitted subject to judgement on extent and consequence of failure

Not permitted Not permitted

Table 7 : Rejection Criteria

NOTE :

If any doubt exists on the integrity of the flexible hose assembly, then it should be replaced as soon as possible, regardless of the criteria in Tables 6 or 7.

8.6 Pressure Testing of Flexible Hose Assemblies

If it has been agreed that a pressure test is to be used to assess the integrity of a FHA, then, in-situ pressure testing can be performed to verify the integrity of the complete assembly. The test pressure should be 110% of the design working pressure unless the hose remains connected to a system protected by a relief valve, in this case 95% design pressure should be used.

Reference should be made to any relevant local Safety Codes of Practice.

Personnel involved with the control of pressure testing must be aware of the hazards associated with, and experienced in the procedures and precautions required when, pressure testing any equipment.

Personnel involved in testing activities of any kind shall be experienced in pressure testing procedures and shall be fully conversant with the specific requirements, precautions and procedures specified for relevant tests.

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

Operators and duty holders should quantify the acceptable leakage criteria for a particular installation by assessment of it’s hazard potential, taking into account local factors such as joint location, toxicity of service fluid, open or closed modules and the operators environmental policy.

9.0 MODIFICATIONS OR CHANGE OF SERVICE CONDITIONS

9.1 Objective

To ensure that the integrity of FHA’s is retained both during and after modification or change of service conditions.

9.2 Changing Conditions

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

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

Process conditions ( e.g. pressure, temperature, flow, fluids )

Functional change

Pipe work configuration

Environmental conditions

Alternative hose type

9.3 Risk assessment

If modifications to the system are required or when the process conditions have changed, then, a full risk assessment in accordance with section 5.3, should be carried out to ensure any proposed changes do not degrade the functionality of the FHA.

9.4 Change Control

All changes in use or application should be recorded with a justification in the local change control procedure.

9.5 Modifications

Flexible hose assembly construction must not be modified in any way.

10.0 DECOMMISSIONING

10.1 Objective

To ensure that FHA’s are properly decommissioned and do not impact on the integrity of other systems

10.2 Disposal

FHA’s, which have been identified as surplus to requirements, should either be retained as a usable spare or removed from the location. They should be identified with previous application, location and service life in the hose register.

FHA’s which have been identified as being unfit for purpose should have the end fittings removed and the main carcass of the hose marked as “ Scrap “. It should then be disposed of in line with local disposal segregation procedures taking into account any de-contamination requirements (e.g. LSA, chemicals etc). Failure to decontaminate FHA’s that have been in hazardous service may render them special waste.

The opportunity to test hoses to destruction, after they have been de-contaminated, should be taken to build up operational knowledge. The hose register should be updated (see section 8.1)

10.3 TransportationFHA’s should be cleaned prior to transportation and labelled if they contained any substance, which could be considered hazardous to health ( COSHH ).

10.4 Change Control

All changes in use or application should be recorded with a justification in the local change control procedure. The local FHA register should be updated to reflect current status.

10.5 Partial Decommissioning

Where FHA’s form part of systems that are only being partially decommissioned, care is required to assess the impact of the decommissioning on the retained plant. Suitable risk assessments should be conducted as appropriate and recorded as part of the change procedure.

11.0 REFERENCES

1. ISO 1307 Rubber and plastic hoses for general purpose Industrialapplications.

2. ISO 8331 Rubber and Plastics hoses and hose assembliesGuide to selection, storage, use and maintenance

3. ISO 7313 High temperature convoluted hose assembliesin PTFE

4. ISO 10380 Corrugated flexible metallic hose and hose assemblies

5. SAE AS 1339 Rev e Society of Automotive Engineers.Hose assembly, PTFE, Metallic Reinforced

6. BS1435 Rubber hoses for Oil Suction and Discharge,Specifications for the assembly of, and recommendationsfor the storage, testing and use of.

7. API 17 B American Petroleum Institute, Recommended Practice

8. IP Guidelines Institute of Petroleum, Model Code of Safe Practice Part 1, Electrical Safety Code, 6th Edition ( 1991 ).

9. BFPA / P47 British Fluid Power AssociationGuidelines to the use of Hydraulic Fluid Power Hose and Hose Assemblies

10. BS 6501 Flexible Metallic Hose AssembliesPart 1. Specification for corrugated hose assemblies

11. HSE Guidance NoteGS4 ( Third edition )

Safety in Pressure Testing

12.0 APPENDICES

Appendix 1 Personnel Competency Requirements

Appendix 2 Legal Requirements

Appendix 3 Human Factors Associated with Flexible Hose Assemblies

Appendix 4 Hose Construction

Appendix 5 Hose Failures

Appendix 6 Hose checklist

Appendix 1 Personnel Competency Requirements

A1.1 General

All personnel that are required to design, specify, install, maintain or inspect systems containing flexible hose assemblies, should have training commensurate with their responsibilities.

The content of the training should include the general requirements of safety, selection, installation and inspection.

A1.2 Authorised Personnel

The authorisation process should be implemented by each offshore installation or onshore site.

The content of training should include the general requirements of safety, selection, installation and inspection.

Each person should be registered and maintain their competency by attending regular training and have their ability to perform tasks routinely assessed.

A1.3 Competency Matrix

The following matrix provides a typical competence profile;

Activity Designer Installer Maintainer Operator InspectorMaterial selection S A A A AMaterial conformance with design

A S S A S

Internal / external conditions S S S A SReduction of joints S S K A SMaterial handling K S K A KMaterial preparation K S S K SBasic installation K S S K SComplex installation K S K K SConditions of use ( restrictions ) K S S S SInspection and testing K K K K SRe-make limitations A K S S SNon conformance identification K S S S S

Criteria;

S = Skilled K = Knowledgeable A = Aware

A1.4 Competence Assurance, Registration and Training Requirements

There should be a formal competency assurance scheme, which ensures that all personnel (company and contractor) required for work on FHA’s are formally assessed as being competent to carry out the range of allotted tasks. Such schemes should cover the range of knowledge and task skills appropriate to the range of flexible hose and components encountered on the installations or plants to be worked on. The scheme should ensure the long-term retention of competence by the periodic reassessment of personnel. For guidance purposes, an example of the range of knowledge and tasks skills specific to FHA’s is provided in paragraph A1.3 above.

Personnel assessed as being competent should be registered as being authorised to carry out that range of tasks. There should be a formal authorisation process, including the retention of a current register of authorised personnel.

It is recommended that management procedures ensure that vendor personnel employed on short-term construction or maintenance work are competent to carry out the range of work to be undertaken and that their competency is recorded in the register of authorised personnel. The work should be subject to additional supervision and once complete, additional inspection prior to commissioning.

A1.5 Personnel Training

Only competent personnel should work with FHA’s.

Personnel employed on the installation or maintenance of FHA’s should have appropriate background skills and experience, ( e.g. instrument or mechanical discipline technicians with general engineering skills and experience ).

Installation or maintenance personnel who have not satisfied the competence assurance requirements should receive supplementary training and/or supervised on the job experience necessary to meet the competency requirements before being added to the register of authorised personnel.

Operational personnel should receive training appropriate to their duties.

Appendix 2 Legal Requirements

NOTE: The following section addresses the health and safety regulations relevant to the UK offshore industry, for which these guidelines have been primarily produced. For onshore locations, other regulations may apply.

It is a legal requirement under health & safety law that those responsible for work activities ensure that:

Hazards are adequately identified Risks are adequately assessed Suitable control measures are put in place

Measures should be taken to eliminate or control risks unless the cost of doing so is disproportionate to the level of risk. Where it is not possible to remove the risk, then the arrangements for managing the activity safely are particularly important.

The main health & safety regulations affecting the use and management of flexible hose assemblies offshore include the following:

1. Provision and Use of Work Equipment Regulations 1998 (PUWER).

These regulations aim to ensure the provision of safe work equipment and its safe use. They include general duties for employers covering the selection of suitable equipment, maintenance, information, instruction and training. They also address the need for equipment to control hazards. As well as use by duty holders, flexible hoses are often associated with equipment that may be introduced by other parties who may be affected by the regulations such as contractors, consultants, suppliers, etc. who employ people.

2. Pressure Equipment Regulations (PER) 1999; Pressure Systems Safety Regulations 2000 (PSSR);

The PER apply to design, manufacture and conformity assessment of pressure equipment and assemblies operating at a pressure >0.5 barg.

The aim of the PSSR is to prevent serious injury from the hazard of a release of stored energy of a relevant fluid because of the failure of a pressure system of any of its components. The regulations are concerned with equipment in service.

Flexible Hose Assemblies may form part of pressurised systems covered by these regulations.

3. Offshore Installations and Wells (Design and Construction, etc) Regulations 1996 (DCR)

The DCR cover requirements for verification of safety critical elements (as defined in the regulations) by independent competent persons. This may relate to flexible hose assemblies if they are deemed safety critical.

4. Offshore Installations (Safety Case) Regulations 1992 (SCR)

The primary aim of the SCR is to reduce the risks from major accidents to the health and safety of employees on offshore installations. The safety case produced for offshore installations is required to demonstrate the provision of a suitable management system to ensure that relevant statutory provisions are met, that adequate audit and audit reporting arrangements are made and that major accident hazards are identified, risks are evaluated and measures taken to reduce the risks to affected people to ALARP.

5. Offshore Installations ( Prevention of Fire and Explosion, and Emergency Response )Regulations 1995 (PFEER).

Performance standards are required under the PFEER regulations such that operators of Installations subject to the SCR are required to perform a process of assessment which;

- identifies fire and explosion major accident hazards and major hazards with the potential to require evacuation, escape or rescue, (EER),

- evaluates the likelihood and consequences of these events,- identifies the measures needed to recover from these events, and- identifies performance standards for the measures adopted to protect persons from fires and

explosions and ensure effective EER.

The results of the process are summarised in the Safety Case for the Installation.

6. Health & Safety at Work Act 1974 (HSWAct)

The HSW Act places duties on employers to ensure, so far as is reasonably practicable, the health & safety of their employees, and others who may be affected by their undertaking. These general duties are supported by the requirement in Regulation 3 of the Management of Health & Safety at Work Regulations 1999 (MHSWR) for employers to undertake risk assessments by competent person(s) for the purpose of identifying the measures which need to be put in place to prevent accidents and protect people

Appendix 3 Human Factors Associated with Flexible Hose Assemblies

Accidents or failures involving flexible hose assemblies can frequently be traced back, in whole or in part, to a failure in human understanding, action or response. Operating hoses may pose hazards to personnel, requiring appropriate control measures such as procedures and use of good practice to minimise risk.

Human failure may frequently be attributed to:

lack of awareness of hose characteristics, function and limitations, or operator error or a failure to comply with procedures, or lack of adequate procedures, or lack of training or competence.

These Guidelines address many of the good practice issues concerning design, installation, maintenance, inspection and testing of hoses. In particular, Section 8 contains guidance on personnel competency and training management and Appendix 1 contains guidance on required skills level.

The following sub-sections aim to highlight some specific areas affected by human involvement, some of which may also be further discussed elsewhere in the document. This appendix should not be regarded as an exhaustive identification of relevant issues.

A3.1 Lack of awareness of hose characteristics, function and limitations.

Flexible Hose assemblies are typically complex structures comprising couplings of various designs and flexible hose comprising multi-layered material and reinforcements. Each layer serves a specific purpose that may include chemical or abrasion resistance, structural strength or physical protection. Only surface layers are normally visible. Hoses may be used in flowing fluid service or static pressurised service. Hose construction, length, materials, and installation arrangement will have been carefully considered at the design stage.

Personnel responsible for specifying, using, maintaining or inspecting hoses should be aware of the elements of construction of a hose assembly and their contribution and application to the specific use. This is important if they are to avoid incorrect use or recognise when a hose no longer meets the required integrity.

The scope for hoses to be used in multiple duties is high. If not properly controlled, this can lead to failures if hoses are subsequently used in services for which they were not originally designed or specified in all respects. For example, a hydraulic power hose of identical specification to another failed hose, but of different length, may be used to replace the damaged hose. However, the difference in length may itself be the cause of failure of the replacement hose due to exceeding minimum bend radius, excess distortion under operation due to movement, additional loads due to inadequate or inappropriate support, etc.

A failure to fully appreciate design limitations can lead to a failure to recognise the implications of a change of service, and the need to reassess the design ( Section 9.2 - management of change). Changing service conditions (e.g. fluid composition) over the life of equipment could result in a hose being used in conditions for which it was not originally specified, placing it at increased risk of failure. It should be remembered that changing conditions can apply to both internal and external elements of the hose assembly, e.g. subsequent addition of external heat tracing or insulation to a hose to overcome a process condition changes the external environment and could create a new corrosion hazard to external reinforcement or affect other layer performance.

A3.2 Operator error or a failure to comply with procedures:

Operator error can occur due to a lack of understanding, inadequate training or competence, violation of procedures, or poor culture. There is a particular risk when FHA’s are used as part of a temporary arrangement. It should be recognised that the flexibility offered by a flexible hose assembly is not a remedy for poor installation. The availability of adaptors for end connections requires control to help avoid flexible hose assemblies being put to a use for which they were not intended.

A3.3 Lack of adequate procedures:

Suitable procedures are a necessary feature for well managed systems involving hazardous plant.

For permanently installed systems using flexible hose assemblies, there should be appropriate procedures in place. Where necessary, these should highlight safety critical features concerning handling and use of those assemblies. The flexible properties of flexible hose assemblies can lead to the assumption that they may be used in a wide range of applications. This assumption may not always be justified, even in apparently similar duties.

Particular care is needed with temporary facilities to ensure that, additionally, necessary short-term procedures are in place. Temporary procedures may be required, linked to the Permit to Work system or other safety management scheme.

A3.4 Lack of training or competence:

A variety of flexible hose assemblies may be found on any installation fulfilling different functions. Section 8 of this guidance document outlines necessary requirements for competency and training.

A3.5 Hazards to personnel:

Flexible hose assemblies come in a wide range of sizes and are used in both permanent and temporary duties. Manual handling of hoses either in the free and uninstalled state or in service needs consideration if weight (including weight of contents) or bulk is excessive, or if release of pressurised fluids from nozzles, etc. can cause whiplash movements causing a loss of control of discharges.

Poorly supported or restrained flexible hose assemblies may present tripping hazards, or impact hazards from assembly collapse or movement.

The transfer of hot fluids and its potential for operator contact with hot surfaces needs consideration.

Flexible hose assemblies handled by operators may contain hazardous substances. Care needs to be exercised to prevent splashes, jets, sprays or other contact with harmful contained fluids when disassembling or handling hoses. Care is required to ensure that no residues remain in hoses that could be incompatible with further usage ( See section 10.1 )

Flexible hose assemblies used manually by operators need careful handling since if the hose becomes blocked as this could suddenly release. Never look into a hose that is connected to a pressure system, even if the system is believed to be isolated.

Appendix 4 Hose Construction

A4.1 Basic Hose Design

It is important to understand some elements of basic hose design and the function of the various hose components. This will help explain the reason for some hose failures.

There are three basic layers in any hose construction. First, there is an inner lining or tube, secondly there is reinforcement and finally there is an outer cover. Each contributes to the integrity of the hose but may have to be supported in carrying out that role by additional components in the hose construction.

A4.2 Tube or Inner Lining

The function of the inner lining or tube is to act as a seal against the fluid being conveyed through the hose. Breakdown of this layer always results in a hose failure and therefore the tube has to be very resistant both physically and chemically to the materials being conveyed, throughout the agreed service life.

A4.3 Reinforcing Layers

The reinforcement provides the ultimate strength of the hose i.e. to achieve the designed working pressure and the final burst pressure. Each type of reinforcement gives different properties to the finished product. Reinforcement layers can be single, wide spaced, spiral cords, bias laid fabric, braided constructions of fabric or relatively fine wire. For high-pressure constructions several layers that are constructed from spiral laid, heavy duty, wire cords are normally used. As the reinforcement increases the hose becomes stronger but very much more rigid, approaching ultimately, an equivalent to a solid pipe; hence the terminology “flexible pipes” used to describe some subsea oil carrying hoses.

The angle of application of the reinforcement, cord, textile or wire is extremely important since it is the angle of lay, which determines how the hose will react under pressure. In general the hose designer aims to achieve an angle of 54° 44’ classed as the neutral angle, at which there would be no movement in length or diameter whilst the hose is under pressure since the hoop stress, attempting to burst the hose and the axial stress trying to stretch the hose are balanced when this condition is met.

If the angle of lay is higher than the neutral angle then under pressure the hose will increase in length and reduce in diameter. If the angle of lay is lower than the neutral angle, then the hose will shorten and the diameter will increase. Clearly both of these conditions could have serious implications for hoses in service especially those in a restricted condition i.e. fixed at both ends prior to pressurising.

In a few cases, the reinforcement is laid axially and radially, so that the length of hose can be rolled in a lay-flat condition without distressing the construction; fire hoses are of this type of construction and being free at one end a change in length under pressure is not critical to their function.

Burst pressures are calculated from the strength of the reinforcement in the hoop direction where the formulae used take into consideration the method of application and angle of lay of each layer of reinforcement.

Each hose is designed to work to a pressure safety factor. As a guide ISO 1307 gives factors 4:1 burst pressure to working pressure, for power hoses i.e. those hoses likely to take shock loads; 6:1 for hoses working with a gaseous medium and 10:1 for those working with steam. Offshore drilling mud hoses have a safety factor of 2.5:1 and choke and kill system hoses working at very high pressures i.e. 15000 psi, of 2.25:1. These later safety factors are a compromise to allow maximum hose flexibility for the expected service conditions.

A4.4 Covers

The outer cover protects the reinforcement layers from the weather, from abrasion in service, from chemical spillage or from impact damage. These covers must be designed for resistance to all expected service conditions over the life of the hose including the possibility of ‘abuse’ in storage or in their working condition.

A4.5 End Terminations

End terminations convert a hose into a hose assembly. With the smaller bore and power hoses these are usually based on a crimped fitment. Whilst this reduced the size of the inner bore, performance is not affected, as such hoses do not deliver fluids but function as a flexible power transmitter..

For drilling hoses and oil production hoses, terminations have been developed so that they are built into the body of the hose with no restriction to the flow or reduction in bore size. These fitments are usually classed as ‘bonded’ and are fixed in place with an epoxy resin.

Appendix 5 Hose Failures

A5.1 Hose Failures

Almost all hose failures occur in three discrete time scales, early failures where the product has survived no longer than 10% of it’s expected life, random failures during service, and wear down failures where a hose has been used well beyond a reasonable life or has been exposed to unexpected fluids or service conditions.

A5.2 Early Failures

Manufacturing defects are the main cause of early failures and they are usually associated with one of the three main hose layers being compromised. Grit or other contamination within the lining can erode leaving a minimal wall thickness to cope with the internal fluid. Under service conditions, cracks propagate from the damaged area and breakthrough occurs.

Further manufacturing defects can be caused by leaving fabrics uncovered particularly in the termination area, which allows ingress of water, then corrosion of the reinforcement and early failure occurs.

Nitrile lined hoses are not designed to be resistant to ozone, as their anticipated service would be with oil based products or hydraulic fluids. It is in long term storage that they break down particularly when they are distorted under the weight of several coils; here the linings crack even before service life begins.

Another common early failure occurs when hoses are fitted in an over bent condition. This often occurs when a hose is replaced on an emergency basis following a previous incident. Reactive procurement will often result in a hose too long for the job being purchased, because it is readily available. It may then be forcibly fitted into the available space becoming distorted or over bent. Over bending causes excess movement of the lay angles of the reinforcement creating unsupported ‘windows’ in the hose structure and the internal pressure forces the lining through the gaps causing failure to occur.

A5.3 Random Failures

Random failures of hoses are typically caused by impact damage, abuse and corrosion of reinforcements.

Offshore environmental conditions are often severe in terms of wind velocity, hoses may hang unprotected from the elements and where not adequately clamped can come into impact and abrasion conditions, which damage the outer covers. Once damaged, ingress of salt water or other fluids causes rapid corrosion of wire cords and weakening of bond strength to epoxy cement. Safety ratio of burst pressure to working pressure is no longer maintained and failure occurs.

Many hose failures occur randomly because of misuse. For example, it is not uncommon for hydraulic hoses designed for transmission of power, not the transfer of fluid, to be used

to deliver a wide range of fluids. Methanol injection is one application where standard nitrile lined hydraulic hoses have been used and have failed after plasticiser loss has caused embrittlement and fracture.

Inadequate communication and realisation of the effects of evolving technology has resulted in FHA failures. For example, the introduction of environmental drilling muds, ester or vegetable oil based has caused failures to outer covers of hoses. It is common for both products to use polychloroprene as outer weather protection. However, polychloroprene and some other rubber types are not resistant to these muds. They swell, weaken, loose insulation and protective properties then fail.

A5.4 Wear Down Failures

Wear down failures should not occur where FHA’s are subject to a rigorous inspection regime ( Section 8.2 ) and change-out times are not exceeded. Over-extended use may result in failure from dry linings, caused by plasticiser removal and weakening due to hardening by amines.

A5.6 Examples of Hose Failures

The following have been included for information only, and show some typical examples of hose damage.

PICTURE 1

Picture 1: Outer cover damaged allowing water ingress

PICTURE 2

Picture 2 : Outer cover abraded allowing water ingress and corrosion of the reinforcements

PICTURE 3

Picture 3 : Damage to external braids

PICTURE 4

Picture 4 : Damage to outer cover allowing severe corrosion to reinforcements

PICTURE 5

Picture 5 : Cover cracked allowing water ingress

Appendix 6 Hose Checklist.The following is provided as an example of minimum information requirements, where possible the FHA manufacturer or vendor’s specification sheet should be used to ensure that all relevant information is provided and the correct FHA for the application is supplied.

Customers Responsibility to define requirements

Media to be carried Defines fluid composition and phase for all foreseeable operating modes

Working Environment

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

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

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

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

Volumetric expansion

Ensures the Flexible Hose Assembly is installed as per Manufacturers /Vendors recommendations.

.

Earth bonding Defines requirementsFire rating Defines requirementsPiping class Defines materials and pipe rating of

connecting pipework or equipment.Erosion and abrasion requirements

Defines any erosion or abrasion issues

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

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