TESS Hose Management

TESS Hose Management is a concept involving all aspects of the life cycle management of hoses.
It involves the set up an equipment hierarchy after the initial survey and registration of each hose.
The registration of all events on a hose assembly, e.g. inspections, pressure tests and replacements gives
the transparancy and overview from the very first batch of hoses.
It also involves the registration of criticality, and inspection and replacement intervals, enabling
maintenance planning.
TESS offer consulting services on choice of the optimal hose for each application and education of
customers own personnel

The TESS Hose Management system (THM) is a highly flexible and advanced risk based hose
management system. THM is a complete concept for the maintenance of flexible hoses where the
customer’s needs and requirements have a major impact on the final implemented solution.

TESS has developed a technology platform enabling our customers to manage the lifecycle of their hoses
with the best technology available in the market today.

The core documents that have been used to develop the system are:
• Energy Institute; Guidelines for the management of flexible hose assemblies
• The so-called Management Regulations with attachments from PSAN
• ISO 14224 – Petroleum, petrochemical and natural gas industries – Collection and exchange of
reliability and maintenance data for equipment

The TESS solution is a value adding hose management system. It offers a seamless integration to other
ERP and maintenance applications. We comply with ISO 14224 in regards to data management and data
collection. We also offer compliance with ISO 27001 in terms of IT security.

The THM concept is based on six elements:

• Ability to quickly perform assignments
• Ability to customer development and cooperation
• Customized software, TESS Hose Management System
• THM hardware and customized THM products
• Competence
• Processes, includes also the customer

THM provides:
• Complete solution for hose lifecycle management and equipment integrity.
• The best uptime solution in the market.
• Independent maintenance solutions for efficient preventive and corrective maintenance.
• Compliance with regulations and standards.
• Customized integration with any customers database.
• Mobile solutions keeps your hose assets updated .
• Specialized trained and certified mobile workforce.

By implementing the THM system the following benefits can be achieved:

• Improved uptime (Reduced replacement time, reduced number of hose failures, upgrade on hose
quality and installation geometry where applicable,)
• Reduced maintenance costs (lifecycle estimates on hoses, planned risk based maintenance)
• Reduced logistics costs (customized spare solutions)
• Reduced ICT costs (SaaS, Reduced developments costs, internal and external, Reduced
administrative cost sourcing best practice).
• Sales and marketing benefits (enhanced image with public regulators)
• Increased skills of employees (Hose Assembly Training, Hose Integrity and Inspection Training,
including Computerized Maintenance Management System (CMMS)).
• HES-Q improvements (Improved safety and environmental performance, Pollution prevention and
risk mitigation, Achieve and improve employee awareness of safety and environmental issues and
related responsibilities, Enhanced compliance, Collaboration with a Flexible Hose Assembly
specialist).
TESS Hose Management System
Most operators are already using electronic maintenance solutions as a part of their Safety and
Environmental Management System (SEMS). TESS use applications from leading global Enterprise Asset
Management software corporations to develop customized hose management solutions.

TESS-Soft offers solutions specifically developed for hose management. The database provides generic
hose and coupling details, documentation, all related details for asset management and inspection
processes. An extensive audit trail provides the management of data governance and changes made in the
database.

The TESS Hose Management solutions are developed as well on the Android platform, providing almost
total flexibility regarding other apps and hardware. Our hardware solutions are the best in the industry and
provides also SLA on different levels. All the products are off course rugged and available with ATEX and
similar certifications.

Software as a Service, SaaS, is a software delivery method that provides access to software and its
functions remotely as a Web-based login.
SaaS allows organizations to access business functionality at a cost less than paying for licensed
applications. As the software is hosted remotely, users don’t need to invest in additional hardware. SaaS
removes the need for organizations to handle the installation, set-up and often daily upkeep and
maintenance. The system is utilizing server applications which are ISO27001 certified.

TESS Soft is delivered as SaaS and is therefore contributing to low cost solution for
our customers.

The customer login, www.hosemanagement.com, allows the customer to enter the TESS Hose
Management system. It is easily accessible wherever there is internet access. This well arranged database
lists information in KPIs according to age and maintenance needs. Best practice and the customer`s
specification will be used as a foundation for calculating the due dates for inspection and hose replacement
respectively. In addition, TESS offers offline solution, allowing users to access relevant data while in the
field on the Android platform.

TESS Hose Management System can be configured to give differentiated access level to the various users:
 • View of hoses data and related documentation
• Editing of hose data and related documentation (deletion/uploading)
• Printing of pressure test certificates
• Issuance of RFQ’s direct from the TESS Hose Management System
• Reporting of Hose Replacements
• Reporting of Hose Scrapings

All hoses are given a unique ID number that is both tagged on the hose and registered in the TESS Hose
Management system together with the collected hose data.

The hose identification will be done by using a high resistance tag (the final layout of the tag with required
information can be agreed with the Client).

If desired, an optional UHF or HF RFID tag can be attached to each assembly.

Life cycle management and cost reducing maintenance

The working life of hoses can vary from just a few months to several years and TESS Hose Management
enables tracking the condition of each hose through its entire life cycle using data from the hose production
and inspection result.

Any value adding activity is dependent on undisrupted operations for optimized financial output. A flexible
hose, although often being a minor part of larger and more expensive equipment can, if it fails, become a
major operational concern. In addition, environmental burdens may be placed on management through
pollution issues.

On any oilrig or vessel there are up to 5000 flexible hoses. In our experience more than 15% of installed
hoses are critical and need special attention. If not given properly life cycle attention the probability of
reduced operational uptime due to hose failures is very high.

Our clients utilizing the maximum potential of the THM system have experienced reduced cost of 26%,
linked directly to the procurement of FHAs. This has resulted in return of investment within 3 years.

Standardizing and optimizing FHAs will give additional cost reduction, e.g. simplifying replenishment and
reduce number of hose replacements.
Identification secures life time history
Hose identification and labelling is important in TESS Hose Management. We need this to be able to follow
the whole life cycle of a hose.

What we are labelling is actually the hoses position and function, but the label needs to be attached to
something, usually the hose.

The label consists of a unique ID-number (a running series of numbers starting with 1 – at the moment the
ID-numbers have 8 digits).

When a hose is replaced we use the same ID-number.

Maintenance plan
The TESS Hose Management maintenance plan is a risk based approach for the setup of inspection and
replacement intervals.
The intervals can be set independently per hose, and our customers can use this information to better
target risk mitigation measures.

All the hoses will be given a Risk Class, the basis for the maintenance planning and based on these data
the preventive maintenance frequencies/intervals for inspection and hose replacement are set.

Our best practices for determining the inspection and replacement intervals are based on criticality and
probability of impact on operations, health and environment.

Certified experts conduct risk assessments, classifications and identification of opportunities for risk
reduction in collaboration with the customer’s lead technical personnel. Our experienced personnel have
long experience with assessing alternative barriers.

Intervals for both inspection and hose replacement are determined in coordination with the customer but
TESS recommends to use the risk classes with their related intervals as shown in the table below.
Risk assessment and risk mitigation
TESS can utilize different methods determine the risk class of the hoses.

Method 1 - Basic, inherit the risk classification of the joining equipment

• Fast, simple but rough. No hoses are evaluated as such.
• Assumes that the attached equipment has a form of risk classification / maintenance plan.
• The hoses gets the same criticality / equivalent inspection intervals as the equipment they are
connected to.

Method 2 – Extended, focusing on environmental impact

• Fast and easy way to reduce emissions / improving corporate green. Still not an adequate risk
assessment of the hose.
• Assumes that the attached equipment has a form of classification / maintenance plan that can be
used to establish a regime for the hoses.
• Hoses considered to have an expanded environmental factor are given a higher criticality rating /
more frequent inspections than other hoses on the same equipment.

Method 3 – Complementary, risk evaluation of all hoses

• Adequate and a more comprehensive method for analyzing the risk of the hoses poses. Focuses
on HSE perspective and up- / downtime considerations in order for the hose maintenance to
provide savings beyond the purely hose-technical savings.
• The method also deals with hoses that are part of safety critically systems. E.g. hoses used as part
of the MOB systems.
• Establishes the basis for a detailed risk based maintenance plan.
• Provides the necessary basis for prioritizing hose replacements after inspection - corrective
maintenance plan.
• The risk class of a hose can be adjusted and documented through mitigating measures
related to the 6 various risk factors that are considered.

The Risk Class is governing for both maintenance types (PM & CM) and based on consequences and
probability of hose failure, as shown in table below:

Consequences
Probability

TESS utilizes a Matrix for determining the Risk Class of a hose based on the combination of consequences
and probability of failure, as shown in picture below:

The higher the class number, the higher the risk.

Knowing the details of the analysis that lead to the consequences and probability scores will enable the
client better understand its risk exposure.

TESS will support the customers risk reduction efforts and based on the determined Risk Classes, work in
conjunction with the CLIENT to establish proper risk mitigation measures

Spare and Emergency Hose kits

Based on the customer’s selected maintenance plan and the surveying results, TESS can recommend
customized emergency and spare arrangements for hoses and fittings.

Emergency hoses are cost-effective systems that enable our customers to install a temporarily hose in case
of a hose failure. Such an emergency hose will typically fit on to several hose installations and are
especially suitable when hose production is not carried out on board. Emergency hoses must be replaced
with a new hose with the original hose specifications as soon as possible.

Spare hoses are cost-effective systems that enable our customers to rapidly replace a hose in case of a
hose failure. A spare hose is tailor-made to a specific hose installation, but it can fit on to several alike hose
installations. Especially suitable when hose production is not carried out on board. If a spare hose is
utilized, a new spare hose should be ordered, but the one that has been put in to operation are to be
regarded as a normal hose that has been replaced.
Training
TESS offers a comprehensive range of highly focused technical courses. The emphasis is on useful
practical skills and a ‘hands-on’ approach to training for controlled application of new skills in the workplace.

TESS can provide convenient delivery of training at the Client sit, both On and Offshore.
TESS has established and implemented a robust training program through our own
TESS Academy. The academy offers training to both employees and clients. With
Regards to Hose Management, TESS has developed a certification program based on relevant industry
standards. This ensures the competency of our employees and the quality delivered by them.

Customized courses can be created to match specific training needs but we recommend the below off-the-
shelf trainings:

• Risk Based Maintenance

• THM Administration
• Inspection routines

The training will be tailored to fit the customers chosen hose management system.

The Belt training

Based on the defined processes, TESS has developed a tailored THM education. The core of this
education is the education related to operative work. The training is given status as level forming within
TESS.

TESS has established a requirements catalogue for each belt courses where particular HSE and hose- and
hydraulic knowledge are key elements. In addition, practical experiences from hose management
assignments are considered as an important for the development of the competence of each individual
employee.

Other THM related education

In addition to the belt courses, TESS has a number of other courses that are relevant to get the best
knowledge and understanding of THM. Some of these courses are required as a basis for getting into the
level-forming belt courses.