OISD - STD - 135

FOR RESTRICTED
CIRCULATION ONLY
No.

INSPECTION
OF
LOADING AND UNLOADING HOSES
FOR
PETROLEUM PRODUCTS

OISD-STD-135
First Edition, February 1996

OIL INDUSTRY SAFETY DIRECTORATE

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

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.
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.
---------------------------------------------------------------------------------------------------------------------------

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 OF TESTING OF HOSES
DURING MANUFACTURE
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)

PART A

HOSES FOR ROAD AND RAIL TANKER

1.0 SCOPE Construction of hoses & materials for
lining, reinforcement, helical wire, electrical
This section covers the requirements bonding, cover and end connections shall be
and methods of sampling/testing of as per IS-10733.
electrically bonded road and rail tanker
hoses, resistant to petroleum and blended 4.0 INSPECTION AND TESTING OF
products, having maximum 25% aromatic HOSES DURING MANUFACTURE
hydrocarbon content and suitable for -25
deg C to 65 deg C working temperature The following inspection checks and
range. Inspection/testing of new hoses and testing shall be carried out as per IS-10733.
periodic inspection of hoses in service have
been discussed separately. i) Visual inspection
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
2.0 TYPES OF HOSES
Checking of mass and dimensions/
The hoses used in the Petroleum
tolerances
Industry are of the following types:
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
2.1 TYPE-1A
Tensile strength and elongation at break for
Type-1A hoses are rough bore hoses, the lining and cover.
with internal and external helical wire
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
reinforcement, corrugated outer cover and
for a maximum working pressure of 3.5 Accelerated Ageing Test
Kg/Cm2.
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
2.2 TYPE-1B Adhesion Test
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
Type-1B hoses are smooth bore hoses
with embedded helical wire reinforcement, Swelling Test
plain or corrugated outer cover, used for a
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
maximum working pressure of 3.5 Kg/Cm2.
Test for soluble matter.
2.3 TYPE-2A
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
Type-2A hoses are rough bore hoses Test for resistance to vacuum.
similar to type-1A, used for a maximum
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
working pressure of 7.0 Kg/Cm2.
Hydrostatic pressure test.
2.4 TYPE-2B
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
Bursting pressure test.
Type-2B hoses are smooth bore hoses
similar to type-1B, used for a maximum
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
working pressure of 7.0 Kg/Cm2.
Electrical bonding checks.
2.5 TYPE-3
5.0 INSPECTION AND TESTING OF
Type-3 hoses are smooth bore reeling
NEW HOSES PRIOR TO USE
hoses without helical wire reinforcement,
used for a maximum working pressure of 7.0
i) All hoses shall be serially numbered for
Kg/Cm2.
maintaining service records.
3.0 MATERIAL AND
ii) Hoses shall be inspected for the
CONSTRUCTION OF HOSES
following
- Dimensional check-up. 6.3.1 Elongation during hydrotesting

- The hose cover for cracks, Hoses shall be subjected to

tear, puncture, abrasion or hydrostatic testing at designated test
any other damage. pressure. Elongation under working
pressure shall not exceed 5% for type-3
- Couplings for cracks or any other hoses and 10% for all other hoses.
deformity. Permanent elongation for all hoses shall not
exceed 2.5%.
- Liner for defects and physical
damages from both ends. 6.3.2 Test procedure

iii) Hoses shall be hydrostatically tested to the Test shall be carried out as per
designated pressure. procedure given in IS-10733.

iv) Hoses shall be checked for electrical 6.4 ELECTRICAL CONTINUITY

continuity.
Hoses shall be checked for Electrical
6.0 PERIODIC INSPECTION AND Continuity after each hydrotesting.
TESTING OF HOSES
7.0 DOCUMENTATION
6.1 PERIODICITY
Records of the observations, tests,
Each hose shall be inspected/tested remarks etc. in respect of each hose shall be
after 6 months of initial operation. suitably maintained. These records shall
Subsequent testing shall be done at 3 show all details pertaining to origin and
months interval irrespective of the number of manufacture, identification, service history,
operations. However each hose shall be inspection and maintenance etc. of the hose.
visually checked for damage every time prior
to use. 8.0 REFERENCES

6.2 VISUAL INSPECTION AND i) IS-10733-Specification for Electrically

DIMENSIONAL CHECKS Bonded Road and Rail Tanker Hose of
Rubber, Resistant to Petroleum
Detailed inspection as per Para 5.0(ii) Products.
shall be carried out during each periodic
inspection. ii) BS-3492- Electrically Bonded Road &
Rail Tanker Hose and Hose assembly
6.3 HYDROSTATIC TESTING for Petroleum Products.

PART B

HOSES FOR LIQUEFIED PETROLEUM GAS (LPG) SERVICE

1.0 SCOPE
2.0 TYPES OF HOSES
This section covers the requirements
and methods of sampling/testing of hoses 2.1 TYPE-1 :
and hose assemblies complete with end
connections for transferring Liquefied Wire Braided Reinforced Hose upto
Petroleum Gas (LPG) for loading tank and including 76 mm nominal bore.
trucks/tank wagons, limited for use at
temperatures between -25 deg C to 65 deg 2.2 TYPE-2 :
C, working pressure upto 25 Kg/Cm2 and
size upto 102 mm nominal bore. Metallic Textile (including Metallic Cord)
hoses for unloading of LPG from tankers are Reinforced Hose upto and including 76 mm
excluded. nominal bore.
ii) Reinforcement plies of textile in cord or
2.3 TYPE-3 : woven form or metallic cord together
with at least one helix of heavy steel
Textile Reinforced Hose with wire wire embedded in rubber.
helix and built-in couplings, 76 mm and 102
mm nominal bore. iii) An outer cover of synthetic rubber
resistant to abrasion, atmospheric
3.0 CONSTRUCTION OF HOSES exposure and to LPG.

The constructional details of various iv) Both lining and cover shall be smooth,
types of hoses mentioned in Para 2.0 are as uniform, free from porosity and other
given below. Hoses shall be uniformly defects.
vulcanised and reasonably concentric
throughout its length. 4.0 MATERIAL OF CONSTRUCTION

3.1 TYPE-1 4.1 LINING & COVER

i) An inner lining of synthetic rubber The rubber shall meet the following
resistant to L.P.G. requirements:

ii) A reinforcement consisting of layers of Property Lining Cover

braided wire as necessary. If more than
one layer is used, each shall be Tensile strength, 100kgf/cm2 100kgf /cm2
separated by an insulating layer of min.
rubber.
Elongation at break, 150% 150% min.
iii) An outer cover of synthetic rubber
resistant to abrasion, atmospheric Tensile strength after 75% of 75% of
exposure and to LPG. ageing, min unaged unaged
value value
iv) Both lining and cover shall be smooth, Elongation at break, 75% of 75% of
uniform, free from porosity and other min. unaged unaged
defects. value value

3.2 TYPE-2 Swelling in n-pentane 25% 25%

max.
i) An inner lining of rubber resistant to
LPG. Soluble matter max. 5% Not
applicable
ii) Reinforcement plies of textile in cord, Low temperature No cracking No
woven or braided form or metallic cord Flexibility at - 20oc cracking
where reinforcement is of textile at 20°C
material, two or more electrical bonding
wires of corrosion and fatigue resisting
material each of not less than 9 strands 4.2 WIRE REINFORCEMENT
shall be provided.
The steel wire braid quality in Type-1
iii) An outer cover of synthetic rubber hoses shall be as agreed between the
resistant to abrasion, to atmospheric purchaser and the manufacturer. The steel
exposure and to LPG. wire used in Type-3 hoses shall be hard
drawn or hard rolled with a tensile strength
iv) Both lining and cover shall be smooth, of not less than 70 kgf/mm2, galvanized or
uniform, free from porosity and other coppered.
defects.
5.0 INSPECTION AND TESTING OF
3.3 TYPE-3 HOSES DURING MANUFACTURE

i) An inner lining of rubber resistant to The hoses shall be subjected to the

LPG. following tests during manufacture:
i) Visual inspection Hydrostatic testing of LPG hoses at
periodicity outlined in Para 7.1 shall be at a
ii) Dimensional check.
pressure equal to the highest of the
iii) Tensile strength and elongation at break following:
for lining & cover in unaged and aged
conditions. I) Maximum shut-off pressure of the
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.
a) Proof Test 7.3.2 Test Procedure
b) Burst Test
The hose shall be placed on a test table
viii) Electrical continuity test or plain surface so as to lie straight, without
twist. The surface on which the hose rests
should be slightly inclined so that the supply
6.0 INSPECTION AND TESTING OF end is lower than the other end. The
NEW HOSES PRIOR TO USE pressure in the hose shall be increased
gradually at a rate of 0.1 to 0.7
i) All hoses shall be serially numbered for Kg/sq.cm/sec. Test pressure shall be held
maintaining service record. for a minimum period of five minutes after
stabilization. During the entire test period,
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmcdxcvi)
the hose shall be carefully inspected for
Hoses shall be inspected for the following:- signs of leakage, uneven expansion,
ballooning, air bubble on external surface
− Dimensional check. due to entrapped air or any other indication
− Hose cover for cracks, tear, puncture, of failure. The pressure shall then be
abrasion or any other damage. released gradually at the same rate.
− Coupling for any cracks or sign of
abuse. 7.4 ELECTRICAL CONTINUITY
− Check the ends of the assembly for
irregularities in liner. Hose shall be tested for electrical
− Check for electrical continuity. continuity.

7.5 DISCARDING LIMIT

mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmcdxl)
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 be
LPG hoses shall be inspected & 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 hose.
DIMENSIONAL CHECKS
9.0 REFERENCES
Inspection specified in Para 6.0(ii)
shall be carried out. I) IS 9573 - Specification for Rubber Hose
for LPG.
7.3 HYDROSTATIC TESTING ii) BS 4089 - Specification for Rubber Hose
and Hose Assembly for LPG.
7.3.1 Test Pressure
iii) NFPA 58 vi) Philips Engg. Standard.

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.

PART C

MARINE HOSES FOR OFFSHORE TERMINALS

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

ii) Half Reinforced/Half Float Hoses 3.0 GENERAL REQUIREMENTS

Half Reinforced/Half Float hoses are
characterised with positive 3.1 PRESSURE RATINGS
buoyancy of 5% in sea water. These
hoses are used as the first hose off Hoses shall be designed &
the buoy. manufactured for a minimum rated pressure
of 15 Kg/cm2. Hoses with higher pressure
iii) Tanker Rail Hoses ratings may be manufactured as per specific
customer’s requirements.
Tanker Rail hoses are characterised
with more flexibility, reinforced ends 3.2 BENDING CHARACTERISTICS
Outer cover shall be resistant to
i) Minimum bending radius of hoses shall ageing, abrasion, weathering,
not exceed 6D where D denotes internal tearing, sunlight, oil and sea water
diameter of the hose. For rail-tail hoses penetration and shall extend to the
and submarine hoses, this limit is 4D. back of flange extension.
Hoses with lesser bending radius are
also available. vi) Flanged Joint

ii) Hoses if required with certain specific Both ends shall have ANSI 150
stiffness values and bending radius may series flat face weld neck forged
be specified by the customer. flange conforming to ASTM A105
steel of maximum 0.25% carbon,
3.3 FLOW VELOCITY with a protective galvanising of
minimum 85 micron thickness.
The design flow velocity of liquids
inside hoses shall be limited to 15 m/sec. vii) Nipple

3.4 TEMPERATURE RATINGS Nipple shall be made from steel pipe

conforming to API 5L Grade B of
Marine hoses are manufactured to maximum 0.23% carbon.
withstand following ambient temperature
range: viii) Integral reducers

Maximum : + 52 deg C (125 F) Whenever hoses are fitted with 150

Minimum : - 29 deg C (-20 F) series integral reduces, they shall
conform to ANSI B 16.5.
4.0 MATERIAL & CONSTRUCTION
OF HOSES ix) Colour marking/colour of cover

Marine hoses consist of the following: This may be done as per OCIMF
stipulations
i) Inner tube
5.0 INSPECTION AND TESTING OF
The inner tube shall be made from HOSES DURING MANUFACTURE
smooth, seamless, oil resistant
synthetic compound. The compound 5.1 GENERAL REQUIREMENTS
used shall be Nitrile Butadiene
Rubber. Each hose shall be subjected to
inspection and test at
ii) Body Wire Manufacturer’s shop before
acceptance. The inspection shall be
Hard drawn steel wire helix welded to carried out as per section 1.11.1 of
end connections shall be used for the “Oil Companies International
body wire. Marine Forum 1991 Edition” or “Oil
Ports Committee’s SBM Hose In-
iii) Body Wrap Plant Inspection Guide”.

Body wrap shall be synthetic Inspection at Manufacturer’s shop

rubber. shall include, but not limited, to the
following points.
iv) Flotation Medium
i) Hydrostatic testing.
Flotation medium shall be Integrally
ii) Electrical continuity/discontinuity test.
built over basic hose consisting of
sponge rubber, PVC or polyethylene iii) Vacuum test.
foam or similar closed cell material.
iv) Visual inspection.
v) Outer Cover
v) Checking of all test certificates including
radiography and mill test certificate of
materials.
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
Hydrostatic tests will be performed
defects. In case of doubts regarding
on one float per each size, with minimum of
structural damages in the hose, the affected
one per order or one per ten if there are
hose shall be removed from service for tests shall be carried out as per OCIMF
further and detailed examination. standard:

The hose string should be put to a) Visual

hydrostatic test before resumption of b) Hydrostatic
operation after each replacement activity of c) Electrical
hose. d) Vacuum

Hoses should be checked for 6.3 NORMAL WORKING LIFE TYPE

possible rubbing against anchor chain. OF HOSE SAFE WORKING LIFE
Frequency will vary from 3 to 6 months Floating 3 years
depending on location. Submarine underbuoy 3 years
Tanker rail 1 year
6.1 PERIODIC HYDRO TESTING OF First hose off buoy 1 year
HOSE STRING IN SERVICE
Manufacturers recommendations on safe
The hose strings in service shall be working life should be duly considered.
tested periodically every three to six months
and after every storm to ensure good health 6.4 VISUAL INSPECTION OF HOSE
of the system. COMPONENTS

Testing medium shall be water and 6.4.1 Covers

test pressure shall be 150% of the maximum
working pressure but limited to rated The primary function of the rubber
pressure. The system should be able to hold cover of hoses is to prevent any damage to
the test pressure satisfactorily for a period of the reinforcement or flotation material.
not less than 30 minutes after stabilisation.
Any surface cracking which does not
Valves in the system may be expose the reinforced layer or flotation
operated in logical sequence to pinpoint any material, does not call for replacement of the
weak section or a leaking section. hose.

The underbuoy hose configuration is Any cut, gouge, local abrasion or

to be adjusted with oil-filled condition. tear down to or through the cover breaker,
but not into the outer reinforced layer, may
6.2 PERIODIC TESTING OF be repaired as per manufacturer’s instruction
INDIVIDUAL HOSES and returned to service.

Periodic testing of individual hoses Bulging or ridged area should be

(not in a string) should be undertaken as marked and examined again under
under: pressure. Hardening under pressure
indicates a leaking tube or ruptured
i) New hoses which have been in storage reinforcement and calls for replacement of
for more than six months and used hose.
hoses in which defects are suspected,
should be pressure tested at maximum Hoses shall be replaced if localised
working pressure rating of the hose areas of oil softened rubber are observed.
before being replaced or returned to
service. The hydrostatic testing shall be 6.4.2 Flotation Material
undertaken as per procedure outlined in
Annexure-III. Minor damage to flotation material
shall be repaired as per manufacturer’s
ii) Hoses in service will be taken for testing instructions before returning to service.
depending upon results of visual
inspection and in-situ testing as covered Hose with considerable amount of
in 5.0. floating material missing or with buoyancy
decreased excessively due to shrinkage of
iii) If the hoses are required to be used flotation material shall be replaced. These
beyond normal working life, the following hoses may be kept in store as emergency
spares in case they pass other tests
satisfactorily. Adequate number of auxiliary lifting strap equally spaced between the end
floats may be attached to those hoses slings shall be used.
before they are put into service again.
Spreader bars shall be rigid and
6.4.3 Carcass strong enough to withstand load of individual
hose without bending. Spreader bar shall
Hoses with crushed or kinked spots preferably be made of steel pipes or I-
or broken reinforcement as apparent from Sections of suitable size.
permanent distortion or separation shall be
replaced. A hose shall never be lifted by a
single sling at mid point or by two slings
Any hose used for tail, rail, first off positioned one at each end.
the buoy or underwater and having any
permanent deformity shall be replaced. Lifting strap shall be flat polyester
band of minimum 6" width to prevent any
6.4.4 Fittings chafing of the hose covers. In case of
integrally floating hoses, the lifting strap not
only eliminates chafing of covers but also
The internal & external surface of eliminates damage of flotation medium due
fittings shall be wiped and inspected with to point loading.
flashlight for cracking or excessive
corrosion. Either of these damages shall be A hose shall never be dragged
a cause for hose replacement. across the ground. While moving a hose, it
must be lifted properly and set down with
Any distortion of the nipple and/or care on adequate supports.
flange shall be enough cause for
replacement of hose. Unnecessary rotation of hoses while
lifting is to be avoided to prevent damage
Superficial damage to the coatings that may be caused due to bumping against
shall be touched up before the hose is building or structures. For this purpose, a
returned to service. string may be attached to one end of the
hose.
6.4.5 Inner tube
7.2 HANDLING HOSES IN PALLETS
Hose interior shall be inspected for
blisters, bulges, or separation of the tube Steel pallets shall be properly
from the carcass. Any of these defects or designed so as to hold two or three hoses at
any tearing, cutting or gouging in the tube a time, preventing any relative movement
shall render the hose liable for rejection from during lifting or transportation.
service.
Pallets shall be lifted with four point
7.0 HANDLING AND STORAGE OF lifts using roped slings (wire rope, nylon rope
HOSES or chain). Each shall be long enough to
prevent their contact with hose cover.
The hose strings are critical links in
any offshore installation. They are subjected Slings shall be connected correctly
to dynamic loads of wind and sea currents. with shackles on steel pallets.
Hence, to provide greater reliability and
longer hose life, it is required that utmost 7.3 STORAGE OF HOSES
care should be taken during handling and
storage so as to ensure no damage to the Marine hoses shall be stored in dry
hose during these stages. Hoses are prone area on steel pallets away from sunlight.
to physical damage. All care must be taken Where closed storage is not available, hoses
during handling as specified. shall be covered preferably with a water
proof cover.
7.1 HANDLING INDIVIDUAL HOSE
The storage area shall be protected
Individual hose shall be lifted using against rodents and insects.
spreader bars. Minimum three point lift used
over nipple area at each end and additional
Storage area should not be adjacent 8.0 DOCUMENTATION
to equipment generating heat and ozone.
Records of each hose or string, as
Hoses should not be subjected to applicable, shall be suitably maintained.
temperature exceeding 125 deg F( 52 deg These records shall show all details
C) and lower than -20 deg F (-29 deg C). pertaining to origin and identification, service
history, inspection and maintenance etc. of
For storage of used hoses, it shall the hose.
be drained completely, water flushed
thoroughly to remove combustible vapours 9.0 REFERENCES :
and stored on the steel pallets. Both ends of
hoses shall be kept open to allow free i) OCIMF - Guide to Purchasing,
circulation of air. Manufacturing and Testing of loading
and discharge hoses for offshore
The records of hoses in store shall moorings (Fourth Edition - 1991).
be maintained and referred to ensure that
the oldest hose is put to service first and ii) Dunlop : Hose Handling Manual.
rotational sequence is employed.
iii) Bridgestone Hose Manual.

PART D

HOSES FOR JETTY OPERATIONS

1.0 SCOPE
ii) Thickness of lining and cover.
This section covers the
requirements of inspection and testing of iii) Tensile strength and elongation at break
hoses of size 75 mm to 300 mm nominal for lining and cover.
inner dia, suitable for use in petroleum
products having aromatic content not iv) Accelerated ageing test on lining and
exceeding 25% and with temperature cover.
ranging from minus 20 degree C to 80
degree C. This section also does not cover v) Adhesion test on a piece cut from the
LPG hoses. hose before conducting the bursting
pressure test.
2.0 TYPE OF HOSES
vi) Swelling test.
i) Loading and unloading hoses.
ii) Bunkering hoses. vii) Fuel soluble matter.

3.0 MATERIAL AND CONSTRUCTION These tests shall meet the

OF HOSES requirements of IS 8189/1976. In addition,
the proof test shall be carried out at 150% of
Material and construction should confirm to the maximum working pressure for 5
IS- 8189/1976 or its equivalent. minutes.

4.0 INSPECTION AND TESTING OF 4.2 TESTING Of FINISHED HOSE

HOSES DURING MANUFACTURE ASSEMBLIES

4.1 Testing of Rubber Hose Following tests shall be carried out

on all hoses:
Sample hoses shall be selected at
random from the lot and shall be subjected i) Visual inspection and dimensional
to the following tests: check.

i) Bend test under maximum working ii) Electrical continuity

pressure.
iii) Weight of the hose − Permanent deformation of the hose
body during transportation and storage if
iv) Hydraulic pressure test: any, shall be checked.

Temporary elongation under working

pressure and permanent elongation 7.0 STORAGE AND HANDLING
shall be checked and recorded. Test
pressure shall be as per IS-8189. 7.1 STORAGE

v) Vacuum test. i) New hoses should be wrapped in

hessian cloth over its entire length and
This test shall meet the requirement flanged ends be protected by oversize
of IS 8189/1976 circular discs.

5.0 PERIODIC INSPECTION AND ii) Each hose shall be punch marked on
TESTING OF HOSES the flange with month and year of
manufacture, manufacturer’s name and
i) All hoses shall be serially numbered for Sr.No. of the hose.
maintaining service records.
(iii) The hoses shall be laid out straight on
ii) Hoses shall be subjected to hydraulic solid supports. Light weight hoses
testing at maximum operating pressure should be laid out in such a way that
at least once in every six months or after they are not subjected to flattening.
each 1000 pumping hours whichever is
earlier as per IS 8189/1976. iv) The hoses shall be covered to protect
them from sunlight.
The temporary elongation of a used
hose under test pressure should not v) Before returning a hose to storage after
exceed 1.5 times the temporary use, it should be completely drained.
elongation of the new hose. Hoses after use should be thoroughly
flushed with water.
During the test, if swelling exceeding 3"
dia is observed anywhere on the body of vi) The hoses used in white oil/crude oil
the hose or distortion/ elongation more should be flushed to remove any
than the prescribed limit is noticed, such potential explosive vapours and stored
hose should be rejected. If any leak at in such a way that air can circulate freely
nipple joints or sweating on the body of through them.
the hose is observed, such hose should
also be rejected. 7.2 HANDLING

iii) Hoses shall be checked for electrical i) New hoses shall not be received in bent
continuity. position and shall be laid straight on the
supports.

6.0 INSPECTION & TESTING OF

HOSES PRIOR TO USE

The stored hoses shall be subjected to ii) A hose shall not be lifted from a single
inspection and testing prior to use as point with the ends hanging down. The
follows: hose should be supported at least by
two slings located near the reinforced
− Visual inspection to detect any abrasion ends and a lifting bar should be used.
or damage
iii) The hoses shall not be dragged over
docks or decks. They should be carried
on dollies or rollers or lifted by dericks.
show all details pertaining to origin and
iv) Hoses should not be rolled over more manufacture, identification, service history,
than one revolution. This may twist the inspection and maintenance etc. of the hose
body of the hose resulting in snapping of
electrical continuity wire of the hose. 9.0 REFERENCES

i) BS 1435/1975 - Rubber Hose, wire

reinforced, for oil Suction and Discharge
services.

ii) BS 8189/1976-Specifications for Rubber

Hose for oil Suction and Discharge
services.
8.0 DOCUMENTATION
iii) IS 443-Methods of Sampling and Test
Records of each hose shall be for Rubber Hoses.
suitably maintained. These records shall
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