TKO AS Hoses by jennyyingdi

VIEWS: 6 PAGES: 20

									           ContiTech Rubber Industrial Kft.
            Hose Technical Department
                                                                       Doc. No.:       TKO AS0
                                                                       Revision:       5
                           HANDLING                                    Page:           1/20
                                                                       Date:           31.07.2008
Invalidate the document TKO AS0 rev.4




           HANDLING AND SERVICE
          INSTRUCTIONS FOR HIGH
         PRESSURE FLEXIBLE HOSES




Prepared by:                         Revised by:                               Approved by:


         Imre Domonkos                           József Dávid                          Gyula Bétéri
                               FOR BEST IMAGE QUALITY SUGGESTED TO PRINT IN 600 DPI
                                  HANDLING
                                                                                          Doc. No.:              TKO AS0
   HANDLING AND SERVICE INSTRUCTIONS
                                                                                          Revision:              5
   FOR HIGH PRESSURE FLEXIBLE HOSES                                                       Page:                  2/20


System description ......................................................................................... 3
1. Operational Requirements ........................................................................... 4
       1.1    Design pressure........................................................................... 4
       1.2    Collapse Resistance .................................................................. 4
       1.3    Excessive Axial Load ................................................................... 4
       1.4.   Bending ....................................................................................... 4
       1.5    Torsions....................................................................................... 4
       1.6    Gas service.................................................................................. 5
       1.7    Transported fluid considerations .................................................. 5
       1.8    Temperature limit......................................................................... 5
       1.9    Fluid velocity................................................................................ 5
       1.10 Accidental load ............................................................................ 6
       1.11 Welding........................................................................................ 6

2. Handling, transportation and installation.................................................... 6
      2.1      Handling in general and installation. ............................................ 6
      2.2      Transportation ............................................................................. 6
      2.3.     Storage (in general) ..................................................................... 6

3. Service Inspection ........................................................................................ 7
       3.1.   Inspection            .......................................................................... 7
       3.2    Hydrostatic Pressure Test Procedure. ......................................... 7

4. Appendix 1...................................................................................................... 8
5. Guidelines on storage, handling transportation
    and installation of flexible pipes..................................................................... 10
6. Attachments.................................................................................................... 14

Handling and Service instructions has a purpose: to ensure the safe, long term use of our flexible
hoses. General instructions are supplied with the product, more detailed instructions regarding the use
are described in this document. Our guarantee obligation is valid only in the case, when the use of the
hoses is based on these instructions.
          Additional technical questions can be sent to the following address:
               ContiTech Beattie Ltd.
               Jubilee Industrial Estate
               Ashington, Northumberland NE63 8UB England
               Phone: +44 1670 528 700; Fax: +44 1670 520 535
               e-mail: sales@contitechbeattie.co.uk WEB: www.contitechbeattie.co.uk

               ContiTech Beattie, Corp.
               11535 Brittmoore Park Drive Houston, TX 77041 USA
               Phone: +1 832 327-0141 Fax: +1 832 327-0148
               e-mail: mail@contitechbeattie.com WEB: www.contitechbeattie.com

               ContiTech Rubber Industrial Kft.
               6728 Szeged, Budapesti út 10. Hungary
               Phone: +36 62 566-901; Fax: +36 62 566-999;
               e-mail: sales@fluid.contitech.hu WEB: www.contitech-rubber.hu
                        HANDLING
                                                                 Doc. No.:        TKO AS0
  HANDLING AND SERVICE INSTRUCTIONS
                                                                 Revision:        5
  FOR HIGH PRESSURE FLEXIBLE HOSES                               Page:            3/20


                                      SYSTEM DESCRIPTION

Most aspect of hoses used is covered by API documents as follows:
API Spec 7K / ISO 14693: This is a specification for rotary drilling, vibrator and cement hoses.
API Spec 17K / ISO 13628-10 and API RP 17B / ISO 13628-11: Relevant to hoses for oil and gas field
applications.
API Spec. 16C: This is a specification for all the equipment constitutes a choke and kill system. The
Standard had different drafts, before the final version was issued.
ContiTech Rubber Industrial Kft. can produce according to API Spec. 16C or API Spec. 16C Draft 07C
depending upon the decision of the user or where a governing body dictates (e.g. NPD, DNV). The
formulation and publication of API Standards is not intended in any way to inhibit anyone using any
other practices. The requirements are agreed mutually by the user and the manufacturer and can be
based on any API publication. But an API label can be attached only on a hose, which was designed
and produced exactly according to the valid API Standard and with the sizes defined in it.
The choice of the most suitable API standard or draft standard shall be defined by the user. Before the
order is issued the user has to study and approve the selected standard.
                      HANDLING
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  HANDLING AND SERVICE INSTRUCTIONS
                                                               Revision:        5
  FOR HIGH PRESSURE FLEXIBLE HOSES                             Page:            4/20


                               1. OPERATIONAL REQUIREMENTS

1.1. DESIGN PRESSURE
  The design pressure, which is a performance characteristic of the flexible hose warranted by the
  manufacturer, is the maximum internal pressure to which it should be subjected to during its life. It
  would normally include operating pressure plus allowances for surges. This is equivalent to the
  Rated Working Pressure as defined below:
  Rotary drilling and vibrator hoses acc. to API Spec 7K / ISO 14693: Ø2”-6”; 10,3-51,7 MPa (1500-
  7500 psi)
  Cement hoses acc. to API Spec 7K / ISO 14693: Ø2”-4”; 69-103,5 MPa (10000-15000 psi)
  Choke and kill hoses acc. to API Spec 16C; Ø2”-4”; 34,5-103,5 MPa (5000-15000 psi)
  Bonded flexible pipes acc to API Spec 17K / ISO 13628-10 and API RP 17B / ISO 13628-11; Ø2”-
  14”; up to 51,7 MPa (7500 psi)
  Other diameters and pressure ranges are available on request or acc. to a referred relevant
  Standard or in-house design (e.g. Ø1,5”-16” smooth and rough bore hoses).

1.2. COLLAPSE RESISTANCE
  The flexible hoses are designed and produced in general for topside application.
  Hoses subjected to subsea service shall be inquired, ordered and designed to withstand the
  differential external pressure for the operational depth without deforming the hose to a point where
  they can no longer function as the design specifies. Please ensure that such requirements were
  specified in order correctly!

1.3. EXCESSIVE AXIAL LOAD
  High pressure hoses should not be exposed to higher external axial load, than its full fluid filled
  weight, when there is no internal pressure in the hose. Special design for excessive axial load
  ability is also available for request. Please ensure that such requirements were specified in order
  correctly!

1.4. BENDING
  The minimum bend radius (MBR) is a performance characteristic of the hoses and is specified by
  the manufacturer. The actual bending radius of the hose must never be smaller because it can
  result in permanent damage to the line. The bending radius is depending from the type of
  application. Dynamic application is a service, in which the flexible pipe is exposed to cyclically
  varying loads and deflections. In general the dynamic bending radius is 1,5 times bigger, than the
  minimum bending radius at storage application (without dynamic loads). If the manufacturer gives
  only one value for the minimum bending radius, this is the operational minimum bending radius.

1.5. TORSIONS
  Do not twist the hoses during installation or in use, because it adversely affects the lifetime of the
  hose. Without consultation and agreement with the manufacturer torsion must remain below
  1,0°/individual metre.
                       HANDLING
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  HANDLING AND SERVICE INSTRUCTIONS
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1.6. GAS SERVICE
  Only hoses ordered for defined gas service are suitable for handling gas. The number and velocity
  of the rapid decompressions in gas service should be limited to the possible minimum. It is
  necessary to define at the order of the hose the exact service conditions, or refer to the right
  standard.
  Hoses for continuous H2S service can be ordered with the following parameters: up to 60°C
  operating temperature max. partial pressure 0,1035 MPa (3000 ppm, at 5000psi) up to 90°C
  temperature max partial pressure 0,0345MPa (1000 ppm at 5000psi) H2S content. Couplings for
  H2S service are produced acc. to the standard NACE MR 0175 / ISO 15156.
  Production hoses for gas-containing medium can be ordered referring to the API Spec 17K / ISO
  13628-10 and API RP 17B / ISO 13628-11. The qualification test for gas service is described in the
  API RP 17B § 9.6.11. If there is rapid decompression requirements see TKO AS4
  recommendations.
  Choke and kill hoses can be ordered acc. to the standard API Spec 16C. The qualification test is
  described in the § 9.14.12.
  Choke and kill line can be ordered acc. to API Spec 16C Draft 07C as well, where the qualification
  test can be found in the § 9.7.1.
  The purchaser should take proper care of ordering: either the service conditions should be exactly
  defined, or it should be controlled which performance test covers the service conditions.

1.7. TRANSPORTED FLUID CONSIDERATIONS
  Please ensure, that the medium to be transported inside the hose meets the relevant standard or
  contract terms.
  In any event if there is any doubt as to the effect of particular chemicals on the hoses, the
  manufacturer shall be consulted. Some information can be found in Appendix 1.
  Special remarks: Choke and kill lines are generally smooth bore hoses; they must never be used for
  production or well test purposes. They can be applied for cementing, but the cement hose may
  never be used for choke and kill service.
  At the delivery of oil the composition has to be defined, especially the aromatic content. Special
  care has to be taken, if there is any gas content in the oil, it shall be specified.

1.8. TEMPERATURE LIMIT
  The operator shall determine in the order the minimum and maximum operating temperature. The
  working conditions must comply with the defined temperature limits, exceeding the temperature
  limits can harm the hose especially under dynamic conditions. It is important that both the minimum
  and maximum operating temperatures are taken into account.

1.9. FLUID VELOCITY
  There is a general rule for the determination of the max. fluid velocity in a hose; if the fluid has no
  solid content: for liquid: 15 m/sec; for gas 20 m/sec; for gaseous liquid 8m/sec. If the fluid has solid
  content or there is a corrosion effect as well, a detailed calculation has to be made, based on the
  data of the actual use, while the expected lifetime has to be taken into account. Please contact the
  manufacturer in case of any doubt.
                       HANDLING
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1.10. ACCIDENTAL LOAD
  If the hose has been the subject of accidental load outside of the operating envelope (e.g. higher
  temperature, extreme flow velocity with abrasive fluid, collapse due to irregular outer force,
  elongation due to extreme axial load etc.) it should be replaced.

1.11. WELDING
  No post welding is allowed on the couplings of the hose.

                   2. HANDLING, TRANSPORTATION AND INSTALLATION


2.1. HANDLING IN GENERAL AND INSTALLATION
  When a hose has to be lifted from a reel or packing crate, precautions should be taken to ensure
  that it will not be damaged by dragging it on the floor or against sharp edges of the handling
  equipment or by unacceptable torsional/bending loading.
  The flexible pipe should be securely fastened to its reel or packing crate. The end fittings require
  additional fastening by means of textile bands.
  It is recommended to order the hoses with lifting collars and to use them for installation. Never lift
  the hose in a reverse "U" shape using one band in the middle, because the hose can be severely
  damaged. (See the photographs in the attachment)
  If the hose was delivered in a crate, it should be removed from its crate by hand, laid out in a
  straight line, and then lifted by means of a catline attached near one end of the hose. If a catline is
  used to remove the hose from its crate, the hook of the crane shall have a free rotation possibility.
  The use of a carrier to protect the hose in moving is a recommended practice.
  If the hose is transported on a reel, a suitable let off equipment must be used at the installation.
  It is important during installation not to exceed the minimum bending radius, especially in the area
  close to the end fitting.
  When handling the hoses please refer to the instructions and photographs in the attachment.

2.2. TRANSPORTATION
  Hoses can be transported on a reel or in a packing crate. Hoses should not be placed on a reel or
  in a crate so that the end fittings or other attachments induce unacceptable local loading in the hose
  structure. Weight should be accurately monitored during lifting not to overload the lifting equipment.
  Secure fastenings should be designed for the final transported weight in a dynamic environment. In
  general all hoses must be packed and handled according to the specifications of the relevant API /
  ISO standards.

2.3. STORAGE (IN GENERAL)
  Correct storage of flexible pipes prolongs their life in service. The warehousing area shall be
  relatively cool, dark and free from dampness and mildew. The recommended temperature for
  storage is: between -20°C and +30°C.
  The end of fitting connections shall be protected to prevent damage of the seal area, threads, and
  other areas susceptible to damage.
  The flexible pipes shall be covered to prevent degradation by ultraviolet radiation.
                      HANDLING
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  HANDLING AND SERVICE INSTRUCTIONS
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                                    3. SERVICE INSPECTION

  This section outlines the recommendation to be followed by the contractor to determine periodically
  the condition of the hose. Proper inspection and testing procedures will increase the probability of
  detecting processing failures.

3.1. INSPECTION
  Please see the following documents:
  - INSPECTION GUIDELINES FOR HP DRILLING AND PRODUCTION HOSES,
     doc.no.: ISS-059
  - Suggested log in form in attachment No 1 (See attachments)

3.2. HYDROSTATIC PRESSURE TEST PROCEDURE
  Safety considerations must be incorporated into all hydrostatic pressure testing procedures.
  Permissible test media for hydrostatic pressure test are water or non aromatic oil with care being
  taken to bleed off any entrapped air or gases. Air or other compressible gas must never be used as
  test media. The test may be carried out in-site or the hose may be removed to an onshore test
  facility.
                       HANDLING
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4.     APPENDIX 1

                   Product compatibility of PA lined ContiTech Rubber hoses
                          (Choke and Kill hoses acc. to API Spec 16C &
              hoses c\w st. st. internal carcass acc. to API Spec. 17K / ISO 13628-10)
                                                                 Temperature
                                                    o   o    o       o          o                 o
             Medium             Concentration    -18 C      24 C 66 C 100 C 121 C
                                                                                                        API 16C
                                                                                (90°C)                  API 17K
     Hydrochloric acid HCl          15%             -        -       -      -                 -
     Hydrofluoric acid HF            3%             -        -       -      -                 -
     Methanol CH3OH                100%             +        +       -      -                 -
     Zinc bromide ZnBr2           Saturated         -        -       -      -                 -
     Calcium bromide CaBr2        Saturated         L        L       L      L                 -
     Calcium chloride CaCl2       Saturated         +        +       L      L                 -
     Methane CH4                   100%             +        +       +      +                 +
     Diesel                        100%             +        +       +      +                 +
     Crude oil                     100%             +        +       +      +                 +
     Hydrogen sulphide H2S         <10%             +        +       +      +                 +
     Sodium hydroxide NaOH         <20%             +        L       -      -                 -
     Xylene C6H4 (CH3)2            100%             +        +       +      L                 -


                 Product compatibility of HNBR lined ContiTech Rubber hoses
                    (Choke and Kill hoses acc. to API Spec. 16C 07C draft &
              hoses c\w st. st. internal carcass acc. to API Spec. 17K / ISO 13628-10)
                                                              Temperature
                                                    o   o    o       o      o                 o
             Medium             Concentration    -18 C      24 C 66 C 93 C 121 C
                                                                                                      API 16C 07C
                                                                                 (90°C)               API 17K
     Hydrochloric acid HCl          15%             +        +       -    -               -
     Hydrofluoric acid HF           0,6%            +        +       -    -               -
     Xylene C6H4 (CH3)2             25%             +        +       +    L               L
     Methanol CH3OH                100%             +        +       L    -               -
     Zinc bromide ZnBr2           Saturated         +        +       L    L               L
     Calcium bromide CaBr2        Saturated         +        +       L    L               L
     Calcium chloride CaCl2       Saturated         +        +       L    L               L
     Diesel                        100%             +        +       +    +               -
     Sea water                                      +        +       +    -               -
     Sodium hydroxide NaOH         50%              L        L       -    -               -
     Hydrogen sulfide H2S       20% for C&K         +        +       +    +               +
                                   17K              L        L       L    L               -
                        HANDLING
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              Product compatibility of NBR, NBR/CR lined ContiTech Rubber hoses
                   (rotary & drilling hoses acc. to API Spec. 7K / ISO 14693 &
                     smooth bore hoses acc. to API Spec. 17K / ISO 13628)
                                                                        Temperature
               Medium                Concentration         o        o        o        o           o
                                                        -25 Co 24 C        40 C    82 C     100 C
     Hydrochloric acid HCl              15 w%              +    +            -       -        -
     Diethylene glycol                   100%              +    +           +       +         L
     Isooctane toluol                   70/30%             +    +           +        -        -
     Methanol CH3OH                      100%              L    L           L        -        -
     Calcium bromide CaBr2 +           12/38 w%            +    +           +       +         L
     Zinc bromide ZnBr2
     Oil base mud                      Max. 40%           +        +        +         +       L
                                    aromatic content
     Ester base mud *                                     +        +        +         +       L
     Water-base mud                                       +        +        +         +       L
     Hydraulic oil                     Max. 40%           +        +        +         +       L
                                    aromatic content
     Sea water                                            +        +        +         +       -
     * only for NBR based rubber compound

     +   OK
     -   Not suitable
     L   Limited application


The exact values (temperature, concentration, pressure) are included in data sheets of the actual order.
                 HANDLING
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          GUIDELINES ON STORAGE, HANDLING TRANSPORTATION
                   AND INSTALLATION OF FLEXIBLE PIPES




                      Correct way of hose fixing to the packing case
     (note that hose end should be straight and not forced in & over-bent or stressed)




                  Correct way of lifting/installing by lifting collar on hose
                HANDLING
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            Butt welded coupling with API flange assembled with lifting collar




     High pressure hose assembled with lifting collar, safety clamp and safety chain
                     HANDLING
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 HANDLING AND SERVICE INSTRUCTIONS
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Inadmissible dangerous mode of transport by              Inadmissible dangerous mode of handling,
     dragging hose across the ground                          moving of hose with metal lever




             Incorrect way of hose lifting by its safety clamp (NB: The hose must not
             be lifted via the Safety Clamp as this is likely to induce over bending and
                                   stressing of the end connection)
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 Incorrect moving and lifting of high
           pressure hose




                                           Incorrect installation of hose (touch down
                                        effect) The hose is subjected to abrasion, over
                                        bending and undue stresses in the hose body
                                                       (i.e. compression)
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5.    ATTACHMENTS
     Attachment No. 1 Hose record sheet for onsite periodic inspection
     Attachment No. 2 Safety clamp fitting instruction
     Attachment No. 3 Mounting sketch for safety clamp
     Attachment No. 4 Mounting sketch for lifting collar
     Attachment No. 5 Lifting collar & Safety Clamp location
ContiTech Rubber Industrial Kft.   Page 15/20             Attachment No. 1
                                                Client:
ContiTech Rubber Industrial Kft.                     Page 16/20                            Attachment No. 2
                                                                  Client:




                                  SAFETY CLAMP FITTING INSTRUCTION

The drawing in attachment no.3 (Figure 1) should be used in conjunction with this written section of the
instruction.

The hose is marked on the outer cover with an orange band at each end and text "ATTACH SAFETY
CLAMP HERE" (note: an engraved metallic strap is used on hoses fitted with metallic outer guards).
This band signifies the location for the safety clamps. The safety clamps should be positioned with one
edge in-towards the middle of the hose (i.e. away from the coupling).

Once correctly located, the safety clamp should be fastened in position with the nuts and bolts.



                                  LIFTING COLLAR FITTING INSTRUCTION

The lifting equipment supplied with the hoses, includes a two 2-part lifting device at each hose end (see
Attachment 4, figure 2). These lifting devices are supplied loose and not pre-assembled to the hose due
to packaging limitations and safety reasons.


Note: The element C is only provided with the hose when the customer specifically requests lifting
      collars to be provided. Otherwise, the hose is provided with nothing at the ends.

The normal procedure for handling and lifting the hose involves securing the lifting collar around the
element C. The hose is then lifted via attachment of the lifting line to the lifting collar. After installation,
the lifting collar and element C can be left on the hose together or both removed if preferred.
NB:    At no time should the lifting collar be removed and the element C remained attached to the
       hose. It is essential that the element C be removed from the hose after installation if the lifting
       collar is removed.

It is essential that the hoses be handled in the correct manner, including removal from their packing
media, through movement between locations and installation. The lifting devices we provide are
designed, manufactured and tested to provide this. They ensure that the hose is lifted from the correct
point (i.e. direct from the end coupling) and prevent damage to the hose body through use of other
lifting techniques e.g. soft strops.

In addition to the lifting collars, drilling hoses are often fitted with safety clamps as recommended in
API Spec 7K / ISO 14693 and API Spec 7L. All drilling hoses are clearly marked as to where to fit the
safety clamp and this should not be confused with the lifting collar. Both are used for specific individual
tasks.
The lifting collar is designed to facilitate lifting of the hose and is rated at 1,7 tonne or 2,5 tonne SWL
depending on the hose size. It is located at the hose end and attached directly to the steel end
coupling.
ContiTech Rubber Industrial Kft.                 Page 17/20                           Attachment No. 2
                                                              Client:



The safety clamp is designed to restrain the hose body in the unlikely event of a hose failure when the
hose body and end coupling separate from each other. The safety clamp shall have a minimum
breaking strength of 72640 N (16,000 lbs) or a working load limit of 9600 N (3,000 lbs) with a 5 to 1
safety factor for hoses up to 4 inch internal diameter. For hoses with 5 inch and 6 inch internal
diameter the minimum breaking strength shall be 145280 N (32,000 lbs) or a working load limit of
27240 N (6,000 lbs) with a 5 to 1 safety factor. The safety clamp is located on the hose body behind
the built-in bending stiffener.
Refer to figure 3.

NB:    The hose lifting collar is not designed to be used as a safety clamp as the minimum breaking
       strength and working load limits are less than required and it is not positioned in the correct
       location for this task on the hose assembly.
       The safety clamp is not to be used as a lifting device as its location may result in overbending of
       the hose.
ContiTech Rubber Industrial Kft.                Page 18/20             Attachment No. 3
                                                             Client:




                                              Figure 1
                                   Mounting sketch for Safety Clamp
ContiTech Rubber Industrial Kft.                Page 19/20              Attachment No. 4
                                                             Client:




                                              Figure 2
                                   Mounting sketch for Lifting Collar
ContiTech Rubber Industrial Kft.              Page 20/20                Attachment No. 5
                                                           Client:




                                               Figure 3
                              Lifting Collar & Safety Clamp locations

								
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