ERIKS Hose Technology Part of ERIKS Industrial Services Ltd Proposal for Hose Testing and Related Services Onsite hydraulic and pneumatic pressure testing, online hose registers 1
Contents Company Information... 3 Vision... 3 Strategy... 3 Company History ERIKS Hose Technology Ltd... 4 Hose Testing... 6 The Visual Inspection... 8 Electrical Continuity... 8 The Hydrostatic Pressure Test... 8 Internal Inspection by Fibre Optic Camera... 9 Hose Dating... 10 Hose Tagging... 11 Additional safety requirements and comments:... 13 Awards, Policies and Procedures... 14 QA Systems... 14 Experience and References... 15 Hose Database, Extranet / Certificates... 15 Other Services... 17 Non-ERIKS Hoses... 18 Account Management... 18 Invoicing and Claims... 19 Hose Training... 19 Onsite hydraulic and pneumatic pressure testing, online hose registers 2
Company Information Name of Organisation: ERIKS Hose Technology Name: Position in Organisation: Carl Lilley Business Unit Manager Direct Tel. No. 01753 570863 Fax No. 01753 824141 Email Address for correspondence: Registered Company Address: carl.lilley@eriks.co.uk 692-693 Stirling Road Slough Trading Estate Slough Berkshire SL1 4ST Amber Way Halesowen West Midlands B62 8WG Company Registration Number 3142338 Date of Registration 15th March 2008 for ERIKS Industrial Services Vision Our aspiration and strategy is to reduce your risk profile, add value to our customers operations, increase your productivity and help you achieve your corporate goals, for not only production but also for sustainability and innovation. Many suppliers will be able to supply your standard rubber, composite, PTFE and metallic hoses you require, however, we believe we can make a difference in the total cost of ownership, whilst at the same time minimising your risk and achieving your objectives. Strategy In addition to the supply of hoses, we work to provide value added services such as; hose registers, hose recommendations and on site testing. Proactive Risk management is the primary focus of our proposal. Onsite hydraulic and pneumatic pressure testing, online hose registers 3
Company History ERIKS Hose Technology Ltd ERIKS Hose Technology are the foremost suppliers of hose and couplings to the process industries in the UK and are perceived by many blue chip companies as the UK s market leader of bespoke hose, assemblies, tubing, ducting and couplings. We are an acknowledged specialist supplier of technical solutions, services and products in many sectors of industry. Within our comprehensive sphere of operations there is particular emphasis on the chemical, petrochemical, pharmaceutical, food and brewery markets. We are arranged around two strategically located manufacturing sites in Berkshire and Northamptonshire. These centres provide dedicated sales, engineering and technical support together with local trade counter services to all our customers. ERIKS Hose Technology, in the UK, has over 1 million of working stock and in excess of 80,000 product lines. The sheer size and range of inventory maintained by ERIKS means that off the shelf products are supplied to our customers at an unrivalled speed. This stock is supported by substantial stocks from the ERIKS hose divisions in Europe. In addition to our standard product lines, ERIKS has developed many support and solution based services which include hose management (incorporating on site testing, hose inspection and hose registry establishment and maintenance), hose refit, design of bespoke hose assemblies for individual installations, and of course technical support and advice. ERIKS is committed to utilising the benefits of the latest communications technology to the full. We work closely with our diverse range of customers in many ways beyond the simple supply of hose, especially: Sustainability Energy reduction Leakage reduction Product life Increased uptime Risk management ERIKS current sales of process hoses is approximately 300million Euros, this size allows the development of economies of scale in cost control together with innovative product development and market coverage. We believe that this strategic approach will ensure that ERIKS Hose Technology maintains its leading market position in customer service and provide a successful and rewarding environment for our employees, whose knowledge, dedication, professionalism and skill lay at the heart of our business. Onsite hydraulic and pneumatic pressure testing, online hose registers 4
ERIKS are the largest industrial hose suppliers in Europe, our main warehouses in Asse, Hoboken, Alkmaar and Slough, and hold the largest stocks in Europe. We also utilise our supplier base stockholding to support product availability and drive efficiency. On hoses alone we have 50 million of stocks available next day from our core supply base, not only in the UK but across Europe. Onsite hydraulic and pneumatic pressure testing, online hose registers 5
Hose Testing The next few images give a general outline of how we test hoses for customers. Customer contacts ERIKS and books a site visit by one of the onsite testing teams. Typically we require 4-6 weeks notice although more urgent requirements may be accommodated. Engineers arrive on site and set up equipment, connecting their van to water and air on site. Engineers visually inspect the hoses, before pressure testing them, typically to 1.5 times working pressure. See the internal inspection camera; this is the red coil (cable) with lens and light on the left of the picture. Testing the hoses within the building, where spaces permits Onsite hydraulic and pneumatic pressure testing, online hose registers 6
The water is then drained away. De-Ionised water may be needed in certain applications. Inside the fully equipped van Onsite hydraulic and pneumatic pressure testing, online hose registers 7
The Visual Inspection Each hose is checked for, cracks, bubbles, kinks, wear and / or degradation (corrosion) to the outer jacket. The hose connections are checked for wear and deformation. The terminal connections are checked for the mounting, wear and the attachment to the hose. At the request of the customer an internal inspection can take place with our camera for any hoses greater than 1.1/4 bore A hose would be rejected if there is doubt as to its reliability based on: Serious damage to the outer cover (e.g. cracks, bubbles, cuts, etc) Degradation of the outer cover (e.g., swelling, hardening, etc.) Wear or corrosion of the outer cover (e.g. by braiding metal and PTFE hoses) Deterioration or damage to the hose connections. If the electrical resistance is measured and we find unacceptable deviations from the specified electric resistance at M hoses (with braided earthing wires) or Ohm hoses (hoses where use is made of conductive rubber material). The hoses that pass the visual inspection are then hydrostatically tested. Electrical Continuity The electrical resistance between the end fittings is checked and recorded if required. Most companies require a continuity of either less than 10Ω or 100 Ω. The Hydrostatic Pressure Test If the hose is found visually to be in order, a hydrostatic pressure test will be conducted in accordance with the ISO 1402 Section 7.1 This standard refers to ISO 7751 (see below). The test pressure is partly dependent on the norms and the media. We will conform to UK standards unless our customer notifies us of any specific requirements. Table ISO 7751 Water hoses with a maximum operating pressure to 10 bar - 1.5 times design pressure. Hoses for all liquids / solids in liquids or air and water, hoses with a maximum working pressure of above 10 bar - 2 times design pressure. Hose for compressed air and gases 2 times design pressure. Hose for liquids that turn into gas and cause a pressure drop compared to the atmosphere 2.5 times design pressure. Steam Hoses 5 times design pressure. High pressure hoses for cleaning 1.5 times design pressure. Note: Due to safety restrictions testing on location will go no higher than 90 bar. Onsite hydraulic and pneumatic pressure testing, online hose registers 8
For the pressure test, the hose is capped at both ends and equipped with a filling hose and a valve. Then we will fill the hose with water until all air from the hose is expelled, we then close the valve and pressurise the hose to the desired value (test pressure). When this value is reached, and the elongation of the hose stabilizes, we keep the hose at constant pressure to assess for leaks etc. The hose is rejected if: A leak is detected. If inadmissible torsion is observed. An extreme (continuous) extension occurs Elongation of the hose under pressure will be recorded on the hose report and certificate After testing the hose is marked with a coloured identification band. (For ease of recognition on site, whether a hose is tested or not). Please note hoses can still retain a few drops of water within the hose after testing. Internal Inspection by Fibre Optic Camera Images taken from the internal inspection camera are collated and stored on the secure servers at EHT, Test certificates are stored and can be printed when required. Providing that a hose has passed the external visual test and before we hydrostatically test, we have the option to check the internal condition of the hose to check for any damage to the liner. The below pictures show damage recently found within a food hose. Internal damage is common and can only be found by using such an endoscopic camera. Similar internal damage could be caused in chemical plants, where incompatible products are passed through the hose, leaving the hose to look perfect on the outside but hiding the potential hose failure. When using the fibre optic camera this adds around 15 minutes work per hose, which means that the total tested in a day would be lower but we believe this is an essential tool in managing risk. Onsite hydraulic and pneumatic pressure testing, online hose registers 9
Hose Dating We work with the IMO standard colour coding: 2007 = blue 2008 = Grey 2009 = green 2010 = brown 2011 = blue 2012 = yellow 2013 = red 2014 = grey 2015 = green 2016 = brown 2017 = blue 2018 = yellow For all hoses that are found to be in correct order you will receive a test certificate. Any repairs that might be necessary can sometimes be carried out on location, if correct materials are available and time permits. ERIKS will provide an appropriate solution if hoses are rejected. Any hoses that are rejected are provided with a label with the reason for rejection. In addition, for hoses deemed repairable we will send you a repair proposal and for irreparable hoses we will send you a proposal for renewal. Onsite hydraulic and pneumatic pressure testing, online hose registers 10
Hose Tagging Once the hose has been tested it can be tagged with an inspection record tag showing the inspection history for that hose. Any hoses deemed unsuitable at inspection would be tagged, using card tags as below: We would recommend the use of customer specific tags for hoses, which are changed dependant on the scope of your needs. A durable Stainless Steel tag, as below, secured to each hose that has passed inspection, would be fitted using a stainless steel band. This would be done during the testing. Onsite hydraulic and pneumatic pressure testing, online hose registers 11
Hoses supplied by ERIKS UK could be engraved with a unique identity number if required, as below. Hoses supplied by ERIKS UK could also be marked with a use by date, as below. Use by dates would need to be established in proportion to their usage, risk and manual handling. Silicone coverings can be used on PTFE assemblies for extra protection or wipe clean application, as below: Onsite hydraulic and pneumatic pressure testing, online hose registers 12
We are currently investigating options for using QR codes on both hoses and test certificates, we are not ready to offer this today but feel that we will be able to offer in a few months time. See below. Additional safety requirements and comments: In the case of a contract or order, we assume that: ERIKS to provide Risk Assessment and Work Instruction before visit Customer to supply risk assessment for area to be used for testing Customer to advise dates, types of hoses for testing etc before visit All hoses are cleaned before they are offered for testing. We receive a signed work permit or a written statement that the hoses are cleaned before we begin the work. Customer to provide a suitable employee during testing to advise on safety and assist with moving of hoses Customer to ensure that suitable lifting equipment is available for the handling of the hoses if required You inform our people of site safety rules and provide safety induction. You inform our people about the dangers of the medium to which our operators may come into contact. We will test no higher than 90 bar. (Unless in an enclosed space) ERIKS staff would provide their own PPE (boots, hi-vis, hard hat, safety glasses) If additional safety equipment is necessary, in addition to our standard safety equipment, you will provide us with such. The engineers made available to you are under your responsibility. Our staff will work no longer than 12 hours per day. The work place is previously defined and easily accessed. Water, electricity and air (6 bars) are present. We can discard the testing water in an environmentally responsible way. We have the opportunity to do workplace inspections, in consultation with the customer, prior to testing Customer to liaise with ERIKS a suitable process for testing hoses at any berths where vehicular access is not possible, if applicable ERIKS to comply with Customer procedures ERIKS do not accept consequential loss claims Onsite hydraulic and pneumatic pressure testing, online hose registers 13
Typical site space requirements as above Awards, Policies and Procedures QA Systems ERIKS Industrial Services - ERIKS Industrial Distribution including ERIKS Seals, Transline and Integrated Solutions, plus all central functions based at Halesowen Head Office - ISO 9001 2000, registered with LRQA. Certificate number LRQ 0920018, expires 31st October 2011. ERIKS Industrial Services Electro Mechanical Services - ISO 9001 2000, registered with LRQA. Certificate number LRQ 0964450, expires April 2011. ERIKS Industrial Services Warehousing and Head Office functions - ISO 14001 2004, registered with LRQA. Certificate number LRQ 4001025, expires October 2011. ERIKS Hose Technology Hose manufacturing facility at Northampton ISO 9001 2008, registered with BSI. Certificate number Q05788, expires end February 2013. Currently being extended to Bolton and Slough Core Competence Centres Onsite hydraulic and pneumatic pressure testing, online hose registers 14
Experience and References We have successfully run the hose management system at PPG Stowmarket and AKZO Nobel at Slough and Stowmarket for several years. We use an electronic spreadsheet system that gives each hose a unique reference number. This number identifies not only the hose type but also its length, diameter and fittings as well as its location and the application that it is used for. The spreadsheet records when the hose was last inspected and pressure tested (if applicable). If desirable it is also possible to track how often the hose has been changed and the reasons why, such as crush damage etc. If a hose flags up as being replaced too often this can then be investigated further in order to determine if there is an issue with the hose or the installation or the application in order to provide the lowest lifetime cost hose for each application. We have helped to reduce the hose spend at PPG with regular visual inspections that identifies hoses before they fail, and the unique tag number means that this is all that is required for us to be able to supply a replacement hose. The customer does not require an engineer to measure anything on site thus making ordering quick and simple. Hose registers exist also for the various Robert Wiseman Dairies and Dairy Crest sites. Each Hygienic hose has a unique identifying number etched onto the ferrule when it is made which can be used as a tracking number for the various food sites. The identifying number allows us to not only access the specification of the hose but also the batch of hose and fittings that the hose was made from thus giving full traceability back to the hose batch and fitting supplier database and ultimately who made the coil of hose, which batch of rubber was used etc. This way if a faulty batch is identified then we can do a full recall of all hoses made from that batch of hose. We currently perform on site hose inspections for customers such as Heineken UK, Dow Chemicals and Huntsman Chemicals. Upon receipt of an order a more detailed procedure would be agreed with relevant site engineers. Hose Database, Extranet / Certificates ERIKS offers several options for maintaining a customer s hose register. We can create a bespoke extranet site, covering all you hoses onsite. The ERIKS Extranet offers a hose asset management system that stores the product data along with the current test certificates, which can be printed whenever needed, removing the risk of test certificates being lost. The data is colour coded for ease of use (green for safe to use, amber for hoses that are coming up for testing, red for those hoses that have failed inspection or have not been tested for 12 months. Alerts can be set in the system to inform relevant staff of any noncompliance. ERIKS can maintain a spread sheet of all the customers hoses purchased from us. ERIKS can use a customer s spread sheet or database to enter the data. For the life of the maintenance contract EHT will keep the register up to date with all hose purchases made from EHT, giving full details of each hose, its location, last tested, test certificate etc. The customer can also update details if required (date in and out of service, version updates, etc. The following pages show mock up versions of how the assets register and test certificates could appear. Onsite hydraulic and pneumatic pressure testing, online hose registers 15
Onsite hydraulic and pneumatic pressure testing, online hose registers 16
Other Services Bounce rings, anti-scuff rings and bend restrictors are also available to increase the life of hoses. See below photos of a bend restrictor in use and a bounce ring fitted on an extended neck RJT fitting. Outer sleeves, which protect the outer skin of the hose and can supplied, anti-static where necessary, these give extended life in certain applications. We can also provide hoses with bespoke labelling for specific applications, providing that minimum batch quantities are achieved. For example we currently produce utility hoses where the label is in a spiral, so that whichever way the hose is laying, the operators can still clearly see the label. We also produce composite hoses that absorb light during the day, so that they glow in the dark, which is particularly useful where they are a trip hazard when left outside in the winter. Onsite hydraulic and pneumatic pressure testing, online hose registers 17
Non-ERIKS Hoses We can identify and test hoses that are not supplied by ERIKS. If these hoses are equipped with a unique number this will also be recorded along with a description and hose test results if relevant. Account Management ERIKS Hose Technology Ltd has over 30 years experience in process hose supply and management in the UK. We currently have 3 experienced Application Engineers giving a full national coverage. Onsite hydraulic and pneumatic pressure testing, online hose registers 18
Invoicing and Claims We currently send invoices, either via the post or increasingly via e mail as a pdf or flat file. We could consolidate the invoices onto a single monthly flat file, with supporting documents breaking down the costs and parameters required. Typically such reports show a breakdown by product type, by order number, by contact etc. Such data is almost infinitely configurable in our system and we are confident that with dialogue a suitable system can be quickly completed. ERIKS do not accept consequential loss claims. Hose Training Onsite training on safe hose usage and maintenance can be provided for our clients, and offers lessons on the latest best practice in the industry. We feel that this is a great way of closing the loop regarding risk management. Onsite hydraulic and pneumatic pressure testing, online hose registers 19