How to monitor and inspect service station hoses

The Repsol refinery in A Coruña has found itself needing a service to monitor, inspect and replace hoses in its industrial complex.

This service should also suggest recommendations for optimising the use, management and maintenance of plant hoses and, to the greatest extent possible, preventing the risks that might arise from misuse.

These hoses include those at service stations, with intakes for steam, air, water and nitrogen.

According to the previous study conducted, the total number of stations is more than four hundred. Most are located at street level, except those in towers or strippers, which have special access.

The following activities are included:

• The preparation of a list of hoses in the plant, with appropriate item numbers to allow monitoring of service life and condition.
• Conducting the appropriate inspections and tests needed to comply with regulations that include design and instructions for use.
• Updating the lists of hoses with the relevant tests and issues.

Inspection tests and the schedule need to be marked down, based on regulations applicable to each hose.

The pre-commissioning assembly test (hose/fitting) will be established as the starting point.

Tests and inspections carried out must be marked, with appropriate control systems, on the hose itself.

A testing regime will be established based on a series of segments each day, which will have to be tested for pressure and conductivity, plus the task of marking down and preparing inspection forms.

This will be done to track whether hoses comply with the refinery’s standards for its hose inventory, taking into account the fact that the plant contains more than 400 segments of hose.

Proper logistics requires a team of two people with a vehicle and test equipment (pump, blind flanges, connector flanges, gauges, Meger, etc.), according to a previously agreed-upon inspection procedure.

This task should be supplemented with the implementation of a database for plant hoses. A file will be created for each hose to ensure complete traceability, and to allow constant feedback to relevant departments regarding condition and incidents.