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.
- 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:
• 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.
• 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
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.