HANDLING AND SERVICE INSTRUCTIONS FOR …oil-marine-hoses.com/pages/high-pressure-hoses/service/documents/... · HANDLING Doc. No.: TKO AS0 Revision: 5 HANDLING AND SERVICE INSTRUCTIONS

ContiTech Rubber Industrial Kft. Hose Technical Department

Doc. No.: TKO AS0

Revision: 5

Page: 1/20 HANDLING

Date: 31.07.2008

Invalidate the document TKO AS0 rev.4

Prepared by: Revised by: Approved by:

Imre Domonkos

József Dávid

Gyula Bétéri

FOR BEST IMAGE QUALITY SUGGESTED TO PRINT IN 600 DPI

HANDLING AND SERVICE

INSTRUCTIONS FOR HIGH

PRESSURE FLEXIBLE HOSES

HANDLING

Doc. No.: TKO AS0

Revision: 5 HANDLING AND SERVICE INSTRUCTIONS FOR HIGH PRESSURE FLEXIBLE HOSES

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System description ......................................................................................... 3 1. Operational Requirements ........................................................................... 4 1.1 Design pressure........................................................................... 4 1.2 Collapse Resistance .................................................................. 4 1.3 Excessive Axial Load................................................................... 4 1.4. Bending ....................................................................................... 4 1.5 Torsions....................................................................................... 4 1.6 Gas service.................................................................................. 5 1.7 Transported fluid considerations .................................................. 5 1.8 Temperature limit......................................................................... 5 1.9 Fluid velocity................................................................................ 5 1.10 Accidental load ............................................................................ 6 1.11 Welding........................................................................................ 6 2. Handling, transportation and installation.................................................... 6 2.1 Handling in general and installation. ............................................ 6 2.2 Transportation ............................................................................. 6 2.3. Storage (in general) ..................................................................... 6 3. Service Inspection ........................................................................................ 7 3.1. Inspection .......................................................................... 7 3.2 Hydrostatic Pressure Test Procedure. ......................................... 7 4. Appendix 1...................................................................................................... 8 5. Guidelines on storage, handling transportation and installation of flexible pipes..................................................................... 10 6. Attachments.................................................................................................... 14

Handling and Service instructions has a purpose: to ensure the safe, long term use of our flexible hoses. General instructions are supplied with the product, more detailed instructions regarding the use are described in this document. Our guarantee obligation is valid only in the case, when the use of the hoses is based on these instructions.

Additional technical questions can be sent to the following address:

ContiTech Beattie Ltd. Jubilee Industrial Estate Ashington, Northumberland NE63 8UB England Phone: +44 1670 528 700; Fax: +44 1670 520 535 e-mail: [email protected] WEB: www.contitechbeattie.co.uk ContiTech Beattie, Corp. 11535 Brittmoore Park Drive Houston, TX 77041 USA Phone: +1 832 327-0141 Fax: +1 832 327-0148 e-mail: [email protected] WEB: www.contitechbeattie.com ContiTech Rubber Industrial Kft. 6728 Szeged, Budapesti út 10. Hungary Phone: +36 62 566-901; Fax: +36 62 566-999; e-mail: [email protected] WEB: www.contitech-rubber.hu

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SYSTEM DESCRIPTION

Most aspect of hoses used is covered by API documents as follows:

API Spec 7K / ISO 14693: This is a specification for rotary drilling, vibrator and cement hoses.

API Spec 17K / ISO 13628-10 and API RP 17B / ISO 13628-11: Relevant to hoses for oil and gas field applications.

API Spec. 16C: This is a specification for all the equipment constitutes a choke and kill system. The Standard had different drafts, before the final version was issued.

ContiTech Rubber Industrial Kft. can produce according to API Spec. 16C or API Spec. 16C Draft 07C depending upon the decision of the user or where a governing body dictates (e.g. NPD, DNV). The formulation and publication of API Standards is not intended in any way to inhibit anyone using any other practices. The requirements are agreed mutually by the user and the manufacturer and can be based on any API publication. But an API label can be attached only on a hose, which was designed and produced exactly according to the valid API Standard and with the sizes defined in it.

The choice of the most suitable API standard or draft standard shall be defined by the user. Before the order is issued the user has to study and approve the selected standard.

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1. OPERATIONAL REQUIREMENTS

1.1. DESIGN PRESSURE

The design pressure, which is a performance characteristic of the flexible hose warranted by the manufacturer, is the maximum internal pressure to which it should be subjected to during its life. It would normally include operating pressure plus allowances for surges. This is equivalent to the Rated Working Pressure as defined below:

Rotary drilling and vibrator hoses acc. to API Spec 7K / ISO 14693: Ø2”-6”; 10,3-51,7 MPa (1500-7500 psi)

Cement hoses acc. to API Spec 7K / ISO 14693: Ø2”-4”; 69-103,5 MPa (10000-15000 psi) Choke and kill hoses acc. to API Spec 16C; Ø2”-4”; 34,5-103,5 MPa (5000-15000 psi) Bonded flexible pipes acc to API Spec 17K / ISO 13628-10 and API RP 17B / ISO 13628-11; Ø2”-14”; up to 51,7 MPa (7500 psi)

Other diameters and pressure ranges are available on request or acc. to a referred relevant Standard or in-house design (e.g. Ø1,5”-16” smooth and rough bore hoses).

1.2. COLLAPSE RESISTANCE

The flexible hoses are designed and produced in general for topside application.

Hoses subjected to subsea service shall be inquired, ordered and designed to withstand the differential external pressure for the operational depth without deforming the hose to a point where they can no longer function as the design specifies. Please ensure that such requirements were specified in order correctly!

1.3. EXCESSIVE AXIAL LOAD

High pressure hoses should not be exposed to higher external axial load, than its full fluid filled weight, when there is no internal pressure in the hose. Special design for excessive axial load ability is also available for request. Please ensure that such requirements were specified in order correctly!

1.4. BENDING

The minimum bend radius (MBR) is a performance characteristic of the hoses and is specified by the manufacturer. The actual bending radius of the hose must never be smaller because it can result in permanent damage to the line. The bending radius is depending from the type of application. Dynamic application is a service, in which the flexible pipe is exposed to cyclically varying loads and deflections. In general the dynamic bending radius is 1,5 times bigger, than the minimum bending radius at storage application (without dynamic loads). If the manufacturer gives only one value for the minimum bending radius, this is the operational minimum bending radius.

1.5. TORSIONS

Do not twist the hoses during installation or in use, because it adversely affects the lifetime of the hose. Without consultation and agreement with the manufacturer torsion must remain below 1,0°/individual metre.

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1.6. GAS SERVICE

Only hoses ordered for defined gas service are suitable for handling gas. The number and velocity of the rapid decompressions in gas service should be limited to the possible minimum. It is necessary to define at the order of the hose the exact service conditions, or refer to the right standard.

Hoses for continuous H2S service can be ordered with the following parameters: up to 60°C operating temperature max. partial pressure 0,1035 MPa (3000 ppm, at 5000psi) up to 90°C temperature max partial pressure 0,0345MPa (1000 ppm at 5000psi) H2S content. Couplings for H2S service are produced acc. to the standard NACE MR 0175 / ISO 15156.

Production hoses for gas-containing medium can be ordered referring to the API Spec 17K / ISO 13628-10 and API RP 17B / ISO 13628-11. The qualification test for gas service is described in the API RP 17B § 9.6.11. If there is rapid decompression requirements see TKO AS4 recommendations.

Choke and kill hoses can be ordered acc. to the standard API Spec 16C. The qualification test is described in the § 9.14.12.

Choke and kill line can be ordered acc. to API Spec 16C Draft 07C as well, where the qualification test can be found in the § 9.7.1.

The purchaser should take proper care of ordering: either the service conditions should be exactly defined, or it should be controlled which performance test covers the service conditions.

1.7. TRANSPORTED FLUID CONSIDERATIONS

Please ensure, that the medium to be transported inside the hose meets the relevant standard or contract terms.

In any event if there is any doubt as to the effect of particular chemicals on the hoses, the manufacturer shall be consulted. Some information can be found in Appendix 1.

Special remarks: Choke and kill lines are generally smooth bore hoses; they must never be used for production or well test purposes. They can be applied for cementing, but the cement hose may never be used for choke and kill service.

At the delivery of oil the composition has to be defined, especially the aromatic content. Special care has to be taken, if there is any gas content in the oil, it shall be specified.

1.8. TEMPERATURE LIMIT

The operator shall determine in the order the minimum and maximum operating temperature. The working conditions must comply with the defined temperature limits, exceeding the temperature limits can harm the hose especially under dynamic conditions. It is important that both the minimum and maximum operating temperatures are taken into account.

1.9. FLUID VELOCITY

There is a general rule for the determination of the max. fluid velocity in a hose; if the fluid has no solid content: for liquid: 15 m/sec; for gas 20 m/sec; for gaseous liquid 8m/sec. If the fluid has solid content or there is a corrosion effect as well, a detailed calculation has to be made, based on the data of the actual use, while the expected lifetime has to be taken into account. Please contact the manufacturer in case of any doubt.

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1.10. ACCIDENTAL LOAD

If the hose has been the subject of accidental load outside of the operating envelope (e.g. higher temperature, extreme flow velocity with abrasive fluid, collapse due to irregular outer force, elongation due to extreme axial load etc.) it should be replaced.

1.11. WELDING

No post welding is allowed on the couplings of the hose.

2. HANDLING, TRANSPORTATION AND INSTALLATION

2.1. HANDLING IN GENERAL AND INSTALLATION

When a hose has to be lifted from a reel or packing crate, precautions should be taken to ensure that it will not be damaged by dragging it on the floor or against sharp edges of the handling equipment or by unacceptable torsional/bending loading.

The flexible pipe should be securely fastened to its reel or packing crate. The end fittings require additional fastening by means of textile bands.

It is recommended to order the hoses with lifting collars and to use them for installation. Never lift the hose in a reverse "U" shape using one band in the middle, because the hose can be severely damaged. (See the photographs in the attachment)

If the hose was delivered in a crate, it should be removed from its crate by hand, laid out in a straight line, and then lifted by means of a catline attached near one end of the hose. If a catline is used to remove the hose from its crate, the hook of the crane shall have a free rotation possibility. The use of a carrier to protect the hose in moving is a recommended practice.

If the hose is transported on a reel, a suitable let off equipment must be used at the installation.

It is important during installation not to exceed the minimum bending radius, especially in the area close to the end fitting.

When handling the hoses please refer to the instructions and photographs in the attachment.

2.2. TRANSPORTATION

Hoses can be transported on a reel or in a packing crate. Hoses should not be placed on a reel or in a crate so that the end fittings or other attachments induce unacceptable local loading in the hose structure. Weight should be accurately monitored during lifting not to overload the lifting equipment. Secure fastenings should be designed for the final transported weight in a dynamic environment. In general all hoses must be packed and handled according to the specifications of the relevant API / ISO standards.

2.3. STORAGE (IN GENERAL)

Correct storage of flexible pipes prolongs their life in service. The warehousing area shall be relatively cool, dark and free from dampness and mildew. The recommended temperature for storage is: between -20°C and +30°C.

The end of fitting connections shall be protected to prevent damage of the seal area, threads, and other areas susceptible to damage.

The flexible pipes shall be covered to prevent degradation by ultraviolet radiation.

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3. SERVICE INSPECTION

This section outlines the recommendation to be followed by the contractor to determine periodically the condition of the hose. Proper inspection and testing procedures will increase the probability of detecting processing failures.

3.1. INSPECTION

Please see the following documents: - INSPECTION GUIDELINES FOR HP DRILLING AND PRODUCTION HOSES,

doc.no.: ISS-059 - Suggested log in form in attachment No 1 (See attachments)

3.2. HYDROSTATIC PRESSURE TEST PROCEDURE

Safety considerations must be incorporated into all hydrostatic pressure testing procedures. Permissible test media for hydrostatic pressure test are water or non aromatic oil with care being taken to bleed off any entrapped air or gases. Air or other compressible gas must never be used as test media. The test may be carried out in-site or the hose may be removed to an onshore test facility.

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4. APPENDIX 1

Product compatibility of PA lined ContiTech Rubber hoses (Choke and Kill hoses acc. to API Spec 16C &

hoses c\w st. st. internal carcass acc. to API Spec. 17K / ISO 13628-10)

Temperature

-18oCo 24

oC 66

oC 100

oC 121

oC

API 16C

Medium Concentration

(90°C) API 17K

Hydrochloric acid HCl 15% - - - - -

Hydrofluoric acid HF 3% - - - - -

Methanol CH3OH 100% + + - - -

Zinc bromide ZnBr2 Saturated - - - - -

Calcium bromide CaBr2 Saturated L L L L -

Calcium chloride CaCl2 Saturated + + L L -

Methane CH4 100% + + + + +

Diesel 100% + + + + +

Crude oil 100% + + + + +

Hydrogen sulphide H2S <10% + + + + +

Sodium hydroxide NaOH <20% + L - - -

Xylene C6H4 (CH3)2 100% + + + L -

Product compatibility of HNBR lined ContiTech Rubber hoses (Choke and Kill hoses acc. to API Spec. 16C 07C draft &

hoses c\w st. st. internal carcass acc. to API Spec. 17K / ISO 13628-10)

Temperature

-18oCo 24

oC 66

oC 93

oC 121

oC

API 16C 07C

Medium Concentration

(90°C) API 17K

Hydrochloric acid HCl 15% + + - - -

Hydrofluoric acid HF 0,6% + + - - -

Xylene C6H4 (CH3)2 25% + + + L L Methanol CH3OH 100% + + L - -

Zinc bromide ZnBr2 Saturated + + L L L Calcium bromide CaBr2 Saturated + + L L L

Calcium chloride CaCl2 Saturated + + L L L Diesel 100% + + + + -

Sea water + + + - -

Sodium hydroxide NaOH 50% L L - - - Hydrogen sulfide H2S 20% for C&K

17K + L

+ L

+ L

+ L

+ -

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Product compatibility of NBR, NBR/CR lined ContiTech Rubber hoses (rotary & drilling hoses acc. to API Spec. 7K / ISO 14693 & smooth bore hoses acc. to API Spec. 17K / ISO 13628)

Temperature Medium Concentration

-25oCo 24

oC 40

oC 82

oC 100

oC

Hydrochloric acid HCl 15 w% + + - - -

Diethylene glycol 100% + + + + L Isooctane toluol 70/30% + + + - -

Methanol CH3OH 100% L L L - - Calcium bromide CaBr2 + Zinc bromide ZnBr2

12/38 w% + + + + L

Oil base mud Max. 40% aromatic content

+ + + + L

Ester base mud * + + + + L

Water-base mud + + + + L Hydraulic oil Max. 40%

aromatic content + + + + L

Sea water + + + + - * only for NBR based rubber compound + OK - Not suitable L Limited application

The exact values (temperature, concentration, pressure) are included in data sheets of the actual order.

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GUIDELINES ON STORAGE, HANDLING TRANSPORTATION AND INSTALLATION OF FLEXIBLE PIPES

Correct way of hose fixing to the packing case (note that hose end should be straight and not forced in & over-bent or stressed)

Correct way of lifting/installing by lifting collar on hose

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Butt welded coupling with API flange assembled with lifting collar

High pressure hose assembled with lifting collar, safety clamp and safety chain

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Inadmissible dangerous mode of transport by dragging hose across the ground

Inadmissible dangerous mode of handling,

moving of hose with metal lever

Incorrect way of hose lifting by its safety clamp (NB: The hose must not be lifted via the Safety Clamp as this is likely to induce over bending and

stressing of the end connection)

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Incorrect moving and lifting of high pressure hose

Incorrect installation of hose (touch down effect) The hose is subjected to abrasion, over bending and undue stresses in the hose body

(i.e. compression)

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5. ATTACHMENTS

Attachment No. 1 Hose record sheet for onsite periodic inspection

Attachment No. 2 Safety clamp fitting instruction

Attachment No. 3 Mounting sketch for safety clamp

Attachment No. 4 Mounting sketch for lifting collar

Attachment No. 5 Lifting collar & Safety Clamp location

ContiTech Rubber Industrial Kft. Page 15/20 Attachment No. 1

Client:


Client:

SAFETY CLAMP FITTING INSTRUCTION

The drawing in attachment no.3 (Figure 1) should be used in conjunction with this written section of the instruction.

The hose is marked on the outer cover with an orange band at each end and text "ATTACH SAFETY CLAMP HERE" (note: an engraved metallic strap is used on hoses fitted with metallic outer guards). This band signifies the location for the safety clamps. The safety clamps should be positioned with one edge in-towards the middle of the hose (i.e. away from the coupling).

Once correctly located, the safety clamp should be fastened in position with the nuts and bolts.

LIFTING COLLAR FITTING INSTRUCTION

The lifting equipment supplied with the hoses, includes a two 2-part lifting device at each hose end (see Attachment 4, figure 2). These lifting devices are supplied loose and not pre-assembled to the hose due to packaging limitations and safety reasons.

Note: The element C is only provided with the hose when the customer specifically requests lifting collars to be provided. Otherwise, the hose is provided with nothing at the ends.

The normal procedure for handling and lifting the hose involves securing the lifting collar around the element C. The hose is then lifted via attachment of the lifting line to the lifting collar. After installation, the lifting collar and element C can be left on the hose together or both removed if preferred.

NB: At no time should the lifting collar be removed and the element C remained attached to the hose. It is essential that the element C be removed from the hose after installation if the lifting collar is removed.

It is essential that the hoses be handled in the correct manner, including removal from their packing media, through movement between locations and installation. The lifting devices we provide are designed, manufactured and tested to provide this. They ensure that the hose is lifted from the correct point (i.e. direct from the end coupling) and prevent damage to the hose body through use of other lifting techniques e.g. soft strops.

In addition to the lifting collars, drilling hoses are often fitted with safety clamps as recommended in API Spec 7K / ISO 14693 and API Spec 7L. All drilling hoses are clearly marked as to where to fit the safety clamp and this should not be confused with the lifting collar. Both are used for specific individual tasks.

The lifting collar is designed to facilitate lifting of the hose and is rated at 1,7 tonne or 2,5 tonne SWL depending on the hose size. It is located at the hose end and attached directly to the steel end coupling.


Client:

The safety clamp is designed to restrain the hose body in the unlikely event of a hose failure when the hose body and end coupling separate from each other. The safety clamp shall have a minimum breaking strength of 72640 N (16,000 lbs) or a working load limit of 9600 N (3,000 lbs) with a 5 to 1 safety factor for hoses up to 4 inch internal diameter. For hoses with 5 inch and 6 inch internal diameter the minimum breaking strength shall be 145280 N (32,000 lbs) or a working load limit of 27240 N (6,000 lbs) with a 5 to 1 safety factor. The safety clamp is located on the hose body behind the built-in bending stiffener.

Refer to figure 3.

NB: The hose lifting collar is not designed to be used as a safety clamp as the minimum breaking strength and working load limits are less than required and it is not positioned in the correct location for this task on the hose assembly. The safety clamp is not to be used as a lifting device as its location may result in overbending of the hose.


Client:

Figure 1

Mounting sketch for Safety Clamp


Client:

Figure 2

Mounting sketch for Lifting Collar


Client:

Figure 3

Lifting Collar & Safety Clamp locations

HANDLING AND SERVICE INSTRUCTIONS FOR …oil-marine-hoses.com/pages/high-pressure-hoses/service/documents/... · HANDLING Doc. No.: TKO AS0 Revision: 5 HANDLING AND SERVICE INSTRUCTIONS

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