TESS hose management – from a simple asset to a business critical concept
TESS hose management, THM, is critical to assure the correct maintenance of the hoses, reduce risk and avoid emissions of an installation. The risk-based inspections also saves the company cost up to 33 percent.
This speech was given by Jan Georg Tunes, Operational Director, THM, at energy:connected 2019. Many attendants have asked for it. You can read a slightly modified version her.
TESS has managed to transform it’s most important product group– hoses – from a low status and little regarded product – use and throw away – into a product that is recognised as important for up-time and in need for cost effective solutions (LEAN) to be managed properly.
The management of the flexible hose assemblies is done through a series of defined processes, defined competence levels and a supporting software named TESS Hose Management.
As digitalization is pushing the development on many fronts, TESS has been investing millions every year in further development of the TESS Hose Management Concept – aiming to keep the position as world best.
The biggest challenge developing a maintenance system for hoses is to predict the life spend of the different hose installations. It is almost like asking “how long is a rope…?”
This is directly linked to the fact that most hydraulic hoses are made of rubber and steel – layer by layer - and as rubber being an organic material, it reacts to pressure, temperature, UV radiation, cold and warm, salt from the sea, etc. in a way that no matric is able to calculate without a lot of sensor data both from the inside and from the outside of the hose.
Such solutions have so far proven to be less successful in operational environments, and also quite expensive.
Risk based inspections
Until cheap and trustable ways of predicting the life-length of a hose are in place - other solutions must be developed and implemented.
Risk management has become more and more in focus - also when it comes to hoses. It’s a part of the general development in our society.
A typical risk assessment on hoses evaluate consequences in case of hose failure such as:
- Environmental impact / size of an oil spill
- Operational downtime
- Personnel injuries
The most common use of the risk assessment result is risk mitigation, but since the assessment often is rather extensive, it would be nice if it had other major purposes.
Based on the Guidelines for the management of flexible hose assemblies from UK Oil & Gas, the TESS Hose Management system is developed using a maintenance philosophy called risk based inspections.
This gives our customers a flexible and adaptable maintenance strategy and system for their hoses, which significantly reduces maintenance efforts, and increases plant reliability and availability at the same time.
This correlation results from shifting inspection efforts from “over inspection” of uncritical equipment to an increase in inspections cost-spending on components with potentially higher probability of failure and consequence.
The result is an overall risk reduction and increase in plant safety and reliability while constraining costs.
Since both inspections and replacements are pre-planned, these activities can be coordinated with other maintenance activities, eliminating even more down time.
Many of our offshore-customers typically used to have a maintenance strategy stating that the hoses should be replaced every 5th year – typical during reclassification work.
Our calculations, when comparing the 5th year model with the risk based model, gives an upside to the risk-based model of at least 24% - often 33% on costs. Calculations are backed-up of real life experience.
This transfers in to close to 2 mill NOK saved over a 10 year period when having 1000 hoses in the maintenance plan. These 2 millions are ONLY calculated towards the maintenance work and parts needed.
Savings linked to less downtime, less environmental emissions, fewer deliveries of incorrect hoses, digitalisation of the ordering process for hoses, etc, etc are additional.
It seems that not only good planning, but also the correct way of planning is the way to go to reduce costs and at the same time increase operational up-time and safety.
Do you want to know more? Contact Jan Georg Tunes, [email protected], +47 951 05 968