Outsourcing hose management : Is it a good idea?
Your marine hoses can make or break your offshore terminal. While many companies feel the need to keep hose maintenance in-house, others are choosing to focus on their core business by bringing in specialist partners to whom they entrust hose management and maintenance instead. Here’s what to consider when deciding whether or not outsourcing hose maintenance is for you.
Hose Lifecycle management
While one may think an in-house team may be more familiar with the terminal and its operating history, this is not always true as an in-house team may inevitably rotate staff and the knowledge built up over time is either lost or taken for granted.
Outsourcing hose management means that hose assessments are performed to establish an operating history. These records are kept and disseminated to all the appropriate staff at the outsourced partner company who acts as a whole. Such outsourced hose assessments include OCIMFtesting, destructive testing and OEM laboratory testing.
This data is compared against the basis of design and design criteria which hose specialists will always be well familiar with. Outsourced hose management should support installation, validated methodologies and installed subsea hose profiles. At MASROL we develop a Hose Management Plan encompassing optimal storage, inspections, maintenance and procurement tailor-made for each unique client terminal.
For objective validation and investigation of abnormal events, an outsourced hose management partner will assess the effects on design integrity and life.
Continuous hose assessment objectives:
- Reducing the risk of hose related incidents
- Contributing towards Warranty Extension from OEM & Alliance Partners
- Establishing possible points of failure and mitigation programs
- Cost Certainty
- Maximisation of operational usage of hoses to achieve optimum life
- Contributing to operational and cost efficiencies
- Reducing downtime and interruptions
Hose inventory management, storage and testing
Oil & Gas marine hoses, as the main artery for product transfer, constitute a significant investment that is not always available off the shelf, due to production and other constraints. It is therefore paramount that the hose team takes a holistic approach, considering factors such as environmental influence, purpose, design, inventory management, storage and more.
Outsourcing hose management to the right partner can mean updated knowledge and experience of all terminal types, business models and operating environments.
Ideally the hose inventory management and storage program should provide a comprehensive life cycle management service for both subsea and floating marine hoses used in oil and gas offshore terminal loading and unloading facilities. The hose inventory management solution should be based on OCIMF specialist testing guidelines and customised to suit the terminal at hand.
Here a specialist hose partner also holds the upper hand as they will strictly conform to the latest OCIMF guidelines and should be endorsed by their marine hose manufacturing alliance partners.
Hose Storage Services should include the following onshore elements
- Procurement and Supply
- Storage Facilities & Services
- Onshore Hose Maintenance
- OCIMF Testing of stored hoses
- Realtime Tracking
- Hose movement through its entire Life Cycle
- Transportation including Handling, Lifting, and Sea Fastening
- Environmentally Safe Hose Disposal
- Performance Monitoring
At MARSOL we have proven that such a comprehensive hose support plan can optimise the quality and stock levels of spare hoses provided either from in-house stock or Marsol regional Service Centres. It also prevents the use of hoses that are beyond set timeframes or identified as not-fit-for-purpose. We aim to avoid premature hose disposal with proper handling, storage and management practices, so as to maximise the hose lifespan and save overall client OpEx.
With vast experience and knowledge of hose behaviour it is possible for an external hose maintenance partner to improve hose reliability, asset integrity and facility availability by minimising operational and production interruptions associated with hose failure or malpractice. This also allows the hose partner to perform asset tracking which leads to historical performance data gathering for the improvement of predictive life models.
Hose Change Out
Hose Change out solution is an essential component of a comprehensive Hose Life Cycle initiative. The procedure constitutes a significant activity requiring specialised and experienced personnel, combined with proven methodologies to ensure a safe, efficient and cost-effective hose change out. This engineered solution should be custom-designed by the outsourced hose maintenance partner to cater for each client and their specific location, with the endorsement of the hose manufacturing OEMs and Alliance Partners.
Hose Change outs need to be planned in line with OEM recommendations and OCIMF Guidelines.
Submarine and Floating Marine Hose Change out may include:
•Flushing
•Removal
•Towing
•Disassembly or assembly of strings
•Launch or recovery
•Installation
•In Situ Testing
OCIMF testing
Destructive testing
Our objective is to provide a comprehensive, QHSE-Driven, Hose Change out service customised by MARSOL to optimise a client’s available assets and resources. The service allows the client to focus on their core business activities, without the need for additional investment or specialist in-house capability.
Your hose maintenance partner will aim to reduce QHSE risks during change outs through the use of proven methodologies, qualified and experienced personnel, appropriate vessels and assets to ensure the personnel’s safety, environmental and facility protection.
As an outsourced hose maintenance partner is held responsible for damage to infrastructure and assets during installation or removal, you can trust that extra care will be taken to reduce the potential of such damage.
At MARSOL we aim to preserve our client’s corporate reputation and stakeholders’ interests. Choose a hose management partner you can trust.
SPM hose emergency support
Oil & Gas marine hoses are the primary conduits for offshore product transfer. These critical components constitute a substantial investment, often with long lead times, and are the most vulnerable link in the distribution chain. Oil & Gas marine hoses are exposed to harsh environmental and operating conditions, operating to high levels of availability, yet must comply with exacting QHSE standards.
Oil leaks, reduced reliability, reduced asset Integrity and unplanned shutdowns, constitute significant QHSE, reputation and economic impacts for the asset owner, all other stakeholders and the environment. For this reason it is paramount that your outsourced hose maintenance partner has a good emergency support plan in place.
Conclusion
While an in-house team has benefits, a specialist hose management partner can be the better choice. MARSOL provides a comprehensive Hose Management Service which ensures a safe, reliable and fit for purpose operation of marine hoses. The service allows the client to focus on their core business activities without the need for a specialist in-house capability.
Project Report: OCIMF testing and Hose change out – what you see is not what you get.
When planning for SPM hose changeout project, it is paramount that the old hoses are tested, as this helps to determine wear patterns and root causes of hose decay or failure. Visual inspection does not tell all about the hoses’ condition and full OCIMF testing is recommended to properly understand the hose condition. Here’s what to expect when you are planning a hose changeout with OCIMF testing project.
Hose manufacturers typically recommend SPM hose changeout after 5 years (depending on certain parameters), but it may also be needed earlier due to unusual wear, damage or failure. Note that certain high-wear hoses have shorter lifespans. Catering for such events becomes easier when you have a solid SPM Hose Plan that favours longevity and sustainable reliability.
When it comes to SPM Hose testing, Marsol follows the regulations brought forth by the Oil Companies International Marine Forum (OCIMF), to ensure safe and environmentally friendly processes that are in accordance with the most modern standardised methods available.
Hose Changeout and Testing Activities and Schedule
First the team will divide the project into phases, depending on the scope. During a complete hose changeout project, the phases are likely to include:
• Phase 1: Testing of the new hoses (if they have been in prolonged storage or used before)
• Phase 2: Replacement of all hoses (Floating and Submarine)
• Phase 3: Testing of the removed hoses
The personnel involved in the phases would follow method statements specifically developed for the asset and its environmental conditions.
At Marsol these method statements are developed in line with the OCIMF Guidelines, International Standards (ISO, ISSGOT), OEM Manuals and industry best practice.
Hose Changeout Timeline
From start to finish, a project changing out a set of floating and subsea hoses can take 4 weeks. At Marsol, the proprietary Roller System for floating hose deployment is used. This system is specially designed to not only increase efficiency, but also minimise hose damage throughout the onshore part of the hose changeout procedure.
Using this system, the floating hose changeout part of two strings will see the SPM downtime reduced to just about a week, given streamlined conditions and excluding any unexpected events.
The team will begin with Mobilisation and Site Setup, to start OCIMF testing of spare hoses as soon as possible. Concurrently, assembly of the Roller System will start, and at the same time, offshore works at the SPM will begin in by disconnecting the old floating hoses and towing them to shore.
The submarine hose changeout and new floating hose installation will be performed next, ensuring that all SPM pressure tests are completed and Class witnessed.
Finally, the old hoses are OCIMF tested to identify potential decay trends or wear patterns that could result in a shortened lifespan. This will also identify hoses that can be reused as spares for times of emergency.
Hose Changeout General Considerations
- Hose testing should be performed according to the OCIMF Guidelines for the Handling, Storage, Inspection and Testing of Hoses on shore, 2nd Edition, 1995
- Both the submarine and floating hoses are to be tested according to the OEM specifications.
- Spare hoses to be used in the changeout should undergo testing according to OCIMF Guidelines before assembly and installation.
This includes:
- Visual inspection
- Hydrostatic pressure test
- Vacuum test
- Electrical test
- All the ancillary materials (gaskets, nuts and bolts) to be used as part of the assembly, will have to be checked.
New SPM hoses that have been factory tested prior to installation do not need to be tested again, as long as the manufacturer has supplied you with testing certificates.
OCIMF Test Data Measuring and Recording
For long-term improvements in operational efficiency, it is important to record data obtained from your hose changeout and testing. This means that every hose tested must be documented, including a visual reference, pressure, vacuum tests and graphs combined with time and pressures.
Indicators of Concern during Hose Inspection
During inspection and OCIMF testing the following indicators should alert the inspector that the hose may be in an unsatisfactory state:
Visual Inspection:
• Excessive cover/floatation damage.
• Crushed or kinked hose wall.
• Local reduction in bore diameter
• Distinct circumferential “ribbing” (indicating fatigue or fabrication flaw).
• Mechanically damaged lining.
• Lining separation from rest of hose wall (delamination).
• Movement of end fitting nipple relative to flexible hose section.
• Bulges/blisters (other than air pockets or local delamination in cover).
• Excessive fitting corrosion.
• Excessive wear to lifting lugs.
Hydrostatic test
• External leakage
• External bulge / bursting appears
• Difficulty holding pressure if not due to equipment malfunction (suggests leak path into hose wall)
In-Situ Pressure test:
• Failure of holding pressure
• Twist Warning System (TWS) activation
• Leak detector activation
Conclusion
SPM hose changeouts, whether they are routine or an emergency, cause down time and loss of operational capacity which is of major concern to SPM operators. It is the aim of every operator to undertake the changeouts as quickly and efficiently as possible. Marsol has developed methodology and the Roller System for hose deployment which ensure maximum speed and efficiency of the changeout process. OCIMF testing of the old hoses after the changeout is critical to understanding the condition of the hoses and any causes of the reduction in their life expectancy. This information can be used to make operational decisions and ensure the root causes of the failures are addressed.