Dantec Document No: HHITG1

Rev No: D

Dantec Limited Technical Dept

30/10/2019

Dantec Ltd Head office and works Tarran Way Moreton Wirral CH46 4TL England Tel: +44 151 678 2222 Fax: +44 151 606 0188 Email: sales@dantec.com

Dantec Document No: HHITG1 Revision: D

HOSE HANDLING, INSPECTION

& TESTING GUIDELINES

For Dantec composite hoses installed in service

DANTEC LTD.

Dantec Document: HHITG1 Rev D

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Preface This manual has been prepared to explain the best practice to handle, store, inspect and test composite hoses in order to prevent potential failure or accidents, and ensure safe, dependable liquid transfer operations. Whilst essential to dedicate attention to composite hose once installed and in service, it is recommended to adopt a proactive approach to pre-purchase selection and develop a functioning hose management system. Always wear full PPE (personal protection equipment) when handling composite hose as appropriate to your company practice. This guide should be used alongside your own SHE and COSHH regulations.

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Contents: Part 1 Hose suitability

1.1 Checklist 1.2 Parameters 1.3 Medium 1.4 Working at elevated temperatures/pressures

Part 2 Hose management 2.1 Hose records 2.2 Recording products/parameters of intended use 2.3 Setting Test Intervals 2.4 Dantec Hose Management Part 3 Hose handling 3.1 Installation and Transport 3.2 Hose handling do’s and don’ts. 3.3 Working at temperature 3.4 Hose support accessories Part 4 Hose storage 4.1 Draining 4.2 Cleaning 4.3 Infrequently used hoses 4.4 Storage 4.5 Hoses on arms/towers Part 5 Inspection and testing. 5.1 Regular inspection 5.2 Visual inspection 5.3 Electrical continuity 5.4 Pressure testing 5.5 Final checks/Recording data 5.6 Third party inspection Part 6 Removing hose from service 6.1 Failed hoses 6.2 Repairs 6.3 Claims and warranty 6.4 Retirement 6.5 Disposal

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Part 1 – Hose suitability/selection

1.1 – Hose suitability checklist

It is imperative that all working parameters and factors are considered before purchasing and/or using a composite hose.

1.2 – Parameters

Table 1

General Parameters Other Factors

Chemical medium Simultaneous use of elevated pressure & temperature

Viscosity of medium Cleaning requirements

Working pressure Risk of cross contamination

Working temperature External conditions

Temperature spikes Mechanical support available

Pressure spikes. Environmental/Health and Safety factors

1.3 – Medium

Dantec’s online configurator allows users to search and select the recommended hose for the media being conveyed. Users can search by media/chemical name or CAS number. www.configurator.dantec.com

Dantec does not recommend using composite hose for any medium being transferred with a viscosity above 400 centistokes (cSt). Hose recommendations are based on available data for media transfers at ambient temperature. The hoses listed may be suitable for product transfer above or below this. If unsure always check with the manufacturer or distributor for further guidance. 1.4 – Working at elevated temperatures/pressures. It is not recommended to use composite hose at any time to its maximum working pressure, operating temperature and/or minimum bend radius simultaneously. Doing so could reduce the working life of the hose severely. Maximum working pressure and maximum working temperature and minimum bend radius are available on the Dantec website, product data sheet and (if already ordered) on the hose assembly test certificate. Working pressure for hoses assemblies may also be reduced due to the rating of the end coupling attached. Always rate the hose at the lowest working pressure of the hose or fitting.

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Part 2 – Hose management 2.1 – Hose records When receiving new hoses it is important to record the hose information, for auditing and for regular inspections Dantec recommend recording the following information as good practice:

Table 2

1 Hose Serial number

2 Hose Type

3 Hose manufacturer

4 Bore size

5 Hose length

6 End coupling 1

7 End coupling 2

8 Date New

9 Date tested

10 Tank/Tanker/Area

11 Location (if applicable)

12 Products ordered for see 2.3

13 Test Intervals see 2.4

14 Colour in test see 2.4 Parts 1 to 9 of the above information is available on the manufacturer’s hose Test certificate. Parts 10-14 will need to be completed by the end user. 2.2 Recording products/parameters ordered for: By recording what products the hoses were ordered for at time of order, it can help avoid cross contamination, and give the user the opportunity to check with the manufacturer/supplier when transferring a new product or changing the general working parameters (see 1.2) 2.3 Setting test intervals By setting the desired test intervals at the time of receiving the hose, it initiates good hose management structure going forward. Testing and inspection criteria are covered in section 5 of this document. Some users prefer to colour code their hoses with tape or cable ties to show easy visual evidence the hose has been tested within the current test interval. (See 5.5) If this practice is to take place, it is best to include the current tagging colour on any new hoses. 2.4 Dantec hose management Dantec and their distributors offer a hose management system, recording the above data on your behalf. Please consult your hose supplier for information. It is the end user’s responsibility to inform the hose manager of any changes to circumstances. Including repairs, relocation, and removing hose from service.

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Part 3 – Hose Handling

To ensure users gain the maximum working life of their composite hoses, it is imperative that hoses are handled correctly. Composite hoses over the size of 4” (100mm) nominal bore in particular must be supported at all times. All Dantec HD (Heavy Duty) hoses are suitable for both ship to shore and ship to ship (STS) applications in accordance with OCIMF STS guidelines 3.1 Installation & Transport Incorrect installation can unduly stress hose assemblies leading to a shortened working life or premature failure

Table 3

Installation & Transport

Hoses should not be dragged over rough surfaces

For transport make use of equipment such as trollies, rollers or derricks

Do not place your hose on hot surfaces

Do not lift the hose by the couplings, support the hose at numerous points including supporting the end connection at the ferrules at all times

To assist with lifting; make use of saddles, bridles, slings, bend limiters, and hosebuns

Take care not to bend the hose beyond the minimum bend radius (MBR) during transport and installation

Hose assemblies must not be twisted either in installation or whilst in use

Flanged hose assemblies should ideally have a swivel flange at one end to lessen any distortion

Hose assemblies subject to movement whilst operating should be installed in such a way that flexing occurs in the same place

In areas such as jetties or hose pits, hoses should be laid out to avoid crossing over each other, allowing easy disconnection without force to separate

Where possible the manifold should be set/installed at an angle allowing the hose a more natural curvature 3.2 Hose handling do’s and don’ts. Do’s

When a string is required, use a shorter

length and a longer length hose to avoid

additional strain. Ensure as much support to

the hose at the termination area using a

bend limiter.

Lift the hose near the flange and use a

cradle, web sling or a hose bun

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Don’t’s

Avoid over-stressing the hose

Adjust supports with tide movements

Hose should be long enough to allow for

tide changes and fall and rise of ship

Support hose at termination point ideally

using a bend limiter

Support hose with slings

When connecting hoses in a string where

possible use web slings or a hose bun to

support the couplings where they meet

Never support a hose with a single rope Never lift hoses from their flanges or end

fittings

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This guide is available to view as an animation download from our website https://dantec.com/downloads/dantec-web-explainer.mp4 3.3 Working at temperature Using a hose at elevated temperatures can affect the working pressure and/or reduce the life expectancy of the hose. This applies to composite hoses, rubber hoses & stainless steel hoses. Due to the characteristics of the thermoplastics used in composite hose, there can be some disadvantages associated. The latest standard for composite hose is EN13765/EN13766: 2018 which covers the various requirements of pressure and temperature ratings. However, whilst the hose can work at its maximum working pressure and maximum working temperature it is not recommended to operate both in union. Simultaneous use of elevated temperatures and pressures will severely impact service life. As temperatures rise, thermoplastics lose rigidity and strength As a result of plastic deformation under load, particularly at higher temperatures, hoses can elongate. Hoses will need to be well supported, and this is even more essential in hoses being operated in elevated temperatures conditions (50°C +). Lack of support can cause over bending, especially near the couplings resulting in displacement of the helical support wires from their pitch. This can create the potential for hose collapse and coupling displacement. 3.4 Hose support accessories As expressed in parts 3.1-3.3 Bend Limiter Hosebun Hose Trolley

Never exceed the minimum bend

radius unsupported

Never use a hose unsupported

Protect against hard edges

Never overbend a hose or allow a hose to

hang between quay and ship

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Part 4 Cleaning & Storage

Correct and thorough hose cleaning is essential to avoid contamination of product, and to extend the service life 4.1 Draining On completion of a transfer operation and as part of the line clearing procedures, hoses should be cleared of all product. The transfer hose should be elevated to ensure it is completely drained before disconnecting. Once disconnected from the manifold, end flanges should be blanked securely and the assembly transported for cleaning. Note: Hoses on ships and barges can been cleaned while connected to the manifold in compliance with MARPOL regulations. 4.2 Cleaning For most chemicals cleaning the hose out with fresh water is adequate. Care must be taken if using hot water not to exceed the working temperature of the hose. If cleaning with water is an issue, chemical cleaning should take place. Chemicals used should be on the guidance of your own chemical engineer, and must also be compatible with the hose. Whilst cleaning via open ended (loose) steaming can be also be undertaken, we recommend that this is performed for no longer than 15 minutes. Care should be taken not to exceed the working temperature of the hose, nor expose the hose lining to excessive localised heat Warning: Steam lances should never be used and composite hoses should never be pigged. Hoses must always be cleaned before pressure testing. 4.3 Infrequently used hoses It has become common practice to blank off hoses which are only used for one dedicated product and leave ready for the next use. Long term exposure of the product must be considered, therefore always drain after use and where approriate clean the hose. 4.3 After cleaning After flushing/cleaning hoses should be well drained and blanked. Follow guide 3.1 for transporting hoses to the storage area.

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4.4 Storage Incorrect short and long term storage of hoses can lead to damage and a shortening of the life expectancy. Effects can be immediate such as being hit with objects or vehicles resulting in impact damage. Slow deterioration due to adverse or incorrect storage conditions may also occur.

Table 4

Storage procedures Hoses should be stored off the ground horizontally on a solid platform with end fittings in line with the hose The hoses should be sheltered from climatic conditions especially direct sunlight Do not stack hoses as they could damage each other Ensure the flanges are not hanging, unsupported Ensure fittings are not in positon to damage the hose body

Storage procedures Storage procedures 4.5 Hoses on Arms/Towers When hoses are permanently installed in hose arms, or tower gantries, hoses should be under suitable shelter from climate and sunlight

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5 Inspection and testing

5.1 Regular inspection Hose assemblies should be inspected on a regular basis;

If in constant or frequent use, they should be visually inspected before each loading/unloading operation

When this is impractical they should be visually inspected at least once per day

Hose assemblies used infrequently should be visually inspected each time they are used

Hoses should be tested for electrical continuity every 6 months.

If a hose assembly has been stored for over 12 month it is recommended to perform pressure test before use (see 5.3)

It is recommended to have all chemical and general purpose composite hoses pressure tested at 6 month intervals and oil hoses at 12 month intervals.

Note: There are no worldwide official standards for periodic hose testing in service, this guidance is classed as manufacturer’s best practice. Local legislation, including harbour authority legislation, may be in place in your location, please check with your relevant local authority. 5.2 Visual inspection To best understand composite hose, below are the main features.

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As listed in 5.1 hoses should be regularly visually inspected. Any inspection should concentrate on the following points:

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NB: Providing that the relative position of the inner and outer wires is not compromised, some shallow denting may be acceptable. However severe indentation may cause lateral wire

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movement, which will lead to the hose collapsing. There may also be internal film and fabric damage, which could lead to product leakage and severe indentation will create flow restriction in the hose. It is recommended that a hose be failed if it has more than a 10% reduction in diameter in 3 or more areas throughout the hose length. Similarly, if there is serious displacement of the outer wires, caused by indentation, the hose should be failed. If in doubt please withdraw the hose and refer to Dantec, a Dantec agent or independent hose tester. 5.3 Electrical continuity Prior to pressure tests, all electrically continuous hoses must be tested for electrical continuity. This should be done regularly within periods not exceeding 6 months. These should be recorded in your hose management register.

Table 5

Electrical Continuity procedure Ensure the hose is cleaned, drained and dry Lay the hose out flat on a dry non-conductive surface Where possible raise the flanges/fittings off the ground Ensure you are using a calibrated Ohmmeter Connect the ohmmeter to each end connection of the hose and take a reading A reading of 100Ω (ohms) or less per assembly is a pass, and the hose can now be pressure tested (see 5.4) A reading of over 100Ω (ohms) is a failure and the hose must be taken out of service*

NB: This process will need to be repeated after the pressure test (see 5.4/5.5) *A reading over 100Ω may be due to corrosion, cleaning of the end fittings may solve this (NB rust is an excellent insulator). 5.4 Pressure test Dantec recommends pressure test intervals should be 6 months for chemical hoses and 12 months for oil hoses. Testing should be done hydrostatically; with water at ambient temperatures being the recommended medium. Where this isn’t feasible please consult with Dantec technical team or your Dantec agent. Testing with air and or other compressed gases is not recommended. Hoses can be pressure tested individually or bolted together in a hose string. New hoses will have been initially tested to 1.5 x the working rating of the hose assembly and this will be stated on the initial test certificate provided by Dantec. (NB the assembly rating is defined by the lowest rating of the hose body or the hose fitting) To avoid over stressing we recommend regular pressure test inspections should be 1.5 x the actual operating (working or AWP) pressure the hose in which the hose is regularly exposed to. If you are unsure of the regular AWP, testing the hose at the original factory test certificate assembly rating will suffice (Manufacturer working pressure or MWP). Customers may test the hose at 1.5 x the manufacturer’s original assembly rating (MWP) at their own request and risk. (Manufacturers test pressure or MTP)

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Testing procedure is as follows:

Table 6

Pressure Testing

Lay the hose straight and horizontal ,allowing additional space at each end for elongation under pressure

Flange end should be placed on hose trolleys to allow for controlled movement while under test

Hose ends should be blanked off with blanks which are adapted for testing

One end should be blanked with a vented test adaptor/valve to allow for pressure release

The other end should be blanked with test adaptor that allows for water filling and pressurisation

The end with the vent fitting should be slightly raised to allow for air to be bled from the hose.

Connect the water source to the test adaptor and fill with water, venting all the excess air through the vented end

When full close off valves and disconnect water source

Connect test pump and fit pressure gauge, raise the pressure to 0.7 bar for hose stabilisation (Ensure the pressure gauge is within calibration)

Slowly Increase pressure to 1.5 x operating working pressure and hold for 5 minutes

Visually examine the hose for leaks and end fitting movement

After 5 minutes reduce pressure to the operating working pressure for a further 5 minutes

Visually examine the hose for leaks

After 5 minute period of test, perform a controlled release of pressure and drain the water

NB: A Feature of composite hose is elongation under pressure, which is relatively high compared with rubber hose. This characteristic of thermoplastic composite hose cannot be used as an assessment of the condition of the hose or an indication of failure.

5.5 Final inspections/Records Once pressure test is complete please repeat the electrical continuity test (see 5.3) Perform visual checks again in line with the visual criteria (see 5.2) Assuming hose have passed all inspections the hose management records should be updated and if appropriate the latest colour marking should be applied for easy recognition (see 2.4) Failed hoses should also be recorded in the database and removed from service. It is good practice for inspectors to record any signs of wear and tear for hoses that may be deemed suitable but not in perfect condition (5.2 insert) so operators can take extra care and keep a closer subsequent inspection of the hose. 5.6 Third party inspectors Dantec & our agents can perform hose inspections on site, providing test certificates and maintaining hose management systems. Third parties not nominated by Dantec should follow the instructions listed in this document.

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6 Removing hoses from service 6.1 Failed hose If hoses have failed any inspection during the hose inspection they must be removed from service. Hose management systems must be updated to remove the hose from the system. 6.2 Repairs Some hose can be repaired which have been damaged in service this will usually result in loss of length. Kinks and wire displacement cannot be repaired. Only at the stage of repair can Dantec/Agent advise whether the end fittings can be re-used. Caution must be taken with hoses being transported and repaired and they must be fully decontaminated by the end user before doing so. An MSDS for all products transferred must be provided. 6.3 Claims/Warranty If the client needs to make a warranty claim on any hose failure or investigation pending claim they must contact Dantec or the company who supplied the hose. They will be provided with a form to fill detailing the nature of the claim. Photographs, videos, working life, operation parameters, and list of products transferred must be provided. Never return the hose, until Dantec/supplier has instructed that it is OK to do so. Caution must be taken with hoses being transported and repaired and must be fully decontaminated by the end user before doing so. A completed Dantec returns form and MSDS for all products transferred must be provided. 6.4 Retirement Composite hose has a long shelf life. Unlike rubber hose it does not degrade quickly. Therefore composite hose does not need to be retired after x amount of years. Many clients still include a retirement policy for hoses that have been in service, it is always best to discuss your operational parameters with your Dantec representative who could offer more advice. 6.5 Disposal Hoses that are due to be scrapped must be done so following your own countries/companies environmental policy. We hope you have found this document useful for any further information please do not hesitate to contact Dantec technical team at info@dantec.com or +44 151 678 2222

Dantec Ltd Head office and works Tarran Way Moreton Wirral CH46 4TL England Tel: +44 151 678 2222 Fax: +44 151 606 0188 Email: sales@dantec.com

Dantec Document No: HHTIG1 Revision: D