500 Flexible Hose

Abstract
This section gives the reader general information about flexible hose and its use in the Company. Care and inspection of cargo hose for marine use is also discussed. Contents 510 511 512 513 514 515 516 517 520 521 522 523 524 525 526 530 531 532 533 534 General Information Where Flexible Hose is Used Types of Hose on the Market Physical Characteristics of Flexible Hose Couplings for Flexible Hose Company and Industry Specifications and Standards; Qualification of Hose for Critical Service References Inspection and Testing of Critical Service Hose at the Point of Manufacture or Assembly Use and Handling of Cargo and Submarine Hose (275 Psi) Operating Limitations Handling of Hose (General Conditions) Handling of Submarine Hose (Special Conditions) Damaged Hose Cleaning of Cargo Hose Storage In-Service Inspection of Cargo Hose (275 psi) Frequency of Inspection Inspection Procedure Inspection Results Disposition of Condemned Hose 500-14 500-9 Page 500-3

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Evaluation Test Hose Inspection Report

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510 General Information

This section discusses where flexible hose is used, types of hose on the market, and lists Company and industry specifications and standards for hose in various services.

511 Where Flexible Hose is Used

Hard piping is always preferred over flexible hose in the oil and petrochemical business. However, flexible hose is called for wherever a temporary connection is needed or where flexibility is required to accommodate motion, alignment, vibration, thermal expansion and contraction, and ease of routing. The Company uses flexible hose to transfer crude and refined products between ship or barge and shore, between offshore terminal and ship, between onshore terminals and trucks, and from marketing facilities to cars and aircraft. Other Company uses are LPG hose, steam hose, vacuum hose, rotary drilling hose, utility hose, and fire hose.

512 Types of Hose on the Market

Three categories of hose are produced today: rubber, composite, and metallic. Nearly all hose in Company use today is rubber.

Rubber Hose
Rubber hose is made of an inner tube of rubber or elastomer wrapped in reinforcement of either textile and/or metal, and covered with rubber, plastic, or textile materials. These components are normally bonded together during the vulcanization process. The inner tube must resist fluids the hose will carry. Reinforcement must be chosen for the needed strength and flexibility, and the cover must protect the reinforcement from oils, abrasion, flexing, temperature extremes, etc. Most hose in Company use is smooth bore. In rare services such as hot asphalt or tar which could cause the inner tube not to adhere to the hose, an inner coil of wire keeps the tube in place. Such a hose is called rough bore hose.

Composite Hose
Composite hose is made of layers of polypropylene or polyethylene spiraled over a wire coil core and then covered by a wire coil on the outside. To date, no composite hose can meet the 275 psi working pressure required of cargo hose. Although some composite hose can meet the 200 psi requirement of barge hose, it is not light enough to meet the weight limitation of the Companys barge hose specification. The Company has tried a composite hose to transfer fuel between terminals and tank trucks (bottom loading hose), but unleaded gasoline attacked the hose; a subsequent 3 year trial of several brands of composite hose in this service resulted in leakage at or adjacent to end fittings, leaks through the wall of the hose itself, and fittings improperly installed. The component layers of composite hose are not bonded

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together and the sealing boundary layer is only a few thousandths of an inch thick in some hose designs. The end fitting design for composite hose depends on an elastomer gasket cap at the end of the hose (within the fitting) to prevent leakage; this and other aspects of the end fitting design and installation result in a hose assembly of questionable reliability. Composite hose also has a lower fluid velocity limit than rubber hose. Composite hose is not recommended for hydrocarbon service (it can be considered for vapor recovery hose).

Metallic Hose
This hose consists of a stainless steel corrugated liner covered with stainless steel braid. The Company has used it in a few locations for LPG service. Corrugated metal hose is very easily damaged and a great deal of care is required in handling it and avoiding bending that results in permanent deformation/damage. This type of hose also has been found to emit noise (vibration of the corrugated liner) at flow velocities as low as 20 ft/sec (rubber hose typically has flow velocity capabilities of 50 to 70 ft/sec); this vibration in the corrugated liner could lead to fatigue failure or failure by liner abrasion against the braid. The liner is thin stainless steel so there is risk of chloride cracking or pitting when this type of hose is used in a marine environment.

513 Physical Characteristics of Flexible Hose

Flexibility
The hose chosen must be able to conform to the smallest anticipated bend radius without overstressing the hose. Hose manufacturers usually assign their hose a minimum bend radius, which is measured to the inside of the curvature. Flexibility is not always desired. For example, hose for abrasive blasting would be destroyed wherever high velocity sand strikes the tube where the hose changes direction.

Suction/Vacuum
Hose in suction or vacuum service must be stiff enough to resist collapse. The hose body can be built with a helical wire reinforcement for this purpose.

Hose Identification
Hose for specific services is often ordered with colored bands or stripes to denote intended service. Hose can also be ordered with identifying marks. Not all of Chevrons operating companies use the same color coding, however. Check with your facility before ordering hose with color coding. The Companys hose specifications cover identifying marks, where required.

514 Couplings for Flexible Hose

Couplings are of three types: reusable with clamps, reusable without clamps, and nonreusable. In addition, the coupling must be able to withstand the service pressure, and coupling material must be suitable for the service fluid.

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For more information on couplings, refer to Publication IP-2, Hose Handbook by the Rubber Manufacturer's Association. This publication and others are available from the following addresses: Rubber Manufacturers Association 1901 Pennsylvania Ave., N.W. Washington, D.C. 20006 Rubber Association of Canada 100 University Ave. Toronto, Ontario M5J 1V6

End Fittings (Couplings) for Hose in Bulk Hydrocarbon Service

There are 3 types of end fittings that are suitable for rubber hose in bulk hydrocarbon service: built-in, externally swaged or crimped, and internally expanded. All 3 types are nonreusable. Built-in fittings are an integral part of the hose construction; the raw hose components are assembled over the end fittings, adhesive bond is made between the tube material and the shank of the end fitting, and binding wire is used to pull hose reinforcement material down between ribs welded to the shank. The entire assembly is then vulcanized. Built-in fittings are the most reliable type of end fitting, but the most difficult type of fitting to deal with when manufacturing a hose. All submarine and floating hose have built-in end fittings (except hose in MTBE service). Externally swaged (or crimped) end fittings (also known as pressed-on fittings) have a serrated shank that is positioned inside the hose and a serrated or grooved cylindrical ferrule that is placed on the outside of the hose. The ferrule is reduced in diameter while assembled on the hose with the shank in place by forcing it axially through a die or by crimping with a split die that moves radially. This type fitting is shorter than a built-in fitting, so the hose assembly is more flexible at the ends. End fitting selection and installation criteria are critical factors that must be considered to assure that end fittings do not leak or blow off the hose in service. Internally expanded fittings are similar in construction details to the externally swaged type, but the shank is expanded rather than the ferrule being swaged/crimped. Internally expanded fittings are less forgiving of selection/assembly errors than externally swaged fittings and are considered less reliable. As for externally swaged fittings, end fitting selection and installation criteria are critical. Internally expanded fittings should normally be limited to tank truck bottom loading hose and aircraft refueling hose.

Couplings for Steam Hose

Two types are available: the (older) interlocking clamp-type and the (newer) TriLockt-type. The clamp-type coupling requires the steam hose user to check clamp bolt tightness before each use and occasionally the clamp must be changed to the next smaller size if the clamp halves have been tightened enough that they touch other. This procedure is time-consuming and if not done, a safety hazard exists. In addition, the clamp-type coupling's large size and protruding bolts is more cumbersome to use, difficult to use in tight spots, and snags easily on equipment.

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The Tri-Lockt-type coupling, once installed, needs no retightening. It has been in existence 20 years, and suppliers have not heard of any failures to date. The Rubber Manufacturers Association recommends the interlocking clamp-type coupling. However, until the CRTC Materials and Equipment Engineering Unit contacted the RMA in 1989 it had not heard of the Tri-Lockt-type coupling. Company use varies: Pascagoula specifies the clamp-type but El Segundo and Richmond specify the Tri-Lockt type.

515 Company and Industry Specifications and Standards; Qualification of Hose for Critical Service
Not all hose in Company use is required to comply with a standard, for example, utility hose. However, certain categories of hose must meet Company-set criteria before purchase. CRTCs Materials and Equipment Engineering Group set criteria for cargo, barge, SPM, and other hose in critical service. The M&EE Quality Assurance Team normally qualifies hose for critical service by review of hose drawings and end fitting selection/installation procedures, and requiring a successful prototype burst test; this includes hose for marine transfers, LPG hose, bottom loading hose, and corrugated metal hose. Hose meeting the criteria go on a qualified suppliers list maintained by the M&EE Quality Assurance Team. Corporation HE&LP specifies fire hose and has opinions on LPG hose, cargo hose, and temporary hookups. Company criteria for acceptance are summarized below.

Hose for Marine Transfers

Hose in this category includes cargo hose, lightweight cargo hose for barge use, and SPM hose. Hose for marine transfers must be conductive, but either one length in the string must be nonconductive, or else there must be an insulating flange between the shore-to-ship system. Often this flange is in the riser piping onshore. This electrical insulation is required to prevent sparking, since ships and barges are at one potential and shore at another. Bonding alone does not make it safe. For SPM hose, the over-the-rail hose should be nonconductive or the end connection should be insulating.

Cargo Hose (275 psi)

The Company's Model Specification PIM-MS-2923 in this manual covers cargo hose for submarine use, for dock use and for use between ships (called lightering hose). Hose meeting this specification is rated for 275 psi maximum working pressure, including surges. Sections 520 and 530 give more information about this type of hose.

Barge Hose (200 psi)

Barge hose is cargo hose, and in fact the 275-psi cargo hose can be used on barges. However, the hose lengths are very heavy. Because of this, the Company developed a specification for a lightweight hose to be used between barges and a land site. Hose meeting this specification (PIM-MS-3133) is rated for 200 psi maximum working pressure, including surges.

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SPM Hose
Hose for single point mooring systems (SPM) includes submarine (called underbuoy) and floating hose. Underbuoy hose connects the buoy to the pipeline end manifold. Floating hose connects the ship to the buoy. The Companys Model Specification PIM-MS-3092 covers SPM hose. This specification is meant to supplement Guide to Purchasing, Manufacturing and Testing of Loading and Discharge Hoses for Offshore Moorings, by the Oil Companies International Marine Forum (OCIMF), 1991. Hose meeting the Company's specification is rated for 275 psi working pressure. Section 900 of the Civil and Structural Manual discusses SPM systems and gives hose data of interest to the engineer planning an SPM system.

LPG Hose
In sizes 2" and smaller, hose must be UL listed as meeting the UL-21 standard and marked with the UL symbol. (There is currently no acceptable supplier of UL-21 hose in sizes larger than 2".) The hose, typically used between the marketing terminal and the LPG truck, has a 350 psi maximum working pressure, 1750 psi minimum burst pressure. Only externally swaged or externally crimped end fittings should be used on UL-21 hose. End fitting selection/installation is critical but end fittings are not within the scope of UL-21; therefore, qualification of small diameter LPG hose assemblies involves the specific brand/type of hose and end fitting, and the hose distributor who installs the end fittings and presure tests the hose. Qualification must include a prototype burst test since experience has shown that end fittings may blow off the hose at substantially less than the minimum rated burst pressure of the hose itself. For LPG hoses in sizes larger than 2" there is currently only one qualified supplier of rubber hose; this hose design has built-in fittings and meets British Standard BS4089 (not UL-21) except that the hose meets the 5:1 burst/MAWP ratio which is the Company standard for hose in hydrocarbon service. There is currently one qualified supplier of corrugated metal hose for LPG service (see limitaitons/precautions to be observed for metal hose in Section 512 of this manual). Refer to Paragraph 7.5 of Section 1100, LPG Guidelines, for more information on Company requirements.

Steam Hose
Although hard piping is preferred for steam service, flexible hose is used for temporary hookups and as a vibration dampener between steam lines. Materials and Equipment Engineering at CRTC, with Chevron USA Quality Assurance, gives and evaluates the results of a test on steam hose. The test consists of putting the hose under steam pressure for thirty days and then observing condition of the tube. If it hasn't popcorned, deteriorated, or cracked, the hose is tested for another 30 days. Hose passing the 60-day test is added to the Company's list of approved steam hose. Materials and Equipment Engineering at CRTC will be testing again in late 1989, and in order to find the brand with the lowest effective cost, tests will continue until each hose fails. For maintenance information, refer to Rubber Manufacturers' Association Publication IP-11-1, Steam Hose; Manual for Maintenance, Testing and Inspection.

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Vacuum Hose
This hose is used for tank cleaning. There are no Company or industry specifications for it, but vacuum hose should be able to withstand a vacuum of 30 inches water column and should be grounded with static wire, especially hose used with bulk dry materials.

Fire Hose
Corporation HE&LP specifies fire hose. See the Fire Protection Manual.

High Pressure Water Hose

The Company uses this hose for computer chilling water. It has a maximum working pressure of 250 psi. There is no Company specification for this hose.

Tank Truck Bottom Loading Hose and Aircraft Refueling Hose

The Companys Marketing Operations Standard MOS 201 covers aircraft refueling hose (from cart to aircraft, not from hydrant to cart), tank truck bottom loading hose, and vapor recovery hose for tank truck bottom loading. This specification is based on API Bulletin 1529.

Dispenser Hose for Marketing Facilities (with vapor recovery system)

The Companys Marketing Operations Standard MOS-244, Service Stations Pumps and Dispensers covers this type of hose.

API Rotary Drilling Hose

The Company engages contractors for rotary drilling work, so it does not purchase this type of hose. The hose (4000 to 5000 psi working pressure) supplies mud and water to the drill bit during drilling operations. The hose is made to API Specification 7, Grade C.

516 References
1. International Safety Guide for Oil Tankers and Terminals, Witherby & Co., Ltd., England (can be ordered from George Butler Co., (415) 421-8454). Chevron Shipping uses this guide as a minimum and must comply with all the Coast Guard regulations (CFRs). The guide has 3 sections of interest: Connections, Cargo Hose, and Static Control. API Recommended Practice 2003, Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents. A copy of API RP-2003 is in an appendix of the Fire Protection Manual. Chevron Shipping Marine Regulation (MR) 200. This document is based on Reference 1. Steam Hose Survey, D. L. Nail, Materials Division File 38.35, September 1, 1989.

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517 Inspection and Testing of Critical Service Hose at the Point of Manufacture or Assembly
Shop inspection of marine hose and other critical service hose is warranted. Inspection at the point of hose manufacture (or at the distributor where the end fittings are installed and the hose assembly is tested) is normally done by the Quality Assurance (QA) Team that is part of CRTCs M&EE Group, or by a qualified inspector contracted for the work by M&EE QA. Inspection and testing of new hoses (and hose assemblies) will always include a complete visual examination inside and outside and a hydrostatic test. For specific types of hose, vacuum testing, kerosene testing, and electric bond testing may be required. Descriptions of these tests are included in Section 532 of this manual. The degree of inspection might be reduced with an Alliance supplier or a supplier that is highly reliable. Guidelines for source inspection of hose and hose assemblies from CRTC qualified suppliers are as follows: Floating and Submarine Hose to PIM-MS-3092 (OCIMF)Resident inspection during manufacture and testing of the hose. Cargo, Lightering, and Submaring Hose to PIM-MS-2923Final inspection including witnessed vacuum test and witnessed electric bond test; review of pressure recorder charts for hydrostatic and kerosene tests. Double Carcass Cargo and Lightering Hose to PIM-MS-3092 or PIM-MS-2923Final inspection as for PIM-MS-2923 hose plus witnessed air test of secondary carcass. Barge Hose to PIM-MS-3133Final inspection similar to PIM-MS-2923 hose. LPG Hose up to 2" sizeNo inspection. LPG Hose over 2" sizeFinal inspection similar to PIM-MS-2923 hose. Corrugated Metal HoseInspection after end fittings are welded to the hose and witness of hydrostatic test. Tank Truck Bottom Loading Hose and Aircraft Refueling HoseNo inspection.

520 Use and Handling of Cargo and Submarine Hose (275 Psi)
This section describes procedures covering the use, handling, and storage of cargo hose for marine and submarine use, for dock use and for use between ships (called lightering hose). It does not cover hose for single point mooring systems or barge hose. (Size range in Company service currently runs from 3-inch to 20-inch hose with the use of 24-inch submarine hose scheduled in the near future. Affiliate companies currently use hose to 24-inch diameter.) These procedures were developed to minimize the chance of failure during operation and to ensure maximum service life. Inspection procedures are given in Section 530. For procurement of cargo hose, see Model Specification PIM-MS-2923, Smooth Bore Cargo and Submarine Hose.

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For SPM hose, refer to Model Specification PIM-MS-3092 and SPM Hose Standards, Guide for Handling, Storage, Inspection and Testing of Hoses in Field and SPM Hose Ancillary Equipment Guide, latest issue, for recommendations adopted by the OCIMF Oil Ports Committee. The Oil Companies International Marine Forum (OCIMF) is a voluntary association of oil companies having an interest in the shipment and terminaling of crude oil and oil products. For barge hose, refer to PIM-MS-3133.

521 Operating Limitations

Pressure
Hose constructed in accordance with Specification PIM-EG-2923 is designed for a maximum operating pressure of 275 psi and a test pressure of 425 psi. Pressure limitations of ANSI Class 150 flanges are dictated by temperature when product carried is in excess of 100F. Exceeding Maximum Working Pressure. Applying a continuous pressure to a hose above the maximum working pressure may permanently damage the carcass. Although the burst pressure of new hose is at least five times its maximum working pressure, used hose may burst at pressures as low as 500 psi. Hose Life. Hose that has been in service 6 or more years should be retired. This is because you canot tell by looking at a hose that it is ready to fail. Continued use of hose may result in catastrophic failure due to age deterioration of tube and carcass materials. However, hose that is handled carefully and not continuously exposed to sunlight could be considered for longer use than 6 years by the user. Federal Safety Requirements. U.S. Federal rules and regulations pertaining to safety define the testing and pressure limitations in the use of hose in a cargo piping system (Federal Register, Volume 35, No. 1779/11/70 Title 33, Chapter 1, Part 126.15, Paragraph 7-IV and 7-V). Hose must not be used in a cargo piping system where the maximum available pressure (pump, static head, and surge or relief valve setting) exceeds the maximum rated working pressure of the hose. Instead of installing relief systems in the hard piping at wharves, the Company has elected to use hose designed as strong as the Class 150 piping system. Federal Pollution Control Rules. Federal rules and regulations covering pollution control relating to hose are listed in the Federal Register Vol. 37, No. 246, 12-21-72, Title 33, Part II, Chapter 1, Parts 154.500, 154.20, and 156.170. Paragraph 156.170 requires that information about each hose be available in one of two ways: The hose must be stenciled with product(s) handled (oil service), date of manufacture, burst pressure, manufacturer's recommended working pressure, date of last test, and pressure used for that test, or This data must be recorded elsewhere at the facility and the hose marked so as to identify it with the information in the record.

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Test requirements (pressure and frequency of test) as stated in the Federal Register, Volume 35 (pertaining to safety) must take precedence over that stated in Volume 37 where there is an apparent conflict. Applying Federal Regulations Outside the U.S. It is recommended that these regulations be applied to hose supplied to all Company installations although some berthing locations may be outside the continental limits of the United States. Transfer System Pressure Gage. Each piping system should have a recording pressure gage, in operating condition with chart, in the transfer system.

Vacuum
Cargo and submarine hoses are designed to withstand a vacuum of 20 inches of mercury column. This assures adequate resistance of the hose carcass to vacuum in service and also gives assurance that the tube is firmly attached to the rest of the carcass. Badly kinked hose may not withstand this much vacuum without partial collapse.

Temperature
Recommended maximum temperatures vary by service: Crude and heavy fuel oils Diesel and light fuel oils Gasolines and aromatics Asphalt/tar 180F 125F 85F 350F

Hose for regular asphalt service should be purchased to Specification PIM-MS-2923, but the engineer should specify rough bore for 350F asphalt service so that the hose will be manufactured with an internal metal reinforcement to hold the liner in place. Such hose has been giving satisfactory service. Refer to Materials and Equipment Engineering at CRTC for recommendations on use of high temperature Neoprene tube carcass materials as an alternate to using rough bore hose. Where operating requirements exceed normal temperature or pressure limits of hose, articulated rigid pipe with ball bearing swivel joints has been used successfully.

Hose Lining Materials

An inner tube of Nitrile or Neoprene will provide continuous service for 1) crude and heavy oils at 180F containing a maximum of 30% aromatics, 2) manufactured gasolines with a maximum aromatic content of 45% at 85F and 3) natural gas containing 25% butane at 85F. When these limits will be exceeded, even intermittently, hose with special liners (Viton) are required. Aromatic liquids such as reformate, benzene cumene, toluene, xylene and alkanes all fall in this category. Hose used in neat methyl tertiary butyl ether (MTBE) service at any temperature requires the use of low density cross-linked polyethylene (XLPE) liners approved by Materials and Equipment Engineering at CRTC.

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Leaks While in Service

Suspend operations and remove from service any hose developing bulges, sweating, or pin hole leaks in the carcass, or leaks between the nipple and carcass.

522 Handling of Hose (General Conditions)

Cargo and submarine hose should not be dragged or rolled. Acceptable ways to move hose are with rollers, dollies, or derrick. The following instructions are intended to aid in the prevention of hose damage.

Lifting of Hose
Hose should be lifted in accordance with the following: 1. 2. 3. 4. 5. Never lift a hose by a single sling at the midpoint. Support hose at no less than 10-foot intervals. When attaching lifting bridles to hose, provide saddles at least 3 hose diameters in width. Do not bend hose in service to a radius of less than 6 times its nominal diameter without consulting Materials and Equipment Engineering at CRTC. Preferably, use more than one sling to suspend hose over the rail of a vessel, or in similar situations. However, when a hose is being lifted vertically, a single sling may be used if it is attached at the end and bend radius limits are not exceeded. Provision should be made, while lifting hoses, for the possibility of spills, including retention and recovery of spilled material before it reaches navigable water.

6.

Connecting of Hose to Vessel

When making vessel connections with hose, the following precautions apply: 1. Each time before placing a length of hose in service, inspect it externally for severe damage such as corroded or broken reinforcing wires and tears or breaks in the carcass (layers of wire or textile cord under the cover and breaker fabric). Hose showing such damage is unsafe for service. Whenever the cover of a hose has circumferential ridges, remove it from service. This deformation indicates a broken helix wire. Use sufficient hose to compensate for vessel movement during cargo exchange and tides, adjusting hose as necessary to avoid kinking and abrading or tearing of cover. As the ship changes elevation adjust the supports to keep the curvature evenly distributed. Avoid kinking the hose. Position and support hose so that no sharp bends will develop. This is most important at the hose end fitting.

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4. 5. 6.

Do not permit more than 50 feet of hose to be vertically suspended in the air without intermediate support. Prevent contact of hose with hot lines. Contact Materials and Equipment Engineering at CRTC for suggested hose cover insulating overwrap. If the cargo hose comes in contact with the vessels rail, deck edge, and dock edge, rollers or chafing mats must be provided. These precautions will also help prevent abrasion of hose cover due to pulsations from reciprocating pumps. If necessary, minimize pulsations by adjusting pump speed and keeping air chambers charged at proper pressure.

523 Handling of Submarine Hose (Special Conditions)

Most frequent damage occurring to submarine hose is kinking while in service. To prevent kinking, keep adjusting mooring lines as the vessel changes position as a result of operations or variations in the weather and tides, so that the vessel will not crush the hose, bend it too sharply, override it with the keel, or cut it with the propeller. The larger the diameter of hose the more destructive the effect of kinking will be. Dragging hose across the bottom at any time must not be permitted because coral, rocks, debris, etc. will severely cut and abrade the cover. Locate ship as close to position of hose as possible and adjust position of ship when raising hose so that it will be suspended in a gradual long curve.

524 Damaged Hose

Line Pull
Whenever a cargo or submarine hose system is damaged by a longitudinal pull or by other means, all hose in the string should be removed from service. Such hose will require close visual examination for defects and all inspection tests to determine if it is still serviceable. Longitudinal pulling may dislocate helix wires, distort or crack flanges, and tear reinforcing cord or fabric.

Kinking
Once a hose has been kinked, its useful life may have been seriously reduced. Kinking damages inner strength plies and often breaks metal reinforcements, making it unsuitable for use. In addition, if a hose is operated while kinked, the increased velocity of flow at that point may tear the tube, plug the hose, and result in a rupture failure.

Tears, Cuts and Abrasions

Tears, cuts, and abrasions penetrating through the hose cover will permit water to enter the carcass, corrode the reinforcing wire, and deteriorate the textile plies. Tears, cuts, and abrasions through the cover should be repaired by vulcanized patching or cold vulcanizing elastomeric putty to increase hose life and prevent

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failure in service. A hose with tears or cuts that damage reinforcing plies should not be repaired.

525 Cleaning of Cargo Hose

All cargo hose should be thoroughly drained immediately after use to remove excess liquid and then allowed to aerate for 24 hours. Then the hose should be blinded to slow down the drying and reduce extraction of the plasticizers from the tube. Submarine hose should be filled with a non-aromatic hydrocarbon. Hose being aerated should be placed so that any spills from the hose will be contained and recovered. No special cleaning procedures are necessary for hose in frequent service. When hose is to be placed in storage for an indefinite period, cleaning procedures vary with the type of stock the hose carries.

Light Stocks
Evaporation will adequately cleanse hose that has handled light stocks when hose is laid straight and level so that air may circulate freely. Hose being aerated should be placed so that any spills from the hose will be contained and recovered.

Heavy Stocks
Hose which has handled heavy stocks normally requires special provisions for cleaning. In some areas, this might be handled by the reclamation organization.

526 Storage
Hose stored for indefinite periods should be laid level and straight in a cool place protected from direct sun. When necessary to store in sun, protect with canvas or reinforced building paper. The cover of stored hose deteriorates faster by action of the sun and ozone than hose in service, according to the manufacturers. Hoses should be stored in single height layers. Hose to be stored should be free of oil accumulations which could cause a spill.

530 In-Service Inspection of Cargo Hose (275 psi)

This section gives a procedure for routine inspection of cargo and submarine hose during service. Hose that passes this inspection should not be expected to fail before the next required inspection.

531 Frequency of Inspection

Frequencies given in Figure 500-1 apply to all active hose. Where unusual service conditions warrant, to minimize the possibility of hose failure and resultant spillage, complete internal and external inspection should be made at more frequent intervals, particularly at new submarine terminals. Any hose which has been out of

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service and not tested for more than six months should normally be hydrostatically tested prior to reuse.
Fig. 500-1 Maximum Intervals Between Inspections Submarine Hose Type of Inspection External Internal Vacuum and Hydrostatic Test Cargo Hose 6 months 6 months 12 months Hose at Surface(1) 6 months 12 months 12 months Hose at Depth 12 months 12 months 12 months

(1) Sections that can be lifted above water

When service conditions have been abnormally severe and hose has been subjected to unusual stress or damage, resulting from movement of the vessel, serious storm conditions, or excessive pressure, or when appearance of exposed hose shows damage, a complete inspection, including a hydrostatic test, should be made prior to reuse, unless local management deems otherwise. U.S. Federal regulations require an annual hydrostatic test to 1 times maximum allowable working pressure (Federal Register, Vol. 35, No. 1779/11/70, Title 33, Chapter 1, Part 126.15).

532 Inspection Procedure

External Inspection
1. Look for kinking of the carcass and indications of broken reinforcing, as evidenced by flat spots and circumferential ridges on the surface of the cover. Inspect for bulges, cuts, and abrasion through the cover. Examine the external surfaces of all flanges, nipples, and ferrules which are not rubber covered, for excessive corrosion, cracks, dents, scars, distortion, etc. Whenever circumferential ridges protrude along the cover of any hose, remove it from service. This deformation may indicate a broken helix wire. Broken helix wires may penetrate tube material and/or tear reinforcing plies, making the hose less leak- and burst-resistant. Submarine hose may be externally inspected without disconnecting, as follows: a. b. Hoist as many lengths of hose from the water as possible and note condition. When conditions warrant, have a diver examine the outside surface of those lengths remaining below the water.

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4.

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c.

Pay particular attention to the lengths closest to the vessel where possibility of damage is greater due to movement. This applies particularly to the second, third, and fourth length from the ship.

Internal Inspection
1. Disconnect each length of hose in the string and place it on a flat surface. Reflected sunlight or an enclosed and gasketed lamp should be used for illuminating the hose interior. Examine for bulges, cuts, tears, or looseness of the inner tube. An extruded lip at the end of a built-in fitting sometimes forms when rubber flows between the fitting and mandrel during vulcanization; this is not harmful and may be cut off except in the case of viton lined hoses which need to be evaluated carefully to insure that the viton layer is not cut through. Examine the surfaces of all flanges, nipples, and shanks for corrosion or possible cracks.

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4.

Hydrostatic Test
Extend the hose horizontally on dollies or rollers. Blind both ends, connecting one end to a test pump by means of a flexible hose and fitting the other end with an air vent valve. Fill the hose with water, elevating the vent to assure removal of all air. With personnel at a safe distance perform the following steps: 1. Establish the benchmark for the hoses Original Length, Lo (if you do not already have it from hose test inspection records): a. b. Raise pressure to the rated working pressure and immediately release to zero pressure. Raise the pressure in the hose to 10 psi and hold for 5 minutes. During this period measure the length of the hose from end of flange to end of flange. This shall be recorded as the Original Length, Lo.

2.

Raise the pressure to 1 times the rated working pressure for the grade of hose being used and hold this pressure for 15 minutes. During this hold period, the hose shall be examined for any leaks at the couplings or nipples or for any indication of weakness in the hose structure such as hard bulges, ridges, grooves and fitting movement. Measure and record the length of hose from end of flange to end of flange. This shall be recorded as the Test Pressure Length, Lt.

3. 4. 5.

Reduce pressure to 25 psi and hold for 5 minutes. During this period, examine nipples for low pressure leaks. Reduce pressure to 10 psi, permit hose to rest for 15 minutes and then measure the length. This will be recorded as the Permanent Elongated Length, Lp. Using Equations 500-1 and 500-2, calculate:

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500 Flexible Hose

a.

Test pressure elongation, percent Lt L o - 100 = ---------------Lo

(Eq. 500-1)

b.

Permanent elongation, percent Lp Lo - 100 = ----------------Lo

(Eq. 500-2)

6.

Examinations of Elongations. After each periodic pressure test, compare the elongation test results to those obtained when the hose was new. At the end of any periodic testing, if the increase over the original value is greater than that shown below, the hose should be retired from service. a. When tested at 1 times rated working pressure, test pressure elongation at any periodic test shall not be greater than the new hose test pressure elongation (5a) plus 4% or twice (5a), whichever is greater. Permanent elongation at any periodic test shall not be greater than the new hose permanent elongation (5b), plus 4% or twice (5b), whichever is greater. Excess values mean that hose carcass materials have deteriorated or been subjected to pressures (tensions) greater than or at point of yield.

b.

Electric Bond Test

At each stage of the hydrostatic test and upon its completion, the electrical bond in submarine hose is tested. Wires connected to each flange and to a flashlight battery and lamp in series are commonly used for this test. For the hose to pass the test, the lamp should light. Water inside the hose or moisture on the outside can establish a conductive path, so continuity (or non-continuity) should always be checked with the hose empty and as dry as possible on the inside and outside.

Vacuum Test
After the pressure test the internal bore of cargo and submarine hose should be examined under vacuum for bulges or blisters, i.e., areas where the tube has separated from the carcass. For this test, close one end of the hose with a plexiglass plate, use a flashlight in the hose to illuminate the interior near opposite end, and close the opposite end with another plexiglass plate attached to a vacuum pump or other aspirating device. Soft rubber gaskets may be used at each end. A vacuum of 20 inches of mercury is adequate to disclose tube separation or significant flattening/kinking of the hose. Submarine hose, because of its larger diameter, is more susceptible to internal damage as a result of kinking.

Chevron Corporation

500-17

January 1998

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Piping Manual

533 Inspection Results

Hose which has tears, cuts, or abrasions through the external cover only, but is otherwise in good condition, is suitable for repair. After repair, it should be fully tested. When inspection reveals any of the following defects, hose is normally condemned: 1. Internal Inspection Bulges in tube. Cuts, tears, or splits through tube. Looseness of the tube or any part of it hanging into the bore of the hose (except see comment on extruded lip at nipple end in Section 532 of this manual). Any flanges, nipples, or shanks with cracks.

2.

External Inspection (Solid Helical Wire Reinforced Hose) Severe kinks. (These are kinks in which the minor outside diameter of the hose is reduced 20% or more. They show up as a hinge action when the hose is secured a few feet away from the kink and lifted.) Exposed carcass with broken strength wires or torn fabric. Evidence of severe corrosion of reinforcing wires by exposure to sea water. Lumpy appearance of surface of cover caused by buildup of corrosion products on reinforcing wires. Cracks in flanges, nipples, or ferrules. External Inspection (Stranded Helical Wire Reinforced Hose or Helix Free Kink Tolerant Hose) With no internal pressure the hose must be generally round and free of sharp kinks, evidence of crushing, and damage to hose cover such as cuts and tears. Under a vacuum of 20 inches of mercury general flattening exceeding 55% of the nominal hose diameter and kinks which might be obvious under the vacuum test and are indicated by a complete collapse of the carcass wall over a short distance (generally less than 9 inches) shall be cause for rejection. Hydrostatic Test Any sweat or pinhole leak. Bulges that are hard or liquid filled. Bond Test Internal electrical bonding between nipples of submarine hose is necessary if the hose is to be an integral part of a cathodically protected system. Failure of the electric bond in service, however, would not justify condemning an otherwise acceptable hose. Instead, the hose would be placed at the outboard end of the hose assembly. Internal electric bonding of hose is not required for static protection.

3.

4.

5.

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500 Flexible Hose

The helix wire in the hose's carcass is part of the circuit. Loss of electrical bonding may mean that the helix wire has broken. If such a break occurs in the main body of the hose (between the inboard ends of the hose nipple skirts), the hose should be condemned.

534 Disposition of Condemned Hose

Condemned hose should be immediately so marked in large letters and removed from service at once.

535 Evaluation Test

When in doubt as to serviceability, condemn and apply a burst test to the hose. This information should be reported through normal communication channels as a contribution to the Company's accumulated experience on deterioration and adequacy of inspection criteria.

536 Hose Inspection Report

A carefully supervised record should be kept for each hose on either a card or a log book. The record should include: Date received Date placed in service Manufacturer's name Hose brand and serial number Hose size Hose length Rated working pressure Rated burst pressure Type of fitting (built-in or pressed-on) Date removed from service Date and results of periodic hydrostatic testing and examination (Indicate items to be measured; name of tester, agency name; comments on results) Date returned to service Comments Date of retirement

Chevron Corporation

500-19

January 1998