P30167_TS_505-2_Hoses_and_Expansion_Joints.pdf

U.S. Coast Guard Naval Engineering

Technical Standard

Title

Prepared by:

Author Date

Reviewed by:

Chief, Engineering Services Division Date

Surface Forces Logistics Center

Approved by:

Chief

Office of Naval Engineering (CG-45)

Date

Distribution Statement D: Distribution Authorized to the DHS/ USCG/DOD and their contractors to protect publications required for official use or for administrative or operational purposes only, determined on 9 DEC 2010. Other requests shall be referred to: Commander

SFLC-ESD-TIMB 2401 Hawkins Point Rd M/S 25 Baltimore MD, 21226

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Published by Commander, Surface Forces Logistics Center

REV

SFLC TECHNICAL STANDARD 505-2

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HOSES AND EXPANSION JOINTS

1. SCOPE

1.1 Intent. This standard contains the general technical requirements for shipboard and other nonmetallic hose and expansion joints.

1.2 Appendices.

SUB-STANDARD APPENDIX

HOSE AND EXPANSION JOINT MANAGEMENT A

MAINTENANCE OF HOSE STOCK B

EXPANSION JOINTS (FLEX JOINTS) C

IN-HOUSE HOSE ASSEMBLY D

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction Manual (COMDTINST) M9000.6 (series), Naval Engineering

Coast Guard Commandant Instruction Manual (COMDTINST) M3150.1 (series), Diving Policies and Procedures, Volume 1

OTHER REFERENCES

American Society of Testing and Materials (ASTM) F1123, 1987, Standard Specification for Nonmetallic Expansion Joints

Code of Federal Regulations (CFR) Title 46, Part 56, Section 60-25, 2011, Nonmetallic Materials

Code of Federal Regulations (CFR) Title 46, Part 56, Section 97-5, 2011, Pressure Testing of Non-Standard Piping System Components

Commercial Item Description (CID) A-A-50604, 1993, Expansion Joint, Sleeved (Non- Flanged), Fire-Retardant, with Retaining Clamps

The Expansion Joint Manufacturers Association (EJMA), Inc., EJMA Standards, 9th Edition, http://www.ejma.org

Fluid Sealing Association, Non-Metallic Expansion Joints and Flexible Pipe Connectors Technical Handbook, 7th Edition (FSA0012) www.fluidsealing.com http://www.ejma.org http://www.fluidsealing.com

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International Standards Organization (ISO) Standard 15541, 2002, Ships and Marine Technology, Fire Resistance of Hose Assemblies

MIL-E-15330, 1993, Expansion Joint, Pipe, Nonmetallic, Fire-Retardant

MIL-H-24606, Aug 1994, Hose, Fire, Synthetic Fiber, Double Jacketed, Treated for Abrasion Resistance, with Couplings, Fire Fighting and Other Water Service

MIL-P-15024/15, 1982, Plate, Tags, Hose Assembly Identification

National Fire Protection Association (NFPA) (Various standards may apply to installed equipment on cutters, current revision for date of installation shall apply.)

NAVSEA Technical Equipment Directive S6430-AE-TED-010 (TED-10)/ Rev. 5, Volume 1, Technical Directive for Piping Devices, Flexible Hose Assemblies, 2012

Naval Ships Technical Manual (NSTM) Chapter 505, S9086-RK-STM-010, 2008, Piping Systems

Society of Automotive Engineers (SAE) Standard J518, 1993, Hydraulic Flanged Tube, Pipe, and Hose Connections, Four-Bolt Split Flange Type

Society of Automotive Engineers (SAE) Standard J1273, 2009, Recommended Practices for Hydraulic Hose Assemblies

Society of Automotive Engineers (SAE) Standard J-1406, 2012, Application of Hydraulic Brake Hose to Motor Vehicles - Wheel End and Axle

Society of Automotive Engineers (SAE) Standard J1475, 2009, Hydraulic Hose Fittings for Marine Applications

Society of Automotive Engineers (SAE) Standard J1527, 2011, Marine Fuel Hoses

Society of Automotive Engineers (SAE) Standard J1942, 2009, Hose and Hose Assemblies for Marine Applications

Society of Automotive Engineers (SAE) Standard J1942-1, 2010, Qualified Hoses for Marine Applications

3. REQUIREMENTS

3.1 General Information. Following are the technical standards for Hoses. Expansion Joints are discussed separately in Appendix C. Hoses on Coast Guard cutters and boats primarily consist of 1) hoses supplied as part of assembled equipment provided by a vendor (engines, cranes, etc), 2) hoses provided by a shipyard to install the equipment, and 3) portable and outfit hoses. While documentation and part numbers may exist for the equipment hoses, installation hoses have typically been manufactured to length to fit a specific application and generally are not consistent between sister hulls and thus do not have part numbers.

3.1.1 Design Requirements.

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3.1.1.1 Hoses on Coast Guard cutters and boats shall, unless otherwise noted, meet commercial marine standards and shall be provided by commercial vendors. For Coast Guard assembled hose assemblies, see Appendix D. NAVSEA TED-10 for hoses on US Navy vessels is premised on use of Mil-Spec grade hose purchased in bulk and assembled with fittings by USN afloat and ashore supply support activities. With a few exceptions, USCG does not require use of Mil-Spec grade hose materials and does not have the afloat or extensive ashore supply activities necessary for purchasing and assembling bulk hoses and fittings. TED-10 shall not be extensively referenced, but may be used for inspection guidance.

3.1.1.2 Hose systems for vital fluid systems shall meet the regulatory requirements of 46 CFR Part 56. Hoses transmitting fuel oil, lube oil, hydraulic oil, and seawater shall meet the requirements of SAE J1942 and related approval listing SAE J1942-1, unless of acceptable metal construction and/or PTFE (Teflon) lined construction, (for PTFE hoses see paragraph 3.1.2.3).

3.1.1.3 Hose materials are selected based upon ultraviolet protection, resistance to oils or other materials, resistance to pressure, resistance to tension, equipment manufacturer’s criteria, and other factors. Special factors, such as low radius bend capability if required, shall be noted in the hose log.

3.1.1.4 Hoses shall not be excessive in length, generally not to exceed 30 inches in length. When transitioning between shock or resilient mounted machinery and structure mounted components or piping, the use of dog-leg hose assemblies is encouraged to reduce hose stress and reduce transmission of hydraulic noise.

3.1.1.5 Changes in materials, pressure ratings, fittings, or any other salient characteristic require an approved Engineering Change. Replacement of hoses produced by an alternate manufacturer does not require an Engineering Change if all those required salient characteristics of the hose assembly are maintained.

3.1.1.6 Hydraulic brake hoses on boat trailers shall meet SAE J-1406 and shall be considered “Standard” hoses. These hoses do not require tagging and are not recorded in a vessel hose log.

These hoses shall be inspected at least once annually.

3.1.2 Hose Classification. All flexible hoses shall be classified in one of five groups according to the type of hose and the system in which it is operating; Standard, Non-Standard, Condition Based Maintenance (CBM), Replace-On-Failure (ROF), and Portable/Other. US Navy hose “criticality” classifications for Hull, Mechanical & Electrical (HM&E) piping systems are based on different compartment designation standards and are not applicable for determining the classification on Coast Guard vessels.

3.1.2.1 Standard Hoses. Hoses in the following systems shall be considered standard duty and must be tracked in a hose log or equivalent system.

• Fuel oil

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• Hydraulic oil

• Lube oil

• Engine jacket water and fresh water cooling

• Compressed air and compressed gas (other than fixed CO2 and Halon systems)

• Refrigerant and Oxygen

• Chilled water

• Seawater

• Boiler feed water, steam, and condensate

• Distillate and brine

• Potable water

• Hoses in the weather provided they have appropriate protective coverings

• Bilge and oily

3.1.2.2 Non-Standard Hoses. The following hose applications shall be considered as non-standard and have special replacement schedules established because of known hose degradation, operating limits, or know extended service and replacement schedule for a specific application.

These hoses must be tracked in a hose log or equivalent system.

• Hoses installed in the weather that are exposed to extreme sun, heat, cold, ice, or snow, AND do not have an outer covering specifically designed for such conditions.

• Hoses identified by the hose manufacturer, equipment manufacturer, or by SFLC Product Line that must be replaced on a more frequent basis. As an example engine exhaust system hoses shall be replaced as recommended by the hose manufacturer or equipment manufacturer.

• Water by-product, potable water, bilge water, and oily waste transfer systems (systems that are not corrosive or acidic in nature and operate at low pressures).

• Installed gauge hoses (all fluids). Note: installed gauge hoses shall be minimized by installation of coiled gauge tubing in accordance with Navy standard drawings.

• Ships service/shop air, and pneumatic control system installed hoses (Does not include portable hoses).

• Hard rubber installed AFFF hose reel systems.

• Installed pneumatic control systems for firefighting systems.

• Infrequent use and non-vital hydraulic and lube oil systems (Pressurized and in use less than 200 hours annually).

• Low pressure hydraulic and lube oil purifier, filtration, and transfer systems.

3.1.2.3 Condition Based Maintenance (CBM). Hoses in the Condition Based Maintenance category may not have a fixed replacement schedule; replacement shall generally be based on condition, not service life. Some may require specialized maintenance or testing such as validation of electrical continuity or routine hydrostatic testing. These hoses must be tracked in a hose log or equivalent system. The following hose applications shall be considered as CBM unless otherwise directed and replacement shall be based on condition rather than service life.

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• Metal, PTFE (Teflon), and thermoplastic hoses in high pressure systems. These hoses are typically engineered for a specific application. Hoses must be inspected to insure that they are not becoming externally compromised.

• Metal, PTFE, and thermoplastic hoses in low pressure or infrequently pressurized systems. These hoses are typically engineered for a specific application. An example includes Galley Fire Suppression System hoses.

• JP-5 Aviation Refueling system hoses. Inspected and tested to meet aviation certification requirements.

• Refueling At Sea system hoses. These hoses must be inspected and maintained to insure that fuel oil, JP-5, lube oil, and water being transferred between cutters does not become contaminated or leak (pollute). Includes hoses used to refuel cutters astern.

3.1.2.4 Replace-On-Failure. Hoses in the Replace-On-Failure category are installed hoses or maintenance equipment hoses that are not vital to the mission of the cutter. Failure of a hose in this category is not critical to the mission of the cutter. The following hose applications shall be tagged to indicate date of install but are not required to be tracked in a hose log or equivalent system. These hoses shall be replaced on failure of the existing hose, or in conjunction with other piping or equipment repair activities.

• Portable test, instrumentation, and specialized maintenance hoses. These hoses are frequently part of a test or tool kit, and should be replaced with OEM hoses.

• Auxiliary drain systems, plumbing/gravity drain systems, or other drainage systems open to atmosphere, and which are not vital to the cutter mission.

• Vacuum flush waste systems.

• Hoses internal to manufactured equipment and not in contact with fuels or bulk lubricants, example - food service equipment.

3.1.2.5 Portable/Other Hoses. These hoses are either portable (not installed), fall under Damage Control or Firefighting equipage requirements, or are managed under rotatable pool maintenance programs. The following hose applications shall be tagged or marked to indicate date of install but are not required to be tracked in a hose log or equivalent system. Portable hoses are commercial grade disposable products.

• Outboard Engine Hoses – Outboard engine hoses on cutter-boats are covered by Boat MPCs. Marine fuel hoses shall meet SAE J1527.

• Small Engine Hoses – Hoses internal to small packaged engines (example P100) are covered by Damage Control MPCs. Marine fuel hoses shall meet SAE J1527.

• SCBA and Diving Air hoses – See COMDTINST M3150.1 (series) certification requirements.

• Fire Hoses – Fire hoses (MIL-H-24606), firefighting foam (AFFF) hoses, water main jumper hoses, and other detachable water hoses are covered under Technical Standard 555 and other programs such as Damage Control MPCs.

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• Portable fire extinguisher propellant and discharge hoses, as found on HALON, AFFF, CO2, and PKP extinguishers, are covered by Damage Control MPCs. The hoses shall be maintained to National Fire Protection Association standards.

• Pneumatic hoses with quick-disconnect couplings that connect portable tools to ship service air systems are portable hoses. Replace on failure of general inspection, no date marking is necessary. Commercial grade replacement hoses are acceptable.

• Garden and similar type water hoses used for cleanup services are portable hoses.

Replace on failure of general inspection, no date marking is necessary. Commercial grade replacement hoses are acceptable.

3.1.3 Hose Log. Afloat units shall maintain a log of the hoses and expansion joints installed on the cutter or boat hull and mechanical systems for purposes of planning and for documentation of the hoses and joints for replacement. The log shall also include all hoses maintained on the cutter for the refueling of helicopters, refueling of other cutters at sea, refueling of cutter-boats, and the transfer of fuels, lubricants, and oils to and from the cutter.

Shore based units shall maintain a unique log of the hoses and expansion joints on each boat assigned to the unit.

3.1.3.1 The following data must be maintained on each individual hose: System, Equipment mounted to, Classification, Location, Length, Nominal Diameter, Part Number (if avail), NSN (if avail), 1st End fitting description, 2nd End fitting description, Piping System Design pressure, Hose Rated pressure, Working pressure, Install date, Replacement date, Fluid/gas conveyed, External covering requirements, and any comments. The objective is to provide a complete description of the hoses so that hoses requiring replacement can be identified and planned for in advance, and so that a replacement hose may be fabricated off-line and delivered to the vessel in a timely manner.

3.1.3.2 Hose logs may be maintained in paper format if the vessel is not included in an electronic database. Once the database file is created, the unit shall be responsible for maintaining the data in electronic format. SFLC Product Lines shall provide direction regarding standardized hose maintenance and tracking methods. Cutter and boat classes that are enrolled in the “Integrated” logistics business model may be directed to track hoses using ALMIS in lieu of a separate hose log. Other classes see paragraph 4.1 for information on the Automated Flex Hose Log.

3.1.4 Hose Length. Proper hose length measurement is essential to proper replacement of hoses. Hoses shall be measured as a complete hose assembly over the end fittings, end fitting to end fitting, as installed. For flanged hose end fittings, the measurement shall be taken to the flange face. For male threaded fittings, the measurement shall be taken to the tip of the threads or cone at the end of the fitting. For female threaded fittings, the measurement shall be taken to the exposed end of the fitting. For hose assemblies, the exposed length of hose material is not a generally relevant measurement because of differing lengths of hose material internal to the end fittings between brand and type of fitting. Where a hose end is slipped over piping or a ribbed tube and clamped without a hose end fitting, such as drain hoses, the actual length of the hose

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material may be measured. Bends in hoses are measured at the outside radius of the hose if the hose is not able to be straightened to measure.

3.1.5 Hose Fittings. Hose fittings for approved hoses shall be in accordance with SAE J1475 and SAE J1942-1, which list the fittings styles compatible with the acceptable hose.

3.1.5.1 The use of permanently installed fittings, where the fitting is compressed or crimped under pressure onto the hose, shall be preferred. “Field assembly” style fittings which screw into or clamp onto the hose are also acceptable, but must be listed as such in SAE J1942-1 and be appropriate to the service. “Field assembly” style fittings, sometimes previously identified as “reusable”, should be considered a one-use fitting and shall NOT be reused. Pitting and corrosion of the fitting after an 8 to 12 year service life make reuse of these fittings problematic.

3.1.5.2 For new installation applications or where the piping fittings are being replaced, hose assembly fittings which connect the hose assembly to piping or components with an O-ring seal shall be preferred; this includes SAE or metric straight thread O-ring boss, O-ring face seal, and SAE 4-bolt split flange type fittings. Flared type fittings (37 degree and 45 degree) are also acceptable but are not as resistant to vibration or disassembly and reassembly. Split flange type fittings shall not be used to connect hose to hose.

3.2 Safety. The best safety measures for hoses are to ensure they are fabricated correctly, installed to prevent abrasion, kinking, or stress, and replaced at the proper intervals. Hoses in close proximity to other hoses, equipment, or structure shall have support brackets or chaffing gear installed to prevent chaffing.

3.2.1 Replacement. The condition of hoses can often not be determined from a visual inspection alone. Strict attention must be paid to replacing hoses at the required frequency.

Debris from the internals of hoses found in strainers or downstream equipment should result in the subject hose(s) being replaced.

3.2.2 Proper Installations. Hoses are to be no longer than required for the intended installation. General guidance for length shall be 46 CFR 56.60-25, limiting lengths to 30 inches, unless required to provide for the flexibility of a mechanical joint. Replacement hoses are not to be of significantly increased length. Hoses are not to be installed in place of sections of piping due to poor fit-up of modifications or to avoid installation of runs of pipe. Where existing hoses exceed 6 feet in length, consideration shall be given at time of replacement to replacement with piping and a hose under 30 inches. Hoses are to be prevented from contact with other items so as to prevent chafing and failure in service. Hose selection and routing requirements shall be in accordance with SAE J1273 5 which includes detailed illustrations of proper installations, including installation with curvature to provide room for expansion/retraction. Hoses shall not be installed to pass through bulkheads between spaces.

3.2.3 Fire Resistance. Hoses which require a fire sleeve to pass fire resistance tests (so identified in their approval certification) shall be installed with the appropriate fire sleeve. The current bench test for fire resistance is ISO 15541, and is referenced in SAE J1942.

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3.2.4 Abrasion and Ultraviolet Protection. Industrial weather resistant sleeves may be installed to increase abrasion resistance and to reduce degradation from ultraviolet exposure. Use of such sleeves over hoses not designed for weather deck service can change the classification from Non-Standard to Standard.

3.2.5 Pressure.

3.2.5.1 Piping System Design Pressure is specified for all piping systems and can be found on piping diagrams and some piping installation drawings. “Pressure” piping, “Return” piping, and “Drain” piping design pressures may be significantly different within the same system. The rated working pressure of hoses shall be equal to or greater than the design pressure of the piping in which installed.

3.2.5.2 It is common, but is NOT a requirement, that all hoses in a particular system are of the same hose part number series for programmatic or logistics reasons. This can result in 4000 psi hoses installed in 50 psi drain systems. Replacement hoses need to meet the design pressure of the piping in which installed.

3.2.5.3 Questions concerning the system design pressures and required rated working pressures of hoses shall be referred to the product line or SFLC-ESD-NAME-AMS.

3.3 Operating Principles. Hoses shall be capable of expansion or retraction due to thermal or pressure changes, and shall be capable of absorbing changes in equipment alignment to structure (shock mounted) and changes in equipment orientation. Hoses shall be installed with some curvature, and shall not be installed in a straight line. Hoses in operation should be monitored for leakage or wear, if issues are found a full visual inspection should be done in accordance with

3.4 below.

3.4 Inspection. Inspection of hoses and expansion joints on cutters and boats in accordance with promulgated MPCs is a unit responsibility. The unit shall be responsible for maintaining a record of inspections.

3.4.1 Periodicity. Hose PMS inspections shall be scheduled on at least the following periodicity. The Product Line should consider more frequent inspection on a case by case basis where specific issues apply.

TABLE 1 - HOSE INSPECTION PERIODICITIES

FLUID SYS APPLICATION INSPECTION SCHEDULE *

STANDARD

Standard Hoses Visual - Semi-Annually (6 mo)

NON-STANDARD

Hoses with a service life of 8 years or less Visual - Semi-Annually (6 mo)

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FLUID SYS APPLICATION INSPECTION SCHEDULE *

Hoses with a service life of more than 8 years Visual - Annually (12 mo)

CONDITION BASED MAINTENANCE

JP-5 Aviation Refueling Visual – Semi-Annually (6 mo) or prior to major deployment.

Hydrotest – Annually (12 mo)

Refueling At Sea Visual – Annually (12 mo) or prior to major deployment.

Hydrotest - Biennial (24 mo)

Metal, PTFE, and thermoplastic hoses Visual - Annually (12 mo)

Metal, PTFE, and thermoplastic hose older than 12 years

Semi-Annually (6 mo)

* Alternative inspection schedules shall be based on recommended maintenance procedures of the equipment manufacturer, any regulatory requirements, appropriate commercial or Navy guidance, and Coast Guard experience

(SFLC-ESD, Product Line or Industrial Activity Support) with the equipment or system.

3.4.2 Preliminary. Hoses missing their hose tag (see 3.6.3) shall normally be replaced.

Alternatively, if identification and service life of the hose can be verified from review of other records, the hose may be retagged in lieu of replacement. Hoses shall not remain untagged. Tags may be provided upon request to SFLC-ESD-SSB-DC&LSE.

3.4.3 Inspect Installation. Each hose shall be inspected for proper installation in compliance with SAE J1273. Improperly installed hoses shall be removed and replaced in accordance with the installation and arrangement requirements in SAE J1273 and above.

3.4.3.1 Rubber and Synthetic Rubber Hose: Visually inspect each hose for the following:

• Leakage from hose or fittings.

• Fitting discoloration.

• Hose slipping out of end fittings.

• Twisting, kinking, or distortion of hose.

• Bulging, swelling, necking, or flattening sections exceeding 10% of the hose outside diameter

• Loose or delaminated cover

• Hose cover damaged by cuts, abrasions, cracking, or chafing, or if internal wires or fiber reinforcement is exposed.

• Hose cover wrinkling exceeding 5% of hose outside diameter.

• Blistering or hard spots.

• Paint on the hose cover in excess of 10% of total surface (see 3-6-4 below).

3.4.3.2 Hoses showing any of the above characteristics shall be replaced.

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3.4.3.3 Inspect end fittings for pitting, discoloration, cracks, and corrosion. If any of the conditions are found, initiate corrective action.

3.4.3.4 Inspect segmented fittings for loose or shifted bands or retaining rings and loose nuts or bolts. If any of the conditions are found, replace hose or initiate corrective action.

3.4.3.5 Inspect hose supports for broken welds, loose or damaged clamps, and deteriorated or missing rubber inserts. If any of the conditions are found, initiate corrective action.

3.4.3.6 Operate equipment and inspect the hose under pressure. Inspect hose for vibration damage caused by improper support at fixed ends and for high pulsations, fluid hammer, and whipping caused by pressure surges. If any of the conditions are found, initiate corrective action.

For hoses in systems normally un-pressurized, or open to atmospheric pressure, only a visual inspection is required.

3.4.3.7 If visible rubbing against adjacent items is found, add chafing gear.

3.4.4 Inspection of Metal, PTFE, and Thermoplastic Hoses and Related Components.

3.4.4.1 Inspect each hose for the following:

• Twenty or more external broken wires.

• Cuts involving four or more adjacent wires.

• Twisting, kinking, or distortion of hose.

• Bulging, swelling, necking, or flattening sections exceeding 10% of the hose outside diameter.

• Leakage from hose or fittings.

• Thermoplastic hose cover damaged by cuts, abrasions, cracking, or chafing.

Reinforcement strands shall not be exposed

• Inspect PTFE lined hoses for evidence of internal “folding” or being stepped on, or bent in any way

3.4.4.2 Hoses showing any of the above characteristics shall be replaced.

3.4.4.3 Inspect end fittings for pitting, discoloration, cracks, and corrosion.

3.4.4.4 Inspect segmented fittings for loose or shifted bands or retaining rings and loose nuts or bolts.

3.4.4.5 Inspect hose supports for broken welds, loose or damaged clamps, and deteriorated or missing rubber inserts.

3.4.4.6 Operate equipment and inspect the hose under pressure. Inspect hose for vibration damage caused by improper support at fixed ends and for high pulsations, fluid hammer, and

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whipping caused by pressure surges. For hoses in systems normally un-pressurized, or open to atmospheric pressure, only a visual inspection is required. Examples include firefighting distribution system hoses.

3.4.5 Inspection Damage. Care should be made that hoses not be damaged during the inspection process. All hoses will normally “take a set”; that is, after a period of use in a particular configuration the hose permanently assumes a fixed shape (looses flexibility).

Drastically changing this shape during removal, inspection or to access another part may cause damage, thus shortening or ending the service life of the hose.

3.4.6 Special Inspections.

3.4.6.1 JP-5 Aviation Refueling hoses are inspected in accordance with flight deck certification requirements and Aviation MPCs. This includes annual hydrostatic and conductivity tests.

3.4.6.2 Refueling At Sea hoses and Cutter-Boat Refueling hoses are inspected in accordance with 33 CFR 156.170. Refueling at sea hoses shall be hydrostatically tested with water on not less than a biennial basis to at least 150% of the maximum operating pressure of the system.

3.4.6.3 SCBA and Diving Air hoses are inspected in accordance with COMDTINST M3150.1 (series) certification requirements.

3.4.6.4 AFFF hard rubber hose (installed on hose reels) may be inadvertently subjected internally to the corrosive effects of AFFF concentrate if the hoses are not flushed properly after use. These hoses shall be removed from service, examined for development of soft spots (an indication of internal degradation), flushed (capturing the effluent for examination of potential debris), and shall be hydrostatically tested every 3 years. Any indication of degradation shall be cause for replacement. Hoses which are not degrading may be returned to service.

3.5 Repair. High pressure hoses shall not be repaired.

3.5.1 Replacement Hoses. Replacement hoses shall be to the same criteria, length, i.d., materials, ratings, fire and UV rating, and end fittings as the original hose section. Hoses made by different companies than the original but having the same characteristics above may be used without the need for an Engineering Change.

3.5.2 Aviation Refueling. JP-5 hoses removed from Aviation Refueling Systems only for failure of conductivity tests, may be reassigned to Refueling At Sea service, subject to a hydro test and internal inspection. JP-5 hoses removed from Aviation Refueling Systems for failure to meet cleanliness requirements shall not be reused.

3.6 Maintenance.

3.6.1 General. Maintenance of hoses shall be in accordance with cutter class Preventive Maintenance Manuals.

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3.6.1.1 Piping fittings that are to be connected by hose shall be match marked (Connect points A to A, B to B, etc.) to help insure proper hose routing, particularly in way of multiple hoses run in parallel or close proximity. Where control piping is mounted on a backing plate, the hose routing shall be drawn on the backing plate.

3.6.1.2 The use of petro-tape or equivalent to wrap hose end fittings is strongly discouraged; this material makes visual inspection of the hose joint difficult.

3.6.2 Replacement. Hose service life shall begin upon installation in the system, date of delivery of a new cutter or boat; or the date of installation of a major assembly with pre-installed hoses (crane, davit, hydraulic power unit, etc.). Frequency of replacement will be in accordance with the below table. Specific hose installations may be assigned reduced service life as deemed necessary by the Product Line or Technical Authority.

TABLE 2 - HOSE REPLACEMENT SCHEDULE

DESCRIPTION QUALIFIER SERVICE LIFE * NOTES

Standard Unless further limited by manufacturer

Not to exceed (NTE) 8 years

Non-Standard Hoses installed in the weather without an outer covering specifically designed for service in the weather

NTE 5 years

Non-Standard Specifically limited by manufacturer

Mfgr’s limit

Non-Standard Water By-Product, Potable Water, Bilge

Water, and Oily Waste Transfer Systems

NTE 12 years

Non-Standard Gauge Hoses (all fluids) NTE 12 years Minimize by use of coiled gauge tubing

Non-Standard Ships Service/Shop Air, Pneumatic Control Systems

NTE 12 years

Non-Standard Hard rubber AFFF hose reel hoses

NTE 12 years Remove, inspect, and hydrostatically test at 3 yr intervals

Non-Standard Pneumatic (CO2) control system hoses for installed firefighting systems

NTE 5 years Per NFPA standards

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DESCRIPTION QUALIFIER SERVICE LIFE * NOTES

Non-Standard Infrequent use Hydraulic and LO systems

NTE 12 years

Non-Standard Low Pressure Hydraulic and LO Transfer systems

NTE 12 years

Non-Standard Galley Fire Suppression systems – Rubber and synthetic rubber hoses

NTE 12 years Per NFPA standards

Condition Based General Replace on signs of wear or damage or failure of inspection

After 12 years, increase inspection to bi-annual

Condition Based Hoses that connect CO2, and FM-200 to the fixed system

Hydro at 5 years

Condition Based JP-5 Aviation Refueling systems

NTE 12 years Conditional to annual hydro to 150 psig

Condition Based Refueling At Sea systems NTE 12 years Conditional to biennial hydro to 150% operating pressure

Condition Based Metal HALON 1301 distribution hoses (MIL-SPEC)

Replace on signs of wear or damage or failure of inspection

Internal inspection upon HALON discharge

Condition Based Galley Fire Suppression Systems – Metal or PTFE lined hoses

Examine and hydro test at 12 years

Passing hoses may remain in service

Condition Based PTFE (Teflon lined) Replace on signs of wear or damage or failure of inspection

After 12 years, increase inspection to bi-annual

Portable/Other Portable HALON fire extinguisher discharge hoses

NTE 12 years Per NFPA standards

Portable/Other Portable AFFF and CO2 extinguisher hoses

NTE 10 years Per NFPA standards

Portable/Other Outboard Engine hoses 5 yr or Mfgr’s limit if less

See Boat MPCs

Portable/Other Small engine hoses in packaged equipment

5 yr or Mfgr’s limit if less

See DCMPCs

* The service life of a hose assembly is preempted upon any failure of visual inspection.

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3.6.3 Hose Tags. A tag shall be affixed to each Standard, Non-Standard, and Condition Based Hose upon installation.

3.6.3.1 Tags may be in one of several formats. Tags shall be stamped metal, engraved metal, or units may (optionally) use a scannable bar code identifier. The use of Navy Standard Hose Tags, as described in MIL-P-15024/15 and other USN hose documentation, is acceptable but not required as the data requirements for the USN tag exceed the data requirements herein.

3.6.3.2 Tags shall be attached using materials that will not damage hose or flexible joint in any way; i.e., metal strapping, self cinching nylon straps, or equivalent means. Tag installation shall be done in a manner that will not cause damage to the hose or joint and shall not interfere with the normal flexing motion. To the maximum extent practicable, tags shall be attached to stay bolts on the coupling, to a tab locally manufactured of shim material and captured under a flange bolt head, or to an equivalent fixed point of the hose or joint. Tags shall not be attached with ties of wire (which may bite the hose cover), or with nylon wire ties (which melt). For small hoses, tags may be attached to a single metal band around the hose. Where necessary, hose tags may be attached to bands around the working section of the hose or joint but care shall be taken to avoid interference with flexibility.

3.6.3.3 If a tag is missing from a hose and no firm information exists as to its make-up and installation date it shall be assumed to be out of date and replaced at the earliest possible date. If retained (i.e. found on a system with a known installation/overhaul date), a tag shall be created and affixed with a replacement date no later than the maximum allowed service life from the earliest date the hose may have been installed.

3.6.3.4 Tags associated with the Automated Flex Hose Log database shall include a serial number that is reference keyed to the database file. Service life date and hydrostatic test pressures will be tracked and recorded in the database and are not needed on the hose tag. See the Automated Flex Hose Log Database Desk Guide (contact SFLC-ESD-SSB-DC&LSE for details).

3.6.3.5 Tags associated with ACMS shall use the ACMS CMS code to identify hoses. Service life and hydrostatic test pressure are recorded in ACMS.

3.6.3.6 Tags associated with a paper based Hose Log or Flexible Joint Log shall include the following information, and shall be reference keyed to the applicable Log:

• Item (hose or flexible joint) serial number

• Hydrostatic Test Pressure and Test Date [DD/MM/YY]. This may be provided by the assembly manufacturer on a separate tag. Where a hydrostatic test is not required, insert the annotation "NA".

• Service Life Date (Replacement Date) [QTR "Q"/YY]. References to calendar year quarter should include the letter "Q" after the quarter number to avoid confusion with months. The 4th quarter of 1999 would be represented by "4Q99".

REV - 15 505-2

3.6.4 Paint. Hoses shall not be painted. If equipment is delivered with the hoses painted (i.e.

Caterpillar diesels) the hoses should be tagged for database records, replacement established at the above replacement schedule and the hoses closely monitored for condition under the paint at fittings and bends. Early replacement is recommended. Do not paint replacement hoses.

3.7 Tests/Inspections. All Standard, Non-Standard, and Condition Based Maintenance hose assemblies shall be hydrostatically tested prior to the assembly being installed. This test is of the complete hose assembly, including attached fittings. Pressure tests conducted on the hose alone as it is being fabricated does not replace this test.

3.7.1 Testing Procedures. Procedures for testing shall comply with 46 CFR 56.97-5, which requires a test pressure of twice the rated working pressure of the hose. The test pressure shall be held for approximately 10 minutes. Testing shall take place within a test fixture which restrains the hose and the fluid if the hose were to fail the test. Where a high pressure hose is used in an extreme low pressure application (e.g. a 4000 psi rated hose in a 100 psi drainage system), the hose assembly may be tested to at least twice the design pressure of the system, provided that such test pressure is clearly noted in the hose log. The system design pressure must be verifiable from the system diagram. Test certificate shall be provided to the unit and maintained on file.

3.7.2 Post Testing. After hydrostatic testing, the hose shall be flushed and capped to minimize contamination. For hydraulic system hoses, the flushing procedure shall be to the established contamination level for the intended system.

3.7.3 Low Pressure Hoses. Condition Based Maintenance, Replace on Failure, and Portable/ Other category hoses operating in low pressure systems (less than 150 psi) do not have to be hydrostatically tested.

3.7.4 Instrumentation. Hoses that connect to instrumentation that are factory assembled and subject to factory quality assurance testing do not have to be hydrostatically tested.

3.7.5 Factory Installed Hoses. Where hoses are provided as part of a factory assembled and tested unit, such as an engine or crane, and that unit is hydrostatically tested (with the hoses installed) to at least 150 percent of the maximum working pressure of the system, no additional hydrostatic testing of the individual hoses is required, and separate documentation of a hydrostatic test is not required to be entered in the hose log. The date of the factory acceptance testing of the equipment shall be recorded in the Hose Log as the date of hose acceptance.

However, hoses fabricated and installed by the unit, shipyard or installing activity to install the equipment are subject to the individual hose test requirements above.

3.7.6 Installed Fire System. Flex hoses that connect Carbon Dioxide, and FM-200 to the fixed fire extinguishing system are required to be hydrostatically tested every 5 years.

3.7.7 Halon Hoses. Metallic hoses connecting Halon cylinders to distribution piping are MIL- SPEC hoses and require annual external visual inspection for damage and visual inspection of

REV - 16 505-2

the connection to the bottle and system. They do not need to be routinely replaced and do not have a defined service life. If the halon system is discharged, the hoses should be evaluated for retention by internal inspection of the fitting to hose transitions. If the agent distribution piping were to be hydrostatically tested, these hoses should be included in that hydrostatic test but that is not required unless there are modifications to the distribution piping.

4. NOTES

4.1 Hose Log Automated Flex Hose Log Database. Software has been developed to help units maintain a hose log database at the unit level. The program software is a Microsoft ACCESS™ preformatted database which has been certified by TISCOM for unit level server installation [approval code FHMP]. The program is managed by SFLC-ESD-SSB-DC/LSE. The program is available for use on cutters, boats, and by field units supporting small boats. All surface assets and shore support units may obtain a self-help installation package from that office at D05-SMB- SFLC-HoseLog_Tech@uscg.mil. Once the database is installed, EACH INDIVIDUAL UNIT is solely responsible for maintenance of the data therein. Questions concerning the software and hose maintenance issues should be forwarded the above email address.

4.2 Hose Tags. SFLC-ESD-SSB-DC&LSE has a tag machine which can produce tags for new hoses upon request. Some funding may be required if not previously funded by the parent product line. Contact D05-SMB-SFLC-HoseLog_Tech@uscg.mil.

mailto:D05-SMB-SFLC-HoseLog_Tech@uscg.mil mailto:D05-SMB-SFLC-HoseLog_Tech@uscg.mil

REV - Appendix A - 1 505-2

APPENDIX A

HOSE AND EXPANSION JOINT MANAGEMENT

A1. SCOPE

A1.1 Hose Log Inclusions. Hose logs shall include all Standard, Non-Standard, and Condition Based Maintenance hoses and expansion joints.

A1.2 Hose Log Database.

A1.2.1 Automated Flex Hose Log. Software has been developed to maintain a hose log database at the Unit level. The program software is a Microsoft ACCESS™ preformatted database which has been certified by TISCOM for unit level server installation [approval code FHMP] on VISTA operating systems.

A1.2.2 Program Use. Units shall utilize the software to:

• Track hose and expansion joint inspections. The unit shall query the software to prepare lists of hoses and expansion joints to be inspected, and then update the inspection dates for hoses and expansion joints that have been inspected.

• Track hose and expansion joint replacements. The unit shall query the software to prepare lists of hoses and expansion joints which are coming due or are overdue for replacement, and update the technical data and date upon hose or expansion joint replacement.

• Maintain a descriptive record of the hoses sufficient to procure replacements. The data shall include a complete description of the hose (size, length overall, fluid, etc.), description and part numbers for both end fittings, a part number or stock number for the hose assembly (if applicable), system design pressure, and hydrostatic test pressure required. Technical publication and drawing references should be included where known.

• Prepare documentation for the procurement of replacement hoses and expansion joints. It is suggested that a copy of the Record page accompany each hose and expansion joint being replaced, and a red-line markup of the page be returned with each replacement hose or expansion joint.

• Enter all relevant data for replacement hoses. The unit shall obtain hose and fitting documentation and test data for all hoses being installed on the cutter and all replacement hoses. The unit shall utilize the software to create an archive entry of all hoses being replaced, and enter all data for the replacement or new hose being installed.

REV - Appendix B - 1 505-2

APPENDIX B

MAINTENANCE OF HOSE STOCK

B1. REQUIREMENTS

B1.1 Hose Shelf Life. The shelf life for hoses and prefabricated hose assemblies shall not exceed 10 years. Note that hoses manufactured to SAE J518 and similar industry standards are designed to have a shelf life of not less than 10 years under ideal storage conditions. Shelf life is difficult to qualify as many factors affect the hose or hose assembly. The storage environment can vary the shelf life. Hoses and hose assemblies that have been on the shelf for more than 6 years shall not be automatically rejected for age alone. Hoses and hose assemblies shall be inspected to evaluate their acceptability for use. If there is any question concerning adequacy of a hose assembly, a hydrostatic test may be warranted. Questions concerning hose shelf life should be referred to the cognizant Product Line or to SFLC (ESD) (email: D05-SMB-SFLC- HoseLog_Tech@uscg.mil). Storage of hoses and hose assemblies should be in a cool dry area not exceeding 100° F. Periodic inspection of spare hoses with close visual inspection prior to hose assembly fabrication or installation is recommended. Storage of hoses and hose assemblies should not stack hoses too high as the weight can crush hoses on the bottom. Direct sunlight, rain, high temperatures, or being near heaters or electrical equipment can reduce hose life. SAE J1273, Recommended Practices for Hydraulic Hose Assemblies, provides additional guidance.

B1.1.1 Hose Manufacture Dates. Hose manufacture dates, and the resultant shelf life and service life dates are typically marked in quarter calendar year increments. Most hose manufacturers stamp the manufactured date onto the hose or a hose tag attached to the hose.

B1.1.2 Hose Stowage. Stowage of a minimal quantity of bulk hose and a minimum number of mating reusable or field attachable fittings for emergency use is acceptable. Bulk hose stored on a cutter shall not be routinely fabricated into hose assemblies, with the exception of USCGCs POLAR STAR (WAGB-10), POLAR SEA (WAGB-11), and HEALY (WAGB-20) due to their operational deployments. These cutters shall ensure that personnel fabricating hoses have been properly trained in the operation of the equipment. Unit fabrication of hoses does not obviate the requirement for hydrostatic testing of fabricated assemblies.

REV - Appendix C - 1 505-2

APPENDIX C

EXPANSION JOINTS (FLEX JOINTS)

C1. SCOPE

C1.1 Intent. This appendix addresses expansion joints in fluid systems. It does not address expansion joints in diesel or gas turbine intake and exhaust systems or HVAC duct systems.

C2. REQUIREMENTS

C2.1 General. Expansion joints may be included in a wide variety of applications and are often included in the design of the component being serviced. All rubber expansion joints shall meet the requirements of ASTM F1123 unless otherwise approved by SFLC-ESD-NAME-AMS.

Lacking equipment manufacturer’s specific design and installation requirements the EJMA Standards may help in communicating design requirements to the manufacturers for selection of expansion joints.

C2.1.1 Improper Use. Expansion joints shall not be used to correct for improper piping workmanship or misalignment. Joint movements must not exceed the limits set by the joint manufacturer.

C2.1.2 Standard Applications. For resistance to oils, the outside cover of expansion joints shall be neoprene. For lube oil service, jacket water, and seawater systems the inner sleeve of expansion joints shall be nitrile-butadiene (BUNA-N).

C2.1.3 Alternate Materials. Based on critical factors, such as service fluid, fluid treatments, design pressure, and maximum operating temperature; expansion joint manufacturers may suggest alternate inner sleeve materials. Requests for approval of alternate materials should be forwarded via the cognizant Product Line to SFLC-ESD-NAME-AMS.

C2.1.4 Problem Materials. Chlorobutyl, butyl, styrene-butadiene (BUNA-S), and ethylene-propylene-diene-terpolymer (EPDM) elastomer materials are not compatible with oil-based fluids. Neoprene linings are typically compatible with normal water treatment levels, but are not compatible with high concentrations of treatment chemicals.

C2.1.5 Compatibility. Exposed metallic components of expansion joints shall be compatible with the fluid.

C2.1.6 Special Application. Expansion joints for special applications should have their design and material requirements documented in the cutter equipment publications and/or piping drawings.

C2.1.7 Arch Type Synthetic Rubber Expansion Joints. Arch Type Synthetic rubber flanged expansion joints shall comply with ASTM F1123, Standard Specification for Nonmetallic

REV - Appendix C - 2 505-2

Expansion Joints. These joints were previously specified by MIL-E-15330. This type of expansion joint may have one or more arches.

C2.1.8 Other Expansion Joints. Other types of expansion joints exist on cutters to address special applications. To the maximum extent practicable these expansion joints shall comply with the following:

• Synthetic rubber, non-flanged, corrugated flexible joints shall comply with Commercial Item Description (CID) A-A-50604, Expansion Joint, Sleeved, (Non- Flanged), Fire-Retardant, with Retaining Clips. These joints were previously specified by MIL-E-15330. This type of expansion joint may typically have application in low pressure or vacuum services.

• TFE fluorocarbon resin, corrugated joints shall comply with Commercial Item Description A-A-50605, Expansion Joint, TFE Fluorocarbon Resin, Corrugated with Ductile Iron Flanges. These joints were previously specified by MIL-E-15330. This is a molded TFE expansion joint that is not typically used in Coast Guard applications.

• Flexible Rubber Pipe Connectors, which are reinforced straight rubber pipes designed to absorb noise and vibration in a piping system, should meet the original MIL- E-15330 requirements under which they were designed.

C2.1.9 Installation. Expansion joints shall be installed in such a manner that they can expand and retract as designed. Expansion joints should not be stretched or compressed to fit a specific installation, as this can eliminate the required flexibility. Expansion joints should be manufactured based on the measured dimensions and parameters specific to the individual application. Expansion joints should not be routinely installed to compensate for bad piping installation practices. However joints can be specially ordered to compensate for specific misalignment. For additional guidance, see technical information and installation instructions provided by the expansion joint manufacturer, and Technical Handbook for Non-Metallic Expansion Joints and Flexible Pipe Connectors, published by the Fluid Sealing Association www.fluidsealing.com.

C2.2 Safety. None.

C2.3 Inspection. Expansion joints inspection shall be in accordance with the NSTM Chapter 505 Section 505-3.3.3-3.3.5, manufacturer’s instructions, and cutter specific MPCs.

C2.4 Repair. None.

C2.5 Maintenance. Flexible joints shall be inspected on a semiannual basis and maintained in accordance with cutter specific PMS and manufacturer technical publications.

C2.5.1 Replacement Policy. Flexible joints shall be replaced as a minimum in accordance with manufacturer technical publications. If that is not more stringent the following apply:

• Eight years for general flexible joints.

http://www.fluidsealing.com

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• Five years for lube oil and jacket water applications.

• Twelve years for raw water applications.

• Joints installed in the weather have a 5 year replacement interval if installed without a weather resistant grade covering.

C2.5.2 Abbreviated Replacement Intervals. SFLC Product Line Managers may shorten joint replacement intervals for…