INSTRUCTIONS FOR THE USE OF LONG LENGTH AND SPLICED HOSES

Transcription

1 ContiTech Rubber Industrial Kft. Hose Technical Department HANDLING Page: 1/6 Date: Invalidate the document TKO AS1 rev.3 INSTRUCTIONS FOR THE USE OF LONG LENGTH AND SPLICED HOSES Prepared by: Revised by: Approved by: Imre Domonkos József Dávid Gyula Bétéri FOR BEST IMAGE QUALITY SUGGESTED TO PRINT IN 600 DPI

2 Page: 2/6 1. INTRODUCTION The hoses covered by this instruction are suitable for different offshore applications. The supply of the system with high-pressure hydraulic oil is an important task on hydraulic pile hammer equipment. The stripwound lined bonded long length hoses are proven in the heavy-duty service. Other applications are the use for sweet or sour service production of crude oil, including export and injection applications. Products include oil, gas, water and injection chemicals and combinations of these services, as it is specified in the purchase order. The hoses covered by this instruction are produced in one continuous length or spliced with built-in rigid sleeves over 33,5 m (110 ft). The purpose of the short instruction is to inform the users about the most important special knowledge for the use of the hoses. If the hose is used in high pressure gas service, please ask for the special handling instruction (S-TU 022) for hoses acc. to API Spec 17K and API RP 17B as well a more detailed general publication for the handling, inspection and use TKO AS0 and gas hoses TKO AS4. Address as below: ContiTech Beattie Ltd. Jubilee Industrial Estate Ashington, Northumberland NE63 8UB England Phone: ; Fax: sales@contitechbeattie.co.uk WEB: ContiTech Beattie, Corp Brittmoore Park Drive Houston, TX USA Phone: Fax: mail@contitechbeattie.com WEB: ContiTech Rubber Industrial Kft Szeged, Budapesti út 10. Hungary Phone: ; Fax: ; sales@fluid.contitech.hu WEB: 2. CHECKS PRIOR TO INSTALLATION OF THE HOSES Before installation, the size, pressure range, service requirements, working temperature, bending radius and subsea or topside execution have to be checked whether they are all in accordance with the specification. Cross check to the hose data book and purchase order requirements. The full implementation of the manufacturer's instructions will extend the lifetime not just of the hose, but of the entire high pressure system including seals of flanges and valves. The control measures themselves intrinsically contribute to the prevention of failures and maintaining records are good supporting evidence for specific analysis of any failures. Every individual element of the high-pressure containment structure is sensitive to overloading. Frequent rapid transients in the operational conditions, including pressure, temperature and mechanical loads should be eliminated as a basis of operational philosophy, or limited as much as possible.

3 Page: 3/6 The actual working conditions should be limited to parameters of the manufacturer's design data at all times. Bonded hoses are custom designed and built for the fluid service composition and operating parameters, therefore the buyer should not use the hose for other fluids than the ones specified at the purchase of the hose. Long length hoses can be stored in a number of ways. The best method of storing hose depends on its size (diameter and length), quantities and the way in which it is packaged. Reels are the most commonly used for the storage of hose in long lengths. Reels which are driven by a winch system can also be used to maintain the hoses tension during installation and recovery. There are four main parameters in selecting storage reels for hose. The drum radius should meet or exceed the minimum storage bending radius requirements of the hose. The size of the reel should accommodate the volume of the hose length, including endfittings and accessories. The structure of the reel should be capable of safely supporting the weight of the hose. If the reel is for offshore installation, its dimensions, structural design and construction should account for the loads induced by the vessel motions and the hose tension during installation and recovery. In the fabrication of reels, particular attention should be given to ensure that all surfaces in contact with the hose are free of any sharp edge, burr or cut which might damage the hose cover. 3. SPECIAL HANDLING INSTRUCTION Preferred way of moving hoses in long length requires the use of several low profile dollies with swivel casters. The hose is mounted on these dollies and one end is towed by a truck or forklift.

4 Page: 4/6 Hose may also be lifted by crane. Hook should be attached to lifting lug or lifting clamp. Special precaution should be taken to avoid dragging the hose on any surface. When the hose is transferred from reel to reel, precautions should be taken to ensure that that no damage occurs by dragging it on the ground or against the handling equipment, or by unacceptable torsional loading as a result of improper procedures. How the hose must not been handled? Never lift a hose by a single sling at the mid-point. Never lift a hose by two slings close to the mid-point. Never drag a hose across the ground. Never bend a hose below its minimum bending radius. The two most common methods are: 4. INSTALLATION 1. Chute laying: in this method, the hose is rolled out from its storage reel and launched over a steel chute. 2. Wheel laying: in this method the hose is stored on board of the laying vessel on reels or in straight position of individual lengths. A sheave is used to deflect the hose as it leaves the laying vessel while minimising contact pressure and friction forces.

5 Page: 5/6 It is recommended that intermediate connections of hose segments be pressure tested on the laying vessel before they are launched. Particular attention should be paid to the passage of intermediate connections over a chute, sheave roller or drums to prevent excessive bending behind the end-fittings. Hose can be installed either empty or full of seawater or some other fluid. This will depend on the application and the environmental conditions. The configuration must be carefully controlled during installation and operation against overbending, axial overload and contact to any alien object. Hose can generally be retrieved with great care in a manner similar to its installation. It can, therefore, be re-used for a similar application. However, a number of considerations are critical. No postwelding is allowed on the couplings. The retrieving device should be attached in a manner that will allow surface spooling, but will not damage the pipe. Hose should be retrieved in a manner to prevent kinking, abrasion or other physical damage. Care should also be taken to avoid damage of nearby lines or structures. Hose should be visually inspected for physical damage as it is retrieved. If any visual damage is noticed the user should refer to the manufacturer for repair procedures. After retrieval, hose should be drifted and pressure tested at 1,5x design pressure. If the hose is used for pile hammer service, it has to be pressure tested with 1,1 times working pressure for 6 hours and has to be drift tested after a project is finished. If the hose has to be repaired, then the test pressure should be 1,25 times working pressure for 6 hours. If the hose is used for crude oil or gas service, the above test has to be made once every year.

6 Page: 6/6 If the hose will be used in a new application, then the procedure has to be organized acc. to 12.3 in the API RP 17B / ISO standard. If the pipe is not to be re-used immediately the user should refer to the manufacturer for recommended cleaning and storage procedures. The user should maintain a detailed record of previous use. The record should specify water depth, production fluid characteristics, installation date, length in service, operation pressure and any events, which might affect the hose functions. The hoses can be used in a water depth, not to exceed that which was defined in the purchase order. If the hose was used in high pressure gas service, lifting from subsea can be conducted only after the sufficient gas diffusion from the hose body. Please consult the manufacturer for the necessary time of diffusion and the lifting velocity. It is recommended to have a slow lifting velocity of hoses in high pressure liquid service as well, because liquids always have a certain gas content. 5. INSPECTION Please see the following documents: INSPECTION GUIDELINES FOR HP DRILLING AND PRODUCTION HOSES, doc.no.: ISS-059