Almost every manufacturing facility that handles a hazardous material will utilize hoses in their handling of the material. And one of the biggest risk any facility will manage is the BULK UNLOADING/LOADING of their HAZARDOUS MATERIALS. Whether the hazardous material is a PSM/RMP covered chemical or just a good ole fashion HAZMAT, the integrity of bulk unloading/loading hoses need to be managed using a Recognized And Generally Accepted Good Engineering Practice (RAGAGEP). In this article I will break the news to those who may not be aware of the MI requirements for these bulk hoses; I will be using the holy grail of Hose RAGAGEP’s… ARPM IP-11-7, MANUAL FOR MAINTENANCE, TESTING, AND INSPECTION OF CHEMICAL HOSE
IP-11-7 was revised in 2015, and this revision was significant in that the FREQUENCY of pressure testing went from an “annual” test to…
EVERY 90’s days!
When the hose is used in “NORMAL BULK TRANSFER SERVICE,” it MUST be visually inspected DAILY, and HYDROSTATICALLY TESTED EVERY 90 DAYS. That’s right folks, no longer is an annual hydro acceptable! We now have to test our bulk transfer hoses EVERY 90 DAYS hydrostatically.
The DAILY VISUAL inspections and 90-DAY HYDRO(s) MUST be documented on an “inspection card” and recording system. The hose inspection card shall contain the following information:
- the hose identifier,
- manufacturer’s name,
- date the hose was received,
- purchase order number, and
- date of installation/in-service
The inspection card must be used to record the test results and condition of the hose.
DAILY INSPECTION
Each day, PRIOR to the day’s use a VISUAL INSPECTION must be conducted. If any unusual appearances are noted during the visual inspection, the hose MUST be subjected to a HYDROSTATIC PRESSURE TEST.
In order to conduct the VISUAL INSPECTION, the hose will be laid out in its full length in a clean and dry area. The outside covering of the hose will be inspected for blistering, excessive abrasion or cuts, and coupling slippage. This inspection will be made when the hose is NOT under any pressure! Any cuts, gouges or tears in the cover, which do NOT expose the reinforcement, must be REPAIRED BEFORE the hose is used. If the reinforcement is exposed, the hose MUST be REMOVED FROM SERVICE IMMEDIATELY and DISCARDED. Covers may show surface cracking or crazing due to prolonged exposure to sunlight or ozone, and as long as the reinforcement is NOT exposed, the hose passes.
The visual inspection will also look for any indication of “kinking” or “broken reinforcement” as evidenced by any permanent distortion, longitudinal ridges, or bulges. If damage to the reinforcement is EVEN SUSPECTED the hose MUST be REMOVED from service AND can ONLY be placed back into service AFTER IT PASSES a HYDROSTATIC PRESSURE TEST.
Crushed or kinked spots where the outer diameter of the hose is REDUCED by 20% OR MORE of the standard outside diameter, the hose MUST BE REMOVED from service and DISCARDED (or at least not used for chemical handling!). Hose containing kinked or crushed spots where the outside diameter is reduced LESS THAN 20% may be used AFTER the hose passes a hydrostatic test.
90-DAY HYDROSTATIC PRESSURE TESTING
A “NEW” hose OR a hose taken from “STORAGE” MUST be HYDROSTATICALLY PRESSURE TESTED BEFORE it is placed into service. To perform the hydrostatic test and examination, the hose shall lie in a straight horizontal position, unrestricted so the hose can move freely when pressurized. Water MUST be used as the hydrostatic “test liquid”; NEVER conduct hydro pressure test with solvents, corrosive liquids, or compressed gases (including plant air).
For a “NEW” hose, the test pressure is 2X’s the rated WORKING PRESSURE, and for a “USED” hose, the test pressure to 1.5X’s the rated WORKING PRESSURE. The pressure must be held for 5 minutes, during which, the hose will be examined for leaks at the couplings, fitting slippage, or for any indication of weakness in the hose structure. The hose FAILS and MUST BE REMOVED from service if any sign of leaks, fitting slippage or weakness in the hose structure are found.
The standard is transparent and straightforward in its writing, so this is not some consultant scaring you. Heck, I do not even do hose testing, so I am not trying to sell you anything. But the time has come to revise our MI schedules for these bulk hoses from ANNUAL to 90-days. Now anyone can pick and choose their RAGAGEP for managing the mechanical integrity of their bulk unloading/loading hoses, so IP-11-7 is NOT a requirement, but it is the baseline which OSHA/EPA like to use in their inspections/audits. It is considered the “holy grail” of hose RAGAGEP’s and is an EXCELLENT resource to utilize, but it is up to each facility as to how they will manage their hoses. I believe that IP-11-7 (2015) is the best option.
CLICK HERE to purchase your copy of IP-11-7, MANUAL FOR MAINTENANCE, TESTING, AND INSPECTION OF CHEMICAL HOSE