tff flexible hose user manual.pdf

8/18/2019 TFF Flexible Hose User Manual.pdf

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PCD001 Flexible Hose User Manual

Rev 4 Date: 6.5.15 Drafted by: Andy Thompson Approved by: Barry Ayres

1. Hose Provision and Storage

2. Handling

3. Care and Installation

4. Maintenance and Inspection

5. Hose Damage and Repair

Techflow Flexibles Contacts:

[email protected]

[email protected]

tel: +44 (0) 1670 706210

fax: +44 (0) 1670 706211


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1. Hose provision and storage:

The hose is provided coiled and fastened securely in a wooden crate, or for large bore hoses laidstraight inside a steel frame. This packing media provides a method to move the hose around

safely and securely. The hose should be stored in its crate ideally in a warehouse at ambienttemperature. The hose should remain in its packing crate at all times and only be removed at thetime of installation.

Steel Frame Wooden Crate

Where outside storage is necessary, then for any long period of time, particularly in warm sunny

climates, the hose should be protected from direct sunlight and salt spray. A simple tarpaulincover is adequate. Storage temperature range is between -5oC and +25oC. Temperatures above

25oC should be avoided and do not store near to sources of heat emission.

Some hoses are provided with a thin external wrapping along their body to provide protection

during transport and storage from ultraviolet radiation. This should be left on the hose and onlydiscarded during or after installation. Ozone is particularly detrimental to rubber, hence care

should be taken not to store hoses in rooms where for example electrical equipment maygenerate ozone.


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The hose end couplings are protected against corrosion and ingress of dirt and particles into thehose bore either by solid end cap (eg blind flange) or by greased wrapping.

Blind Flange Wrapped Coupling


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2.

Handling

2.1 Handling the Packing Crate (Wooden Crate):

The wooden crate can be lifted and transported either by forklift (1.) or by crane (2.)

Fork lift (1) – the forks must pass fully through the central strut of the vertical crate andprovide lift front and back. For horizontal crate (4) the forks should be longer than half crate

size to pass centre of gravity. NB: Take care not to touch the hose.

Crane (2) – using a soft strop looped inside the crate and over the surface of the coiled

hose inside

To facilitate removal of the hose from the crate, the crate should be placed on its side,

lowering it using soft strop looped inside the crate and over the surface of the coiled hoseinside (3)

1.

Fork lift forks must enter crate

below centre and pass through

full crate width

2.Crate lifted using soft

strop through crate andover hose coils

3.

Turn crate on side usingsoft strop through crate

and over hose coils

4.

Fork lift forks must befully under crate and

pass half-way


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2.2

Handling the Steel Frame:

The steel frame is provided with four lifting pad-eyes. Lifting of the frame can be with crane and

4-arm chain sling. Alternatively the pallet can be lifted from underneath using a suitable forkliftwith widespread forks.

2.3 Handling the Hose:

2.3.1

Removal of the hose from a wooden crate:

Ideally the hose should be removed from its packing crate at the point of installation andinstalled immediately to avoid unnecessary additional handling or leaving the hose lying

around and exposed to mechanical damage from personnel and machinery

With the packing crate lying on its side, the uppermost side of the crate is removed

exposing the coiled hose inside. Wooden crates have all wooden parts secured with nails.

These should be removed at all points to allow the side to be removed.NB: All nails must be fully removed so that none remain that can cause damage to hose asit is removed

Cut loose the hose restraining straps

The hose is provided with a dual purpose lifting/safety clamp of either single-point or

double-point connection. This clamp is to be securely attached to the hose body at the endto be lifted. The clamp should be positioned on the hose body just behind the tapered body

section ie hose coupling.

The hose can be lifted from one or both of the lifting holes on the lifting collar

The crane hook must be allowed to rotate ensuring no twisting of the hose occurs during

removal from the crate

Take care to note to overbend the hose or kink the body, over tension the hose or twist the

hose body.


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NB: Low temperatures make the hose stiffer and less flexible. Care should be taken whenhandling a hose from very cold temperature.

Handling Do’s and Don’ts


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MIN BEND RAD

EXCEEDED MIN

BEND RAD


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3. Care and Installation

Prior to installation ensure that the end couplings are completely clean, free from mechanical

damage (ie burrs), and that seals are correctly fitted.

Take care not to exceed the hose MBR especially at the end fittings.

Twisting of the hose body should be avoided during installation and where possible in use. Twistin the hose body causes expansions and contraction of the spiralled reinforcement cables, which

in turn reduces the pressure strength of the hose. Hoses are often branded with a straight

coloured stripe along their length – this is used to view any twisting.

Points of abrasion or contact with equipment or steelwork should be identified early and stepstaken to protect the hose at installation. Simple protection can be achieved using several close

wraps of rope around the affected area of hose body, or the use of spiralguard.


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Correct orientation of the end fittings is essential so as not induce overbending of the hose at theend fittings.

Where the routing of a hose may be difficult or assistance is needed, Techflow Flexibles can assistwith 3D modelling of the installation arrangement.

NB: It is often the case that hot work continues in the vicinity of the hose after its installation. Itmust be remembered that the hose body is predominantly rubber and will burn if exposed to

weld splatter or tears from sharp instruments. Necessary precautions should be taken to avoid

this and protective blankets placed over the hose body.


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Use of Safety Clamps and Chains:

Safety clamps must be fitted to API 7K Rotary Drilling hoses as specified in API Spec 7. The

position for the safety clamp is clearly marked on the hose body. TFF hoses are supplied with adual purpose lifting/safety collar. After use for handling the hose, a safety chain can then be

attached to the clamp using suitable shackle.

SAFETY CLAMP

CHAINLIFTING


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4. Maintenance and Inspection

It is essential to afford care and attention to the hose once installed and in service to maintain its

integrity and longevity throughout its working life. By embracing the following guidelines andoperating the hose within its design parameters, the operator can seek to maximize the servicelife of the hose.

The frequency and extent of inspection is dependant upon consideration of the failure modes ofthe hose and its criticality and severity of service. Records off all inspection data for the hose

should be maintained. This will be used by the manufacturer in evaluating the condition of the

hose during the inspection schedules.

In general the hose should be inspected on a regular on-going basis:

3 monthly visual inspection

Annually in-situ pressure test

3 to 5 years major inspection

Visual inspection:

A look at the hose along its full length including the end fittings. Particular attention is paid to any

areas of concern, ie close proximity to equipment or previous repair of hose body. The inspection

should be performed by a competent person and all observations recorded. Visual inspection is acritical inspection technique where potential damage can be identified early allowing remedialaction to be taken before any major damage can occur.

The hose body comprises of several layers, but the critical ones are essentially:

1. Inner rubber liner providing the sealing membrane2. Reinforcement cables or textiles providing the pressure strength

3. Outer rubber cover providing protection of the reinforcement from the externalenvironment

COVER REINFORCEMENT

LINER


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Visual inspection of an installed hose should consider:

- Outer cover looking for signs of looseness, kinks, bulges, soft spots, signs of abrasion, cuts or

gouges.- Hose body behind hose end fitting for signs of over-bending

- Cuts and abrasion of the hose can be repaired, however, exposure of the reinforcementshould be referred back to the hose manufacturer

- Where hose is fitted with external metallic guard it is not possible to check the hose body.

Inspection is limited to the steel guarding and check for signs of cracking or mechanical

damage (ie. Denting or abrasion), or bulging – may indicate swelling of hose bodyunderneath.

- Pay particular attention to areas of hose that are near to steelwork or equipment. The hose

should always be guarded from potential abrasion or impacting with the steel/equipment.- End couplings checked for signs of leakage, corrosion, or cracking of the steel

Cuts or gouges in the hose should be addressed immediately. Damage to the outer cover that isnot too deep and does not expose the steel cables (pic 1) can be repaired (see repair section xx).

If the steel cables are exposed and corrosion is induced or water ingress has occurred then the

hose must be condemned as the strength of the cables will be weakened.

Cover tear - Repairable Exposed Cables rusted – Not Repairable


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Annual In-Situ pressure test:

A pressure test should be performed on the hose to verify the integrity of the hose body and its

connections. The test is performed on the hose as installed. The hose should be tested at 1.1 xMaximum Working Pressure for a period of 1 hour.

NB: Where it is impractical or not possible to achieve the above pressures, then it is acceptable toconsider the maximum working pressure the hose is operating under instead of the design

pressure.

After the pressure test the hose should be examined for any leaks, especially in the area of the

end couplings, any bulging of the hose body, undue twisting or abnormal distortion. Any pressure

drop during the test should be recorded and should not exceed 2%.

A record should be kept of all hose inspections.

If the hose is removed from its installation at the annual test then the opportunity should betaken to perform an internal inspection.

5 year major inspection:

The hose should be considered for a major inspection after it has been in service for a period of 5

years. Thereafter on a 3-year cycle. It is recommended that the major inspection be performed

by the original hose manufacturer. Ideally the hose should be brought onshore for this activity.

This major inspection shall include:

External visual inspection as per 3 monthly routine

Internal camera inspection:

o Small bore camera equipment is used to view the internal surface of the hose liner

and the steel couplings

o Observations made of the rubber liner for bulges, bubbles, cuts or abrasion.

o Where a metallic liner is fitted internally and only visible, observe crack,

deformation or abrasion.

Pressure test:

o A hydrostatic pressure test shall be carried out on the hose to verify the integrity

of the hose body and its couplings. The test is performed at 1.5 x the hoseMaximum Working Pressure for duration of 1 hour. After stabilisation, the pressure

drop shall be monitored and recorded and shall not drop more than 2% over thetest period.

o Checks are made for any leaks from hose body or end couplings, hose bodybulging, undue twist or abnormal distortion. A hose should only grow/contract

during the pressure test; it should not lift or twist or bend – any of these could

indicate the hose reinforcement is damaged.

A review of any recorded inspections held for the hose and where possible the records of theoperating parameters. Typically:


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o Operating pressures

o Operating temperatures

o Service medium type, density and viscosityo pH levels

o Chloride contento CO2 and aromatic contents

o Flowrates

o Stress levels monitored on connecting equipment

o Injected chemicals


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5.

Hose Damage and Repair

Typical Hose cover damage:

Hoses with damaged rubber covers can be repaired where superficial damage has occurred.Typical damage to covers is shown in the images below.

Where the cover is cut through to expose the steel reinforcement underneath then this should beevaluated to determine if the steel is damaged, and no water ingress could have occurred

whereby corrosion can occur. If this is the case then the hose cannot be repaired and must becondemned.

Repair materials:

Recommended materials for the cover repair are Belzona elastomers. The following componentsare necessary to effect a satisfactory repair:

Belzona 2311 SR Elastomer

Belzona 2921 General Purpose Conditioner or Belzona 2911 QD Conditioner

Belzona 9111 Cleaner/Degreaser (optional )

Some small hand tools are also necessary to carry out the repair procedure.

Mixing spatula

Small disposable working surface

Steel roughing brush

Belzona 9341 Reinforcing tape (required for deep cover repairs)

Repair Method:

Remove loose and frayed pieces of rubber from the damaged area.

Lightly graze the rubber in and around the damage to provide a rough surface (necessary for the

elastomer to key-in and bond).

Clean the damaged and surrounding area with the Belzona 9111 degreaser or simply soapy water

rinsed off with clear water.


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Apply a coating of Belzona 2921 Conditioner to the damaged and surrounding area. Allow to dryaccording to Belzona instructions (until it is touch dry) – drying time is dependant upon theambient conditions but is typically 15 to 30 minutes.

Mix the 2-part Belzona 2311 SR Elastomer on a rigid disposable surface whilst the Conditioner is

drying. Apply to the damaged and surrounding area using a rigid applicator ensuring that thecover incision is completely filled and the Elastomer extends to the surrounding area of thedamage. This should be smoothed off at the edges.

Note:

1. For cover incisions deeper than 5mm then the build-up of Elastomer should be reinforced

with Webbed-mesh tape available (eg Belzona product number 9341). The webbing beingplaced into layers of Elastomer built up in stages of 3-5mm at a time.

Belzona Mesh (#9341)

2. For hose bodies that are fire-rated and have fibre-glass layers that have been breached (seeimage below of Techflow Flameshield hose), then the fire rating layer(s) need to be rebuiltinto the hose body. This is done in similar way to point 1 above, but using fibre-glass sheet

instead of the Belzona mesh. This fibre-glass sheet is available from Techflow Flexibles

Fibre-Glass Layer

Cover


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3. For large areas of damage it may be necessary to apply a rubber patch. A piece ofneoprene/chloroprene rubber larger than damaged area should be cut. Then apply a coating

of Belzona 2291 Conditioner to both the hose and the back of the rubber patch. Allow to dryaccording to the Belzona instructions (until it is touch dry). Mix the 2-part Belzona 2311 SR

Elastomer as per above instruction and apply to the hose only. The patch can then be stuckto this and the edges smoothed off

Typical Completed Cover Repair:

NB: All repairs should be allowed to fully cure for 24 hours before flexing the hose.

tff flexible hose user manual.pdf

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