SEAFLEX MARINE HOSE

Maintenance & Repair

22 Apr. 2014

Masuo KURODA
Engineer
The Yokohama Rubber Co., Ltd.

Hitoshi INDO
Engineer
Yokohama Industrial Products Asia-Pacific Pte. Ltd.
 OUTLINE
1. Handling
2. Installation
3. Towing & Leakage Test
4. Storage
5. Appearance ( Visual Inspection )
6. Testing
7. Repair
Handling
 Hose Rack Handling
Lifting by crane to avoid damaging rack and hose

Forklift truck may cause damage

 Hose Handling

Spreader Bar

At least 3 lifting points

Flat Nylon Straps Risk of kinking
Strap over nipple area at each end Damage to integral flotation
 Hose Transportation – Dry Container
Four hoses (20”x35ft)
in one container

40-feet Dry Container

ADVANTAGES
• Higher Frequency of Vessels
Easy transportation
• Easier and safer Transportation to Customer’s Site
Installation
 Hose Installation
Connecting of hoses is
recommended to be carried out
on a jetty or a workboat.

Connecting the flanges, check

the position of the gasket, then
insert all of the bolts and tighten
the nuts using an air-impact
wrench. Then finish tightening
all the nuts in a symmetric
pattern using a torque-wrench
under the values of torque on
Table 1 and Table 2.
 Hose Installation
Hose connecting is in accordance
with the applicable hose arrangement
drawing. In case of double carcass
hoses, to assist hose connections,
the hose has an orange stripe parallel
to the longitudinal axis of the hose
and in line with the oil pot detector.
The oil pot detector shall be located
at the top of the hose.

After tightening flange bolts, the

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

First Off Buoy hose Tanker Rail Hose

SPM buoy side Tanker Manifold side

 Hose Installation

End Gear

The tanker rail hose should be provided

the end gear set which includes the
butterfly valve, camlock with short spool
piece, hang-off chains, pick-up chain,
pick-up rope, small marker buoy and
light weight blind flange. Pick-up chain
should be connected to the pad eye of
the taker rail hose.
 Hose Installation
Butterfly Valve
The butterfly valve should be inserted between the flanges of the tanker rail
hose and the spool piece of the camlock. The top position of the butterfly
valve leans to 45 degrees of clockwise or anti-clockwise to be convenient
operation. The butterfly valve has the
directions such as the upstream side
and the down streamside.
The upstream side is identified by an
arrow on the body of the valve.
Lifting lug

Spool Piece
If spool piece would be used between hose
and hose it should be located in
accordance with the applicable hose
arrangement drawing.
Lifting lugs be located at the top and the
bottom.
 Hose Installation
Winker Light
1. Body shall be put between adaptors with bolt & nut.
2. Winker Light shall be set to the top side of flange with bolt & nut.
Guard

Lantern

Body

Adaptor
 Towing &
Leakage Test
 Towing Hose on Shore
Towing with casters
Do not drag on the ground

Casters
Towing to site - Avoiding premature sinking or damages

Blind flange with Towing Eye Additional flotation

Blind flange with Towing Eye

Maximum towing speed 5 knots
Floating Hose line
Full of air or water
Additional support for hose parts
with no integral flotation
Subsea Hose line
Full of air
Blind flange with bleed valve
 Leakage Test
The leakage test shall be conducted after connecting the flanges in order to
confirm no leakage from the flange connections.
The following is the procedure for the leakage test.
(1) Blind flanges for the leakage test shall be provided to
both ends of the hose string with pressure gauges.
(Please note that the lightweight blind flange is not
suitable for the leakage test.)
(2) The hose string shall be elongate freely. And the butterfly valve should be
opened during the test.
(3) Fill with water, venting to remove all air, and apply a pressure of Maximum
operating pressure.
(4) Raise the pressure to the rated pressure and hold for 3 hours.
(5) Before releasing the pressure, all flange connections shall be confirmed to
be no leakage.
(6) Release the pressure and water for the test should completely drain from
the hose string for the towing.
Storage
 Hose Storage
Indoor Storage Outdoor Storage
Store in a cool, dark, dry area Cover to protect from Ozone and
Store on steel pallets Sunlight (Temperature: -29oC to 60oC)
Cover Sheet
Wooden blanks at both ends

Wooden
Blanks

DO NOT
Do not store close to equipment generating heat or Ozone
Do not store directly on ground
 Hose Storage
Laid out straight to avoid hose bending
Use wide support to prevent deformation

Narrow Supports

Permanent deformation
caused by Narrow Supports
 Visual
Inspection
 Periodic Inspection In-Situ
Submarine Hose Lines Floating Hose Lines

Visual inspection of outer

Frequent routine visual
Frequency inspection outer surface,
end fittings, & joints.
Kink, Body Damage, Oil
Items to
seepage, Heavy marine
check for
growth, Scuff.
Check for any change in
Others
configuration.
surface of hose (especially
the 1st off the buoy hose &
tanker rail hose) prior to each
loading operation.
Damages caused by contact
with vessels, crossed lines,
Kinking, Oil seepage.
Check for any change in line
sinking.

Replace the hose having critical damage before operation.

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

Type of Hose Initial Test Interval

Floating Hose
Except T.R & F.O.B Hose
Submarine Hose
Tanker Rail Hose (T.R hose)
First Off the Buoy Hose (F.O.B Hose)
1 to 3 Years
1 to 3 Years
6 Months to 1 Year
6 Months to 1 Year
OCIMF 1995 Section 4.5
 Cleaning & Inspection of Hoses on Shore
Inspection of Hoses on Shore

Cover Carcass Liner Fittings

Cuts Crushed or Kinked areas Blisters Cracks

Gouges Broken Reinforcement Bulges Excessive Corrosion
Tears Permanent Distortion Tube Separation
Abraded spots Longitudinal Ridges Tear
Bulges
Cover - Cleaning Marine Growth

After cleaning Hose

Marine Growth, Barnacle

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

almost as usual

Damage

Before cleaning After cleaning

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

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

 Damaged Cover of Submarine Hose - Retirement Criteria
Breaker Cover
REPAIRABLE NON REPAIRABLE
Reinforcement Cord

Tube Lining

Helical steel Wire

Exposed Helical steel Wire
Scratches – No Exposed Breaker Plies
Damaged
Reinforcement Cord

Breaker Plies
Exposed Breaker Plies Cord Damage Oil Leakage
Damaged Cover of Floating Hose Retirement Criteria
Cover

REPAIRABLE NON REPAIRABLE

Sponge

Reinforcement Cord

Base Hose

Tube Lining

Damage

Damage under Sponge Oil Leakage

Scratch & Small Cut Extensive Damage

Permanent Deformation on Helical Wire (Kinking)

NON REPAIRABLE

NON REPAIRABLE

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

Inside of Hose

h
Liner H >15mm
Retire Hose Bulge
W

L×W > 30cm2

Retire Hose

NON REPAIRABLE
 Inner Lining Inspection - Cracks
Inside of Hose

NON REPAIRABLE

Crack Cut

Lining
Breaker
NON REPAIRABLE
Cracks grow rapidly under bending during operation
that will lead to oil leakage though the lining.
Examples of lining cracks
Inner Liner Inspection – Separation & Tear

NON REPAIRABLE NON REPAIRABLE

Any separation Any tear reaching hose breaker layer

(Hose should be retired) (Hose should be retired)
 Inner Liner Inspection
– Gap & Step between Nipple End and Lining
Lining

Nipple
Nipple

> 5mm
Gap Nipple End RETIREMENT
> 5mm
Lining RETIREMENT

> 5mm
Nipple End RETIREMENT
Nipple

> 5mm
Step Nipple End RETIREMENT
 Fitting Inspection - Corrosion
Clean up and examine for cracks or excessive corrosion

Inside of Fitting

RETIREMENT

RETIREMENT

Excessive Corrosion influence nipple thickness Excessive corrosion on flange face

(Hose should be retired) (Hose should be retired)
Deep tipping (Hose should be retired)
Testing
 Pressure testing of Hose In-Situ
Frequency of pressure testing in-situ
・ Every six months or more
・ After a very severe period of bad weather

Pressure testing
・ Raising the internal pressure to the rated pressure or
operating pressure plus 50%, whichever is lower.
・ Holding it for a period of 3 hours.
・ Visual Inspection : Oil seepage
・ Pressure stabilization
・ Leak detection system : Non activating
(In case of Double Carcass Hose)
 Testing of Hoses on Shore
Type of Hose
Floating Hose
Except T.R & F.O.B Hose
Submarine Hose
Tanker Rail Hose (T.R hose)
First Off the Buoy Hose (F.O.B Hose)
Initial Test Interval
1 to 3 Years
1 to 3 Years
6 Months to 1 Year
6 Months to 1 Year
OCIMF 1995 Section 4.5

Building up a database of wear, damage and failure frequency rates to establish

retirement criteria and on-shore testing cycle
• Serial Number
• Manufacturer
• Type/Model
• Size/Length
• Delivery Date
• Service Records
• Test Data
• Visual Inspection
• Comments
 Testing of Hoses on Shore - Hydrostatic Test
Time - Pressure Diagram L2
Rated Pressure
Pressure

½ Rated Pressure

L1
L3

5 min. 30 min. 30 min. 15 min.

5 min.
5 min.
Time
Temporary Elongation
L3 − L1 To be compared to original test
P .E . =
L1 T . E . situ − T . E . factory ≥ 2%
Permanent Elongation P . E . situ − P . E . factory ≥ 2%
L2 − L1
T .E . = RETIREMENT OCIMF 1995 Section 4.5.1
L1
 Hydrostatic Test Unit
2 PRESSURE HOSE
1 3 4
QUICK COUPLING 2 QUICK COUPLING
FEMALE 20000 FEMALE

3 SUCTION HOSE
WATER 3
TANK 3000 STRAINER

2 6

7 7
4 SURPLUS HOSE
4
3000
HOSE

5 CONNECTION PIPE PRESSURE GAUGE

5 6
WITH VALVE WITH VALVE
1 PUMP
QUICK COUPLING(SUS)
5 6
FEMALE VALVE
VALVE
PF 3/4"
FOR SURPLUS HOSE

100 100 200

740
1/2" QUICK 7 BLIND FLANGE FOR 16"
COUPLING (SUS)
MALE

PF 1"
FOR SUCTION HOSE

500 1000
 Testing of Hoses on Shore - Vacuum Test
Test Requirements: A vacuum of 680 millibar for 10 minutes

C-Clamp

Vacuum Pump

RETIREMENT
Separation

RETIREMENT
Clear Plastic Blind Flange

Inspect for & retire hose if any of the following is

found:
• Blisters • Tear
• Bulges • Cut Tear
OCIMF 1995 Section 4.5.3
• Separation • Gouge
 Vacuum Test Unit
1 VACUUM PUMP

VACUUM GAGE

300 314
1 CLEAR PLASTIC BLIND FLANGE WITH SOFT GASKET

HOSE QUICK CONNECTOR

MALE

HOSE

3
6

552
CLEAR PLASTIC BLIND FLANGES 3
6 PIPE WITH CONNECTOR
WITH SOFT GASKET

HOSE QUICK CONNECTOR

SOFT GASKET MALE

2 VACUUM HOSE
5 FLANGE CLAMP
QUICK CONNECTOR QUICK CONNECTOR
2
FEMALE FEMALE
6000
Testing of Hoses on Shore - Electrically Continuity Test
Measure Electrical continuity to confirm hose satisfies original requirements
Dim Light Resistance < 25,000 ohms

Test Unit

Continuous Hose Discontinuous Hose

Test Lamp: (4 Volt, 0.3 Amp) 500 volt hand cranked Megger,
OCIMF 1995 Section 4.5.2 Battery 4.5 V, Electrical cord Electrical cord
 Electrically Continuity Test Unit
Electrical Tester Resistance Tester

Alligator Clip
Test Unit Assembly Test Pin

Hose

Tester
Hose Repair
Hose Repair - Repair Kit
 Repair Kit
SC4000 with Hardener
Wire Brush with Spare Wire Adhesive for Fabric
for Roughing Surface of Rubber Reinforced Rubber Sheet

Special Cement
Primer for Compound (A+B)

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

Measuring Cup
Hand Roller For Mixing SC4000 and
For Pressing Rubber Sheet Hardener

Fabric Reinforced Rubber Sheet

For Repairing Outer Cover

Sponge
For Repairing Sponge
Wrapper
For Wrapping
Rubber Sheet
 Repair Procedure (1)

Damage Cut the outer cover around Buff well the damaged area
the damaged area with a and adjacent area with a
knife. wire brush. Clean the buffed
area with a solvent.
 Repair Procedure (2)
Mix Compound-A and Compound-B at a ratio of 1: 1.

Caution: Mix well and use within 2 hrs after mixing

Apply two coats of Special Cement. Apply the second coat

after the solvent in the first coat has evaporated.

Fill the damaged area with the mixed Compound and

spread it approx. 5mm thick. Leave it for 3 days.
Repair Procedure (3)

Mix SC4000 and Hardener at a ratio

of 1000: 40 in measuring cup.
(4% of total weight)

Take off plastic film covering green

color side of the Rubber Sheet.

Apply two coats of mixed SC4000

over the mixed Compound (A+B)
and Rubber Sheet. Allow the first
coat dry completely for 30 minutes,
and then apply the second coat.
Repair Procedure (4)

Put the rubber sheet over the

area.

Press the Rubber Sheet firmly

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

Apply the wrapper with

maximum tension around the
repaired area.
Hose Repair - Example (1)
Cut on Outer Cover

Scratch on Outer Cover

Hose Repair - Example (2)
Damaged Sponge Layer
 Thank You for Your Attention !

Terima kasih atas perhatian Anda!