PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

1.

Hose Provision and Storage

2.

Handling

3.

Care and Installation

4.

Maintenance and Inspection

5.

Hose Damage and Repair

Approved by: Barry Ayres

Techflow Flexibles Contacts:

[email protected]
[email protected]
tel: +44 (0) 1670 706210
fax: +44 (0) 1670 706211

PCD001 Flexible Hose User Manual

Rev 4

1.

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

Hose provision and storage:

The hose is provided coiled and fastened securely in a wooden crate, or for large bore hoses laid
straight 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 ambient
temperature. The hose should remain in its packing crate at all times and only be removed at the
time 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 tarpaulin
cover 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 only
discarded 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 may
generate ozone.

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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

Wrapped Coupling

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

2.

Handling

2.1

Handling the Packing Crate (Wooden Crate):

Approved by: Barry Ayres

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 and
provide 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 hose
inside (3)

1.
Fork lift forks must enter crate
below centre and pass through
full crate width

2.
Crate lifted using soft
strop through crate and
over hose coils

4.
Fork lift forks must be
fully under crate and
pass half-way

3.
Turn crate on side using
soft strop through crate
and over hose coils

PCD001 Flexible Hose User Manual

Rev 4

2.2

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 forklift
with 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 and
installed 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 as
it 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 end
to 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.

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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

Handling Dos and Donts

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

EXCEEDED MIN
BEND RAD
MIN BEND RAD

Approved by: Barry Ayres

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

2.3.2

Drafted by: Andy Thompson

Approved by: Barry Ayres

Removal of short-length hoses from a steel frame with lifting beam:

Where the length of the hose is relatively short then it can be lifted using a spreader beam
(not standard supply with our packing crates) of suitable SWL.

The spreader beam should be fitted with equally spaced downward lifting points to which
soft-strop loops can be easily fastened. These soft-strops should be positioned evenly along
the hose length, with the two end strops located mid-length of the end couplings

Ensure the hose is lifted straight and in particular the end couplings do not bend..!

PCD001 Flexible Hose User Manual

Rev 4

3.

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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. Twist
in 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 steps
taken 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.

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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

Where the routing of a hose may be difficult or assistance is needed, Techflow Flexibles can assist
with 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. It
must 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.

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 a
dual 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

LIFTING

CHAIN

PCD001 Flexible Hose User Manual

Rev 4

4.

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 and
operating the hose within its design parameters, the operator can seek to maximize the service
life of the hose.
The frequency and extent of inspection is dependant upon consideration of the failure modes of
the 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
Annually
3 to 5 years

visual inspection
in-situ pressure test
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 a
critical inspection technique where potential damage can be identified early allowing remedial
action 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 membrane
2. Reinforcement cables or textiles providing the pressure strength
3. Outer rubber cover providing protection of the reinforcement from the external
environment

COVER
REINFORCEMENT
LINER

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 reinforcement
should 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 body
underneath.
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 is
not 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

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 x
Maximum 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 to
consider 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 be
taken 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
o
o

Pressure test:
o

Small bore camera equipment is used to view the internal surface of the hose liner
and the steel couplings
Observations made of the rubber liner for bulges, bubbles, cuts or abrasion.
Where a metallic liner is fitted internally and only visible, observe crack,
deformation or abrasion.

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 hose
Maximum 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 the
test period.
Checks are made for any leaks from hose body or end couplings, hose body
bulging, 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 the
operating parameters. Typically:

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

o
o
o
o
o
o
o
o
o

Drafted by: Andy Thompson

Approved by: Barry Ayres

Operating pressures
Operating temperatures
Service medium type, density and viscosity
pH levels
Chloride content
CO2 and aromatic contents
Flowrates
Stress levels monitored on connecting equipment
Injected chemicals

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

5.

Drafted by: Andy Thompson

Approved by: Barry Ayres

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 be
evaluated 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 be
condemned.
Repair materials:
Recommended materials for the cover repair are Belzona elastomers. The following components
are 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.

PCD001 Flexible Hose User Manual

Rev 4

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

Apply a coating of Belzona 2921 Conditioner to the damaged and surrounding area. Allow to dry
according to Belzona instructions (until it is touch dry) drying time is dependant upon the
ambient 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 the
cover incision is completely filled and the Elastomer extends to the surrounding area of the
damage. 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 being
placed 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 (see
image below of Techflow Flameshield hose), then the fire rating layer(s) need to be rebuilt
into 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

Cover

Fibre-Glass Layer

PCD001 Flexible Hose User Manual

Rev 4

3.

Date: 6.5.15

Drafted by: Andy Thompson

Approved by: Barry Ayres

For large areas of damage it may be necessary to apply a rubber patch. A piece of
neoprene/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 dry
according 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 stuck
to 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.