OISD - STD - 135

FOR RESTRICTED
CIRCULATION ONLY
No.

INSPECTION
OF
LOADING AND UNLOADING HOSES
FOR
PETROLEUM PRODUCTS

OISD-STD-135
First Edition, February 1996
Amended Edition, September 2001

OIL INDUSTRY SAFETY DIRECTORATE

Government of India
Ministry of Petroleum & Natural Gas
 OISD - 135
First Edition
February, 1996
Amended Edition,
September 2001

FOR RESTRICTED
CIRCULATION ONLY

INSPECTION
OF
LOADING AND UNLOADING HOSES
FOR
PETROLEUM PRODUCTS

Prepared By:
COMMITTEE ON INSPECTION OF STATIC EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

2ND FLOOR, “KAILASH”
26, KASTURBA GANDHI MARG,
NEW DELHI – 110 001
 NOTE

OISD publications are prepared for use in the oil and gas
industry under the Ministry of Petroleum and Natural Gas.
These are the property of Ministry of Petroleum and Natural
Gas and shall not be reproduced or copied and loaned or
exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of data contained in these documents, OISD
hereby expressly disclaims any liability or responsibility for loss
or damage resulting from their use.

These documents are intended only to supplement and not

replace the prevailing statutory requirements.

Note 3 in superscript indicates the

modification/changes/addition based on the
amendments approved in the 19th Safety Council
meeting held in September, 2001July, 1999.
 FOREWORD

The Oil Industry in India is 100 years old. Because of various

collaboration agreements, a variety of international codes, standards and
practices have been in vogue. Standardisation in design philosophies and
operating & maintenance practices at a national level was hardly in
existence. This, coupled with feed back from some serious accidents that
occurred in the recent past in India and abroad, emphasised the need for the
industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety Directorate
(OISD) staffed from within the industry in formulating and implementing a
series of self regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to ensure safe
operations. Accordingly, OISD constituted a number of functional
committees of experts nominated from the industry to draw up standards and
guidelines on various subjects.

The present document on “Inspection of loading and Unloading

Hoses for Petroleum Products” has been prepared by the Functional
Committee on “Inspection of Static Equipment”. This document is based on
the accumulated knowledge and experience of industry members and the
various national and international codes and practices. This document is
meant to be used as supplement and not as a replacement for existing codes
and practices. It shall be borne in mind that no standard can be a substitute
for the judgement of a responsible qualified Inspection Engineer.
Suggestions are invited from the users after it is put into practice to improve
the document further. Suggestions for amendments to this document should
be addressed to
The Co-ordinator,
Committee on “Inspection of Static Equipment”,
Oil Industry Safety Directorate,
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg,
New Delhi – 110 001

This standard in no way supersedes the statutory requirements of

bodies like IBR, CCE, Factory Inspectorate or any other Government Body
which must be followed as applicable.
 COMMITTEE ON
INSPECTION OF STATIC EQUIPMENT
-------------------------------------------------------------------------------------------------------
NAME ORGANISATION
---------------------------------------------------------------------------------------------------------------------------------
LEADER
Shri R. K. Sabharwal Indian Oil Corporation (Refineries & Pipelines)

Shri Y. P. Ajmani Oil & Natural Gas Commission

(Since March, 1993)

MEMBERS
Shri B. Ravi Indian Oil Corporation (Marketing)

Shri S. F. Kanchwala Bharat Petroleum Corporation Limited (Refineries)

Shri G. Somani Indian Oil Corporation(Refineries & Pipelines)

Shri S. S. Murthy Hindustan Petroleum Corporation Limited, Visakh Refinery

Shri S. Neelakantan Madras Refineries Limited

Shri R. Rehman Hindustan Petroleum Corporation Limited (Marketing)

MEMBER COORDINATOR
Shri K. R. Soni Oil Industry Safety Directorate
---------------------------------------------------------------------------------------------------------------------------------
In addition to the above, various other experts from the industry contributed in the preparation,
review and finalisation of this document.
 INSPECTION OF LOADING AND UNLOADING HOSES
FOR PETROLEUM PRODUCTS

CONTENTS
---------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
---------------------------------------------------------------------------------------------------------------------------
Introduction Note 3

PART A: HOSES FOR ROAD & RAIL TANKER

1.0 SCOPE
2.0 TYPES OF HOSES
3.0 MATERIAL & CONSTRUCTION OF HOSES
4.0 INSPECTION & TESTING OF HOSES
DURING MANUFACTURE
5.0 INSPECTION & TESTING OF NEW HOSES
PRIOR TO USE
6.0 PERIODIC INSPECTION & TESTING OF HOSES
7.0 DOCUMENTATION
8.0 REFERENCES

PART B: HOSES FOR LPG SERVICE

1.0 SCOPE
2.0 TYPES OF HOSES
3.0 CONSTRUCTION OF HOSES
4.0 MATERIAL OF CONSTRUCTION
5.0 INSPECTION & TESTING OF HOSES
DURING MANUFACTURE
6.0 INSPECTION & TESTING OF NEW HOSES
PRIOR TO USE
7.0 PERIODIC INSPECTION & TESTING OF HOSES
8.0 DOCUMENTATION
9.0 REFERENCES

PART C: MARINE HOSES FOR OFFSHORE TERMINALS

1.0 SCOPE
2.0 TYPES OF HOSES
3.0 GENERAL REQUIREMENTS
4.0 MATERIAL & CONSTRUCTION OF HOSES
5.0 INSPECTION AND TESTING OF HOSES
DURING MANUFACTURE
---------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
---------------------------------------------------------------------------------------------------------------------------
6.0 PERIODIC INSPECTION AND TESTING OF HOSES
7.0 HANDLING AND STORAGE OF HOSES
8.0 DOCUMENTATION
9.0 REFERENCES

PART D: HOSES FOR JETTY OPERATIONS

1.0 SCOPE
2.0 TYPES OF HOSES
3.0 MATERIAL AND CONSTRUCTION OF HOSES
4.0 INSPECTION & TESTING OF HOSES
DURING MANUFACTURE Note 3
5.0 PERIODIC INSPECTION & TESTING OF HOSES
6.0 INSPECTION AND TESTING OF HOSES PRIOR
7.0 TO USE
7.0 STORAGE AND HANDLING
8.0 DOCUMENTATION
9.0 REFERENCES

ANNEXURE-I GENERAL GUIDELINES FOR STORAGE AND HANDLING

OF HOSES IN PETROLEUM SERVICE (EXCLUDING
MARINE HOSES)

ANNEXURE-II GENERAL PROCEDURE FOR HYDROTESTING OF HOSES

ANNEXURE-III PROCEDURE FOR HYDROTESTING OF MARINE HOSES

ANNEXURE-IV PROCEDURE OF VACUUM TEST FOR MARINE HOSES

ANNEXURE-V FLOAT HYDROSTATIC TEST (MARINE HOSES)

 "INTRODUCTION" Note 3

This standard comprises of 4 parts as follows:

Part A : Hoses for Road and Rail Tanker

Part B : Hoses for liquefied petroleum gas (LPG) service
Part C : Marine Hoses for Offshore Terminals
Part D : Hoses for Jetty operations

Definitions:

Tank Trailor : a vehicle with a tank mounted thereon or built as integral part
thereof and constructed in such a manner that it has at least two axles
and all its load rests on its own wheels.

Tank Truck : a single self-propelled vehicle with a tank mounted thereon.

Tank Wagon : a Railway Carriage with a tank mounted thereon."

 PART A

HOSES FOR ROAD AND RAIL TANKER

1.0 SCOPE 3.0 MATERIAL AND

CONSTRUCTION OF HOSES
This section covers the requirements
and methods of sampling/testing of Construction of hoses & materials for
electrically bonded road and rail tanker lining, reinforcement, helical wire, electrical
hoses, resistant to petroleum and blended bonding, cover and end connections shall be
products, having maximum 25% aromatic as per IS-10733.
hydrocarbon content and suitable for -25
deg C to 65 deg C working temperature 4.0 INSPECTION AND TESTING OF
range. Inspection/testing of new hoses and HOSES DURING MANUFACTURE
periodic inspection of hoses in service have
been discussed separately. The following inspection checks and
testing shall be carried out as per IS-10733.
2.0 TYPES OF HOSES
i) Visual inspection
The hoses used in the Petroleum
ii) Checking of mass and dimensions/
Industry are of the following types:
tolerances
2.1 TYPE-1A
iii) Tensile strength and elongation at break
Type-1A hoses are rough bore hoses, for the lining and cover.
with internal and external helical wire
iv) Accelerated Ageing Test
reinforcement, corrugated outer cover and
for a maximum working pressure of 3.5 v) Adhesion Test
Kg/Cm2.
vi) Swelling Test
2.2 TYPE-1B vii) Test for soluble matter.
viii) Test for resistance to vacuum.
Type-1B hoses are smooth bore hoses
with embedded helical wire reinforcement, ix) Hydrostatic pressure test.
plain or corrugated outer cover, used for a
x) Bursting pressure test.
maximum working pressure of 3.5 Kg/Cm2.
xi) Electrical bonding checks.
2.3 TYPE-2A

Type-2A hoses are rough bore hoses

5.0 INSPECTION AND TESTING OF
similar to type-1A, used for a maximum
NEW HOSES PRIOR TO USE
working pressure of 7.0 Kg/Cm2.
i) All hoses shall be serially numbered for
2.4 TYPE-2B
maintaining service records.
Type-2B hoses are smooth bore hoses
ii) Hoses shall be inspected for the
similar to type-1B, used for a maximum
following
working pressure of 7.0 Kg/Cm2.
- Dimensional check-up.
2.5 TYPE-3
- The hose cover for cracks,
Type-3 hoses are smooth bore reeling
tear, puncture, abrasion or
hoses without helical wire reinforcement,
any other damage.
used for a maximum working pressure of 7.0
Kg/Cm2.
- Couplings for cracks or any other
deformity.
 - Liner for defects and physical pressure shall not exceed 5% for type-3
damages from both ends. hoses and 10% for all other hoses.
Permanent elongation for all hoses shall not
iii) Hoses shall be hydrostatically tested to exceed 2.5%.
the designated pressure.
6.3.2 Test procedure
iv) Hoses shall be checked for electrical
continuity. Test shall be carried out as per
procedure given in IS-10733.
6.0 PERIODIC INSPECTION AND
TESTING OF HOSES 6.4 ELECTRICAL CONTINUITY

6.1 PERIODICITY Hoses shall be checked for Electrical

Continuity after each hydrotesting.
Each hose shall be inspected/tested
after 6 months of initial operation. 7.0 DOCUMENTATION
Subsequent testing shall be done at 3
months interval irrespective of the number of Records of the observations, tests,
operations. However each hose shall be remarks etc. in respect of each hose shall
visually checked for damage every time prior be suitably maintained. These records shall
to use. show all details pertaining to origin and
manufacture, identification, service history,
6.2 VISUAL INSPECTION AND inspection and maintenance etc. of the
DIMENSIONAL CHECKS hose.

Detailed inspection as per Para 5.0(ii) 8.0 REFERENCES

shall be carried out during each periodic
inspection. i) IS-10733-Specification for Electrically
Bonded Road and Rail Tanker Hose of
6.3 HYDROSTATIC TESTING Rubber, Resistant to Petroleum
Products.
6.3.1 Elongation during hydrotesting
ii) BS-3492- Electrically Bonded Road &
Hoses shall be subjected to Rail Tanker Hose and Hose assembly
hydrostatic testing at designated test for Petroleum Products.
pressure. Elongation under working

PART B

HOSES FOR LIQUEFIED PETROLEUM GAS (LPG) SERVICE

1.0 SCOPE 2.1 TYPE-1 :

This section covers the requirements Wire Braided Reinforced Hose upto
and methods of sampling/testing of hoses and including 76 mm nominal bore.
and hose assemblies complete with end
connections for transferring Liquefied 2.2 TYPE-2 :
Petroleum Gas (LPG) for loading tank
trucks/tank wagons, limited for use at Textile (including Metallic Cord)
temperatures between -25 deg C to 65 deg Reinforced Hose upto and including 76 mm
C, working pressure upto 25 Kg/Cm2 and nominal bore.
size upto 102 mm nominal bore. Metallic
hoses for unloading of LPG from tankers are
excluded.

2.3 TYPE-3 :

2.0 TYPES OF HOSES

 Textile Reinforced Hose with wire with at least one helix of heavy steel
helix and built-in couplings, 76 mm and 102 wire embedded in rubber.
mm nominal bore.
iii) An outer cover of synthetic rubber
3.0 CONSTRUCTION OF HOSES resistant to abrasion, atmospheric
exposure and to LPG.
The constructional details of various
types of hoses mentioned in Para 2.0 are as iv) Both lining and cover shall be smooth,
given below. Hoses shall be uniformly uniform, free from porosity and other
vulcanised and reasonably concentric defects.
throughout its length.
4.0 MATERIAL OF CONSTRUCTION
3.1 TYPE-1
4.1 LINING & COVER
i) An inner lining of synthetic rubber
resistant to L.P.G. The rubber shall meet the following
requirements:
ii) A reinforcement consisting of layers of
braided wire as necessary. If more than Property Lining Cover
one layer is used, each shall be
separated by an insulating layer of Tensile strength, 100kgf/cm2 100kgf /cm2
rubber. min.

iii) An outer cover of synthetic rubber Elongation at break, 150% 150% min.
resistant to abrasion, atmospheric
exposure and to LPG. Tensile strength after 75% of 75% of
ageing, min unaged unaged
value value
iv) Both lining and cover shall be smooth,
uniform, free from porosity and other Elongation at break, 75% of 75% of
defects. min. unaged unaged
value value
3.2 TYPE-2
Swelling in n-pentane 25% 25%
i) An inner lining of rubber resistant to max.
LPG.
Soluble matter max. 5% Not
applicable
ii) Reinforcement plies of textile in cord,
woven or braided form or metallic cord Low temperature No cracking No
where reinforcement is of textile Flexibility at - 20oc cracking
material, two or more electrical bonding at 20°C
wires of corrosion and fatigue resisting
material each of not less than 9 strands
shall be provided. 4.2 WIRE REINFORCEMENT

iii) An outer cover of synthetic rubber The steel wire braid quality in Type-1
resistant to abrasion, to atmospheric hoses shall be as agreed between the
exposure and to LPG. purchaser and the manufacturer. The steel
wire used in Type-3 hoses shall be hard
iv) Both lining and cover shall be smooth, drawn or hard rolled with a tensile strength
uniform, free from porosity and other of not less than 70 kgf/mm2, galvanized or
defects. coppered.

3.3 TYPE-3 5.0 INSPECTION AND TESTING OF

HOSES DURING MANUFACTURE
i) An inner lining of rubber resistant to
LPG. The hoses shall be subjected to the
following tests during manufacture:
ii) Reinforcement plies of textile in cord or
woven form or metallic cord together i) Visual inspection
ii) Dimensional check. pressure equal to the highest of the
following:
iii) Tensile strength and elongation at break
for lining & cover in unaged and aged
I) Maximum shut-off pressure of the
conditions.
system.
iv) Swelling test
ii) Set pressure of any safety valve
v) Test for fuel soluble matter provided in the system.
vi) Low temperature flexibility
iii)1.5 times of maximum working pressure.
vii) Pressure Tests.
7.3.2 Test Procedure
a) Proof Test
b) Burst Test The hose shall be placed on a test table
or plain surface so as to lie straight, without
viii) Electrical continuity test
twist. The surface on which the hose rests
should be slightly inclined so that the supply
end is lower than the other end. The
6.0 INSPECTION AND TESTING OF
pressure in the hose shall be increased
NEW HOSES PRIOR TO USE
gradually at a rate of 0.1 to 0.7
Kg/sq.cm/sec. Test pressure shall be held
i) All hoses shall be serially numbered for
for a minimum period of five minutes after
maintaining service record.
stabilization. During the entire test period,
the hose shall be carefully inspected for
ii) Hoses shall be inspected for the
signs of leakage, uneven expansion,
following:-
ballooning, air bubble on external surface
due to entrapped air or any other indication
− Dimensional check. of failure. The pressure shall then be
− Hose cover for cracks, tear, puncture, released gradually at the same rate.
abrasion or any other damage.
− Coupling for any cracks or sign of 7.4 ELECTRICAL CONTINUITY
abuse.
− Check the ends of the assembly for Hose shall be tested for electrical
irregularities in liner. continuity.
− Check for electrical continuity.
7.5 DISCARDING LIMIT
iii) Hoses shall be hydrostatically tested
at the designated test pressure as per LPG hoses shall be discarded after
clause 7.3.1. 3 years of service or earlier in case the
permanent elongation exceeds 5%.
7.0 PERIODIC INSPECTION AND
TESTING OF HOSES 8.0 DOCUMENTATION

7.1 PERIODICITY Records of the observations, tests,

remarks etc. in respect of each hose shall
LPG hoses shall be inspected & be suitably maintained. These records shall
tested at maximum interval of 4 months. show all details pertaining to origin &
manufacture, identification, service history,
7.2 VISUAL INSPECTION AND inspection and maintenance etc. of the
DIMENSIONAL CHECKS hose.

Inspection specified in Para 6.0(ii) 9.0 REFERENCES

shall be carried out.
I) IS 9573 - Specification for Rubber Hose
7.3 HYDROSTATIC TESTING for LPG.
ii) BS 4089 - Specification for Rubber Hose
7.3.1 Test Pressure and Hose Assembly for LPG.

Hydrostatic testing of LPG hoses at iii) NFPA 58

periodicity outlined in Para 7.1 shall be at a
iv) ANSI/UL 21 Standard for Safety in LP- vii) BS 903 - Methods of testing vulcanized
Gas Hose. rubber, Part A2, A16, A19 & B2

v) API-2510-Design/Construction of LP viii) IS 443 - Method of Sampling & test for

Gas Installations. Rubber Hoses.

vi) Philips Engg. Standard.

PART C

MARINE HOSES FOR OFFSHORE TERMINALS

1.0 SCOPE Tanker Rail hoses are characterised

with more flexibility, reinforced ends
This section covers the material, and higher flow velocity in excess of
construction, inspection, storage, testing and standard velocity of 15 m/sec. The
handling requirements of Marine Hoses hose is positioned at tanker for
used for transferring petroleum products in manifold connection.
offshore terminals.
2.2 UNDERBUOY HOSES
1.1 DEFINITIONS
Underbuoy Hoses are without any
The term rubber shall include all types reserve positive buoyancy. However collars
of rubber materials, i.e. natural, synthetic may be provided at specific intervals for
and compounds thereof unless mentioned fixing bead floats for achieving desired
specifically. Similarly, general mention of configuration while installed under the buoy.
yarns and fabrics shall include those made
from cotton or man made fibres or 2.3 ONE-END REINFORCED HOSES
combination thereof.
One-end reinforced hoses are
2.0 TYPES OF HOSES provided with reinforcement at one end to
impart additional stiffness required for
2.1 FLOATING HOSES connecting to a rigid manifold like Pipeline
Manifold/buoy manifold/buoyancy tank etc.
Floating hoses are characterised with
in-built flotation media to impart positive 2.4 ELECTRICALLY CONTINUOUS/
reserve buoyancy such that these hoses can DISCONTINUOUS HOSES
float without addition of any external floats.
Depending on flotation requirements, use To avoid risks such as dangerous
and other characteristics, Floating hoses build up of static electricity or short circuit of
are sub classified as follows: corrosion protection system, the hoses are
manufactured either electrically continuous
i) Full Float Hoses or electrically discontinuous depending upon
the location of a hose in the system.
Full float hoses are characterised
with minimum positive buoyancy of 2.5 TAPERED BORE HOSES
20% in sea water with pipe full of
sea water. Marine hoses are also
manufactured with tapered bore, to be used
ii) Half Reinforced/Half Float Hoses as floating reducers.
Half Reinforced/Half Float hoses are
characterised with positive 3.0 GENERAL REQUIREMENTS
buoyancy of 5% in sea water. These
hoses are used as the first hose off 3.1 PRESSURE RATINGS
the buoy.
Hoses shall be designed &
iii) Tanker Rail Hoses manufactured for a minimum rated pressure
of 15 Kg/cm2. Hoses with higher pressure
ratings may be manufactured as per specific
customer’s requirements. v) Outer Cover

3.2 BENDING CHARACTERISTICS Outer cover shall be resistant to

aging, abrasion, weathering,
i) Minimum bending radius of hoses shall tearing, sunlight, oil and sea water
not exceed 6D where D denotes internal penetration and shall extend to the
diameter of the hose. For rail-tail hoses back of flange extension.
and submarine hoses, this limit is 4D.
Hoses with lesser bending radius are vi) Flanged Joint
also available.
Both ends shall have ANSI 150
ii) Hoses if required with certain specific series flat face weld neck forged
stiffness values and bending radius may flange conforming to ASTM A105
be specified by the customer. steel of maximum 0.25% carbon,
with a protective galvanising of
3.3 FLOW VELOCITY minimum 85 micron thickness.

The design flow velocity of liquids vii) Nipple

inside hoses shall be limited to 15 m/sec.
Nipple shall be made from steel pipe
3.4 TEMPERATURE RATINGS conforming to API 5L Grade B of
maximum 0.23% carbon.
Marine hoses are manufactured to
withstand following ambient temperature viii) Integral reducers
range:
Whenever hoses are fitted with 150
Maximum : + 52 deg C (125 F) series integral reduces, they shall
Minimum : - 29 deg C (-20 F) conform to ANSI B 16.5.

4.0 MATERIAL & CONSTRUCTION ix) Colour marking/colour of cover

OF HOSES
This may be done as per OCIMF
Marine hoses consist of the following: stipulations

i) Inner tube 5.0 INSPECTION AND TESTING OF

HOSES DURING MANUFACTURE
The inner tube shall be made from
smooth, seamless, oil resistant 5.1 GENERAL REQUIREMENTS
synthetic compound. The compound
used shall be Nitrile Butadiene Each hose shall be subjected to
Rubber. inspection and test at
Manufacturer’s shop before
ii) Body Wire acceptance. The inspection shall be
carried out as per section 1.11.1 of
Hard drawn steel wire helix welded to the “Oil Companies International
end connections shall be used for Marine Forum 1991 Edition” or “Oil
body wire. Ports Committee’s SBM Hose In-
Plant Inspection Guide”.
iii) Body Wrap
Inspection at Manufacturer’s shop
Body wrap shall be synthetic shall include, but not limited, to the
rubber. following points.

iv) Flotation Medium i) Hydrostatic testing.

ii) Electrical continuity/discontinuity test.
Flotation medium shall be Integrally
built over basic hose consisting of iii) Vacuum test.
sponge rubber, PVC or polyethylene
iv) Visual inspection.
foam or similar closed cell material.
v) Checking of all test certificates including Hydrostatic tests will be performed
radiography and mill test certificate of on one float per each size, with minimum of
materials. one per order or one per ten if there are
more than ten floats in the order. Further
vi) Bending test. details are given in Annexure-V.
vii) Adhesion test.
5.3 VISUAL INSPECTION
viii) Weight test
The visual inspection shall be made
ix) Float Hydrostatic Test
on each completed length of hose for the
following:
5.2 RECORD OF TESTS
i) Physical dimensions should be checked
and recorded.
After inspection, the result of all tests
ii) Weight of the hose shall be checked and
and inspection shall be recorded in an
recorded.
‘Inspection and Test Certificate’ for each
iii) Reserve positive buoyance shall be
hose. This certificate shall include all the
calculated and recorded.
relevant details in regard to its compliance
with OCIMF standard or any other standard
6.0 PERIODIC INSPECTION AND
as specified.
TESTING OF HOSES
5.2.1 Hydrostatic Testing
All hoses put in service shall be
subjected to periodic testing and inspection
Each hose shall be tested with water
for trouble free and safe operation. This
to the test pressure specified to determine
includes:
water tightness and in addition, shall be
pressurised to working pressure to
i) Visual inspection of hoses in service.
determine temporary and permanent
elongation. The hydrostatic test shall be
ii) Periodic hydro-testing of hose string in
performed as per details given in Annexure-
service.
III.
iii) Periodic inspection of individual hose.
5.2.2 Electrical tests
Floating hoses shall be inspected
The hose shall be tested for
before and after any operation where
discontinuity within the specified level and
tankers are unloaded and also after heavy
resistance reading recorded. Resistance
storm. Underwater hoses shall be inspected
level for electrically discontinuous hoses
at least once in 6 months for general
shall be measured utilising a 500 Volt Mega
condition and string configuration and also
Ohm Meter with a minimum full scale of
after every heavy storm for string
25,000 Ohms.
configuration.
Electrical continuity in hose is tested
In case of floating hoses, the first
by a test lamp (4.5 V 0.3A) across both
and second hose off the buoy and the tail
flanges. The resistance should be low
hoses including tanker-rail hose deserve
enough to light the test lamp.
more attention than other hoses.
5.2.3 Vacuum Testing
Each hose should be examined for
any possible defect such as oil seepage,
Each hose shall be subjected to a
kinking, abrasion exposing the body wire,
vacuum test, which shall be conducted last
bending etc. For any such defect, the
in the sequence of tests. The procedure to
concerned hose should be replaced
be followed shall be as described in
immediately.
Annexure-IV.

5.2.4 Float Hydrostatic Test

 Other defects of minor nature shall
be dealt with according to the severity of the iii) If the hoses are required to be used
defects. In case of doubts regarding beyond normal working life, the following
structural damages in the hose, the affected tests shall be carried out as per OCIMF
hose shall be removed from service for standard:
further and detailed examination.
a) Visual
The hose string should be put to b) Hydrostatic
hydrostatic test before resumption of c) Electrical
operation after each replacement activity of d) Vacuum
hose.
6.3 SAFE WORKING LIFE TYPE OF
Hoses should be checked for HOSES
possible rubbing against anchor chain. Floating - 3 years
Frequency will vary from 3 to 6 months Submarine Underbuoy - 3 years
depending on location. Tanker Rail - 1 year
First hose off buoy - 1 year
6.1 PERIODIC HYDRO TESTING OF
HOSE STRING IN SERVICE However, safe working life of hose may be
altered based on Manufacturer's
The hose strings in service shall be recommendations and past history records".
Note 3
tested periodically every three to six months
and after every storm to ensure good health
of the system. 6.4 VISUAL INSPECTION OF HOSE
COMPONENTS
Testing medium shall be water and
test pressure shall be 150% of the maximum 6.4.1 Covers
working pressure but limited to rated
pressure. The system should be able to hold The primary function of the rubber
the test pressure satisfactorily for a period of cover of hoses is to prevent any damage to
not less than 30 minutes after stabilisation. the reinforcement or flotation material.

Valves in the system may be Any surface cracking which does

operated in logical sequence to pinpoint any not expose the reinforced layer or flotation
weak section or a leaking section. material, does not call for replacement of the
hose.
The underbuoy hose configuration is
to be adjusted with oil-filled condition. Any cut, gouge, local abrasion or
tear down to or through the cover breaker,
6.2 PERIODIC TESTING OF but not into the outer reinforced layer, may
INDIVIDUAL HOSES be repaired as per manufacturer’s
instruction and returned to service.
Periodic testing of individual hoses
(not in a string) should be undertaken as Bulging or ridged area should be
under: marked and examined again under
pressure. Hardening under pressure
i) New hoses which have been in storage indicates a leaking tube or ruptured
for more than six months and used reinforcement and calls for replacement of
hoses in which defects are suspected, hose.
should be pressure tested at maximum
working pressure rating of the hose Hoses shall be replaced if localised
before being replaced or returned to areas of oil softened rubber are observed.
service. The hydrostatic testing shall be
undertaken as per procedure outlined in 6.4.2 Flotation Material
Annexure-III.
Minor damage to flotation material
ii) Hoses in service will be taken for testing shall be repaired as per manufacturer’s
depending upon results of visual instructions before returning to service.
inspection and in-situ testing as covered
in 5.0.
 Hose with considerable amount of care must be taken during handling as
floating material missing or with buoyancy specified.
decreased excessively due to shrinkage of
flotation material shall be replaced. These 7.1 HANDLING INDIVIDUAL HOSE
hoses may be kept in store as emergency
spares in case they pass other tests Individual hose shall be lifted using
satisfactorily. Adequate number of auxiliary spreader bars. Minimum three point lift used
floats may be attached to those hoses over nipple area at each end and additional
before they are put into service again. lifting strap equally spaced between the end
slings shall be used.
6.4.3 Carcass
Spreader bars shall be rigid and
Hoses with crushed or kinked spots strong enough to withstand load of individual
or broken reinforcement as apparent from hose without bending. Spreader bar shall
permanent distortion or separation shall be preferably be made of steel pipes or I-
replaced. Sections of suitable size.

Any hose used for tail, rail, first off A hose shall never be lifted by a
the buoy or underwater and having any single sling at mid point or by two slings
permanent deformity shall be replaced. positioned one at each end.

6.4.4 Fittings Lifting strap shall be flat polyester

band of minimum 6" width to prevent any
chafing of the hose covers. In case of
The internal & external surface of integrally floating hoses, the lifting strap not
fittings shall be wiped and inspected with only eliminates chafing of covers but also
flashlight for cracking or excessive eliminates damage of flotation medium due
corrosion. Either of these damages shall be to point loading.
a cause for hose replacement.
A hose shall never be dragged
Any distortion of the nipple and/or across the ground. While moving a hose, it
flange shall be enough cause for must be lifted properly and set down with
replacement of hose. care on adequate supports.

Superficial damage to the coatings Unnecessary rotation of hoses while

shall be touched up before the hose is lifting is to be avoided to prevent damage
returned to service. that may be caused due to bumping against
building or structures. For this purpose, a
6.4.5 Inner tube string may be attached to one end of the
hose.
Hose interior shall be inspected for
blisters, bulges, or separation of the tube 7.2 HANDLING HOSES IN PALLETS
from the carcass. Any of these defects or
any tearing, cutting or gouging in the tube Steel pallets shall be properly
shall render the hose liable for rejection from designed so as to hold two or three hoses at
service. a time, preventing any relative movement
during lifting or transportation.
7.0 HANDLING AND STORAGE OF
HOSES Pallets shall be lifted with four point
lifts using roped slings (wire rope, nylon rope
The hose strings are critical links in or chain). Each shall be long enough to
any offshore installation. They are prevent their contact with hose cover.
subjected to dynamic loads of wind and sea
currents. Hence, to provide greater Slings shall be connected correctly
reliability and longer hose life, it is required with shackles on steel pallets.
that utmost care should be taken during
handling and storage so as to ensure no 7.3 STORAGE OF HOSES
damage to the hose during these stages.
Hoses are prone to physical damage. All Marine hoses shall be stored in dry
area on steel pallets away from sunlight.
Where closed storage is not available, the oldest hose is put to service first and
hoses shall be covered preferably with a rotational sequence is employed.
water proof cover.
8.0 DOCUMENTATION
The storage area shall be protected
against rodents and insects. Records of each hose or string, as
applicable, shall be suitably maintained.
Storage area should not be adjacent These records shall show all details
to equipment generating heat and ozone. pertaining to origin and identification, service
history, inspection and maintenance etc. of
Hoses should not be subjected to the hose.
temperature exceeding 125 deg F( 52 deg
C) and lower than -20 deg F (-29 deg C). 9.0 REFERENCES :

For storage of used hoses, it shall i) OCIMF - Guide to Purchasing,

be drained completely, water flushed Manufacturing and Testing of loading
thoroughly to remove combustible vapours and discharge hoses for offshore
and stored on the steel pallets. Both ends of moorings (Fourth Edition - 1991).
hoses shall be kept open to allow free
circulation of air. ii) Dunlop : Hose Handling Manual.

The records of hoses in store shall iii) Bridgestone Hose Manual.

be maintained and referred to ensure that

PART D

HOSES FOR JETTY OPERATIONS

1.0 SCOPE Sample hoses shall be selected at

random from the lot and shall be subjected
This section covers the to the following tests:
requirements of inspection and testing of
hoses of size 75 mm to 300 mm nominal i) Bend test under maximum working
inner dia, suitable for use in petroleum pressure.
products having aromatic content not
exceeding 25% and with temperature ii) Thickness of lining and cover.
ranging from minus 20 degree C to 80
degree C. This section also does not cover iii) Tensile strength and elongation at break
LPG hoses. for lining and cover.

2.0 TYPE OF HOSES iv) Accelerated ageing test on lining and

cover.
i) Loading and unloading hoses.
ii) Bunkering hoses. v) Adhesion test on a piece cut from the
hose before conducting the bursting
3.0 MATERIAL AND CONSTRUCTION pressure test.
OF HOSES
vi) Swelling test.
Material and construction should confirm to
IS- 8189/1976 or its equivalent. vii) Fuel soluble matter.

4.0 INSPECTION AND TESTING OF These tests shall meet the

HOSES DURING MANUFACTURE requirements of IS 8189/1976. In addition,
the proof test shall be carried out at 150% of
4.1 Testing of Rubber Hose the maximum working pressure for 5
minutes.
4.2 TESTING Of FINISHED HOSE 6.0 INSPECTION & TESTING OF
ASSEMBLIES HOSES PRIOR TO USE

Following tests shall be carried out The stored hoses shall be subjected to
on all hoses: inspection and testing prior to use as
follows:
i) Visual inspection and dimensional
check. − Visual inspection to detect any abrasion
or damage
ii) Electrical continuity
− Permanent deformation of the hose
iii) Weight of the hose body during transportation and storage if
any, shall be checked.
iv) Hydraulic pressure test:

Temporary elongation under working 7.0 STORAGE AND HANDLING

pressure and permanent elongation
shall be checked and recorded. Test 7.1 STORAGE
pressure shall be as per IS-8189.
i) New hoses should be wrapped in
v) Vacuum test. hessian cloth over its entire length and
flanged ends be protected by oversize
This test shall meet the requirement circular discs.
of IS 8189/1976
ii) Each hose shall be punch marked on
5.0 PERIODIC INSPECTION AND the flange with month and year of
TESTING OF HOSES manufacture, manufacturer’s name and
Sr.No. of the hose.
i) All hoses shall be serially numbered for
maintaining service records. (iii) The hoses shall be laid out straight
on solid supports. Light weight hoses
ii) Hoses shall be subjected to hydraulic should be laid out in such a way that
testing at maximum operating pressure they are not subjected to flattening.
at least once in every six months or after
each 1000 pumping hours whichever is iv) The hoses shall be covered to protect
earlier as per IS 8189/1976. them from sunlight.

The temporary elongation of a used v) Before returning a hose to storage after

hose under test pressure should not use, it should be completely drained.
exceed 1.5 times the temporary Hoses after use should be thoroughly
elongation of the new hose. flushed with water.

During the test, if swelling exceeding 3" vi) The hoses used in white oil/crude oil
dia is observed anywhere on the body of should be flushed to remove any
the hose or distortion/ elongation more potential explosive vapours and stored
than the prescribed limit is noticed, such in such a way that air can circulate freely
hose should be rejected. If any leak at through them.
nipple joints or sweating on the body of
the hose is observed, such hose should 7.2 HANDLING
also be rejected.
i) New hoses shall not be received in bent
iii) Hoses shall be checked for electrical position and shall be laid straight on the
continuity. supports.
ii) A hose shall not be lifted from a single 8.0 DOCUMENTATION
point with the ends hanging down. The
hose should be supported at least by Records of each hose shall be
two slings located near the reinforced suitably maintained. These records shall
ends and a lifting bar should be used. show all details pertaining to origin and
manufacture, identification, service history,
iii) The hoses shall not be dragged over inspection and maintenance etc. of the hose
docks or decks. They should be carried
on dollies or rollers or lifted by dericks. 9.0 REFERENCES

iv) Hoses should not be rolled over more i) BS 1435/1975 - Rubber Hose, wire
than one revolution. This may twist the reinforced, for oil Suction and Discharge
body of the hose resulting in snapping of services.
electrical continuity wire of the hose.
ii) BS 8189/1976-Specifications for Rubber
Hose for oil Suction and Discharge
services.

iii) IS 443-Methods of Sampling and Test

for Rubber Hoses.
 ANNEXURE-I

GENERAL GUIDELINES FOR STORAGE AND HANDLING

OF HOSES IN PETROLEUM SERVICE (EXCLUDING MARINE HOSES)

i) Hose assemblies should be laid out straight on solid supports. Light weight hose
assemblies in particular should be laid out in such a way that they are not subjected to
flattening.

ii) All hose assemblies shall be covered to protect them from sunlight. A cool, dark, & dry
storage place is preferred.

iii) All hose assemblies should be marked to indicate the service for which they are to be
used, & also whether they have been down-graded from white oil to black oil service. All
persons handling hose assemblies should fully understand the marking system and its
meaning.

iv) Hose assemblies which are regularly flushed with water after use are expected to give a
longer life than those which are left full of oil.

A hose assembly operating at higher flow rates will have a shorter service life than similar
hose assembly operating at lower flow rates.

v) A hose assembly in white oil service will have a shorter service life than a similar hose
assembly in black oil service.

vi) When water is used as the test medium, drain it thoroughly and dry the hose by blowing
air or by hanging before putting to service or storage.

vii) Prevent wire-reinforced or metal lined hose from being crushed, kinked, flattened and the
hose should be discarded if any of these damages are noticed.
 ANNEXURE-II

GENERAL PROCEDURE FOR HYDROTESTING OF HOSES

i) Any available, reliable, pumping equipment with a by-pass arrangement and capable of
producing the required hydrostatic pressure may be used for the test.

ii) Connect the hose assembly under test to the pressure apparatus. Attach a suitable vent
valve to the other end of the hose assembly.

iii) Elevate the vent valve, fill the hose and bleed the air.

iv) When the hose is completely filled and all air has been removed from the hose
assembly, close the vent valve and anchor hose properly.

v) After the hose is completely filled and anchored, dry the outside of the hose, and slowly
raise the pressure. Check the hose for leaks. If couplings leak, release the pressure,
tighten the coupling and again raise the pressure slowly.

vi) If the coupling leaks cannot be stopped by tightening tag the hose to show that repairs
are needed. Repeat hydrostatic test after repairs have been made.

vii) If the hose leaks because of damaged couplings, then it may be recouped, retested, and
returned to service. If the hose leaks through the carcass, tag the hose as faulty and
remove from service.
 ANNEXURE-III

PROCEDURE for HYDROTESTING OF MARINE HOSES

Each hose shall be tested with water to a test pressure of 15 bar gauge (225 psig) unless
otherwise specified by the Purchaser. A pressure recorder shall be provided for this test. The
test procedure shall be as follows:

i) Lay the hose as straight as possible on supports that permit the hose to elongate freely.

ii) Fill with water, vent to remove all air and raise and lower the pressure 15 times at a rate
of 1/2 second per inch diameter of hose per cycle, or as otherwise specified by the
Purchaser, from zero pressure to test pressure and inspect nipples for leaks.

iii) Re-apply a pressure of 0.7 bar gauge (10 psig) and measure the overall length of the
hose assembly. Designate it as original length.

iv) Increase the pressure over a period of 5 minutes, from 0.7 bar gauge (10 psig) to one half
of the rated pressure; hold this pressure for 10 minutes, inspect for leaks, then reduce the
pressure over a period of 5 minutes to zero.

v) Raise the pressure over a period of 5 minutes to rated pressure and hold for 10 minutes,
inspect for leaks.

vi) Measurement of temporary elongation: Before releasing the full test pressure, measure
the overall length of the hose assembly to ascertain the temporary elongation and record
the increase as percentage of the original length measured at 0.7 bar gauge (10 psig) in
para (iii) above.

vii) Reduce the pressure over a period of 5 minutes to zero.

viii) After an interval of atleast 15 minutes, raise the pressure again to 0.7 bar gauge (10
psig).

ix) Measurement of permanent elongation: Measure the overall length of the hose assembly
to ascertain the permanent elongation, record the increase as a percentage of original
length measured at 0.7 bar gauge (10 psig) in para (iii).
 ANNEXURE- IV

PROCEDURE OF VACUUM TEST FOR MARINE HOSES

This test should be carried out on hoses removed from service for hydrostatic pressure test.

Seal off both ends with transparent Plexiglas plates of sufficient strength using putty as a sealant
or bolt up using a soft rubber gasket. One plate shall be fixed for connection to a vacuum source.
An inspection mirror using sunlight may also be manipulated from outside the plates to provide a
proper light source.

Apply a Vacuum of atleast (-) 510 millibar gauge (15 inches of mercury) and preferably (-) 680
millibar gauge (20 inches of mercury) for a period of 10 (ten) minutes.

Inspect the interior of the hose for blisters or bulges. Blisters, bulges or separation of tube from
carcass is a sufficient reason to retire hose from service. Any tear out or gouge through the tube
is also reason to retire hose from service.
 ANNEXURE-V

FLOAT HYDROSTATIC TEST (MARINE HOSES)

Hydrostatic tests will be performed on one float per each size, with a minimum of one per order or
one per ten if there are more than ten floats in the order. The test procedure will be as follows:

i) Weigh each half float (without hardware) on scales calibrated for an accuracy of 100 (at
the approximate float weight).

ii) Place half float in a pressure chamber filled with water and increase the pressure to 6.5
barg over a five minute period.

iii) Maintain the test pressure of 6.5 barg for a period of 2 hours.

iv) Reduce the pressure to atmosphere over a period of 5 minutes and remove the half float
from the pressure chamber.

v) Immediately dry and weigh the half float on the same scale used in step i) above.
Any float-half which has gained in weight more than 500 g or has any evidence of
deformation or voids in the foam filling will be rejected.

Any float half which has gained more than 250 g but less than 500 g during the test will
be retested. Any further gain in weight during the retest will be cause for rejection.
NOTES