Set up your SPM hose test plan
It has been said that hoses are the lifeline of your SPM. Unfortunately, they are also the most vulnerable part of your offshore terminal. To ensure that your hoses are well maintained and reliable, it is important to put an SPM hose test plan in place.
How frequently should I test my SPM hoses?
Hose manufacturers and OCIMF other operators vary on the life expectancy of a hose, but they rarely vary on the requirement for regular testing. Hoses need to be tested every 3-5 years because they deteriorate as they age.
What should an SPM Hose Test Plan include?
OCIMF guidelines offer a range of tests that need to be performed. We have included this list below:
Your terminal, however, is unique and it is important that you inspect your hoses for any known cause of concern. If your area is known for fluctuating temperatures, for example, you may need to test more frequently and pay attention to obvious degradation and other superficial damage that may otherwise be disregarded. Here, it is important that your testing team have the industry knowledge and experience required to offer you the most comprehensive testing tailored to your terminal, without breaking the bank on unnecessary items (or increasing risk!)
Find out more about MARSOL’s OCIFM testing in this case study.
Hose Testing records
Testing records are to be kept accurately and consistently with as much detail as possible. This is important because any new teammates that come on board should be able to analyse the history of your terminal at a glance, using the records.
This type of big picture data will also help you to approach your terminal operations in a holistic way, enabling you to identify the root cause of certain issues. By understanding the root cause of an issue, you can invest CapEx to enhance and optimise your SPM, instead of burning through your OpEx treating the symptoms every year.
Classification Society will review the testing records as part of the special surveys.
SPM Hose Testing does not mean replacing
When you test your hoses frequently, you will be able to predict possible failure before it occurs. This means that your hoses can be replaced or repaired following tests in order to extend their lifespan. This decision of whether or not your hoses are to be replaced or reused is not to be taken lightly. Make your decisions based on accurate data accumulated at YOUR terminal.
MARSOL proposes that you make the most of your change out by replacing failed hoses with new ones or previous spares which have remained unused, but within their design life. Older, serviceable hoses can be kept as spares in case of emergency. It is important to have spares as this will save you downtime should you be faced with an unforeseen event.
.
Conclusion
Skimping on an SPM hose test plan is not a good idea, but that doesn’t mean you need to spend money in places that do not benefit you. The best way to make the most of your SPM hose test plan is to have a team of experts tailor it to your terminal.
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.
Best Practices for your SPM Hose Management Plan
Are you putting together your SPM hose plan or revisiting your O&M strategy? Here we discuss examples of marine hose applications, lessons learned and best practices that help you to fulfil your fiduciary duties.
GREENFIELD OR BROWNFIELD SPM Hose plan
It’s never too early or too late to start your SPM Hose plan the right way.
When hoses begin to show symptoms or points of failure we apply the following process:
1. Find Root Cause
Before you hastily begin to treat symptoms such as ruptures, for example, ask yourself why they have occurred in the first place. This will help you identify numerous holistic factors that could be affecting your SPM hose plan.
2. Assumptions vs Facts / Data / History
Don’t let years of experience blind you. No two terminals are exactly the same.
Change is a constant and the sooner you realise this, the sooner you will begin to value data that can guide your SPM hose plan.
3. Analysis / Knowledge + Experience
Once you have obtained the required data, you can begin to cast an analytical eye.
This is where the application of knowledge and experience is pertinent. Derive correlation and explore all known and unknown paths.
4. Proactive Long Term Solutions
When you have successfully identified the root cause and you have taken into account all holistic factors, you can begin to create a more robust SPM hose plan with long term durability, efficiency and sustainability in mind.
Determining the root cause of issues in your SPM Hose Plan
When looking for symptoms of failure in your SPM hose plan, it is paramount that you determine the root cause through holistic analysis.
Here are some pinpoints to look for.
List of Hose Indicator examples
- Wrap-around
- Kinking
- Auto-submergence
- Change in buoyancy
- Contact
- Sheltering & Chafing
- Leak detector activation
- Catastrophic Failures
- Bearing
- Hose Handling
- Contact
- Float Loss
- String Length
- Environment
- Handling
- Exceeding hose life
SPM Hose Plan – Lessons Learned
In this section, we highlight two case studies, each with its own challenges and bespoke solution for the best performing SPM hose plan.
Case study 1: Changing Environment
In this project, our belief that change is constant was yet again proved by the ever-changing environment and its effects on terminal efficiency and longevity.
Project overview
- System Design
- Assumptions
- Regional data vs Site-specific data
- Landscape changes
- Coastline changes
- Operational consequences
What the hoses told us:
Upon inspection of the current hoses in use, we discovered that local conditions have changed from the basis of design. This was clear through the hose misbehaviour and symptoms, or points of failure.
Symptoms:
Rapid abnormal wear of floating hoses and tanker rail components.
Our listening method:
Collected and analysed data
What we heard:
Through SPM hose plan analysis and site experience we identified
- Root Cause
- Cost-Effective Solutions
- Optimum hose life
Case study 2: Design Assumptions
In this project, we investigated the effect that seabed assumptions in modelling can have on hoses, buoys and PLEM loading.
Project overview
- Seabed variations
- Winter and summer positions
- Near and Far Scenarios
- Understanding current direction & magnitude throughout the water column
- Effect on behaviour and integrity
What the hoses told us:
These hoses showed signs of impact that not only required a temporary fix to preserve the current hoses but also long term solutions that would prevent further damage.
Symptoms:
• Subsea hose string to hose string contact
• Subsea hose string to seabed contact
Our listening method:
Collected and analysed data
What we heard:
Through SPM hose plan analysis and site experience we identified
• Chain trenching, affecting chain pretension
• Increased buoy excursion
• Predominant winter & summer buoy position
• Change in hose profile
Fiduciary duties linked to your SPM hose plan
It is your fiduciary duty to make informed decisions regarding your SPM hose plan.
If you listen to your system you will get to know it. Once you know your system intimately any changes in performance or signs of upcoming symptoms will easily be noticed. This will help you adapt to change and maintain the intrinsic value of the facility.
It is your fiduciary duty to avoid interruption in your efficiency by predicting system behaviour. This, in turn, will help you to protect the environment and offer safe operating practices with reduced risk.
When your system is understood holistically you will begin to progress from O&M towards integrity, resulting in all the above-mentioned successes.
Conclusion
It is important to give SPM Hose plan management the tools to make informed decisions regarding hose and system O&M.
At Marsol we strive to share our holistic philosophies that have proven success time and time again.
- Listen to the hoses
- Find the root causes
- Implement optimum solution
These best practices within the SPM hose plan enable design modifications and operational changes that are fit for purpose.
Is your management team equipped with the best tools and processes for the job? Find out today.