New generation marine hoses for offshore transfers

A new-generation marine hose may look similar on the outside to one installed years ago, yet it may be based on a different technological philosophy. Current advancements include specialized architectures, cryogenic solutions, instrumentation, simulation, and a more systematic use of data collected during service.

With the new generation marine hoses, innovation shifts the question from “What pressure can it withstand?” to a more comprehensive one: How was it designed and qualified for service, what variables can be monitored, and what information will help us understand its condition once it enters service?

What does a “next-generation marine hose” really mean?

“New generation” is neither a formal category in the GMPHOM (Guide to Manufacturing and Purchasing Hoses for Offshore Moorings) nor a regulatory term defined by ISO. In this article, it is used to describe the technological evolution of hoses and the tools used to design them, qualify them, and manage the information obtained during their service life.

Depending on its design, a bonded marine hose consists of an inner lining, reinforcement layers, an outer cover, and end connections, as well as components designed to provide resistance to vacuum or collapse, buoyancy, or other functions. Advances can be seen in the selection of materials, the layered structure, calculation and testing methods, and monitoring technologies.

The technical literature documents developments in hoses used in CALM (Catenary Anchor Leg Mooring) systems connected to PLEMs (Pipeline End Manifolds), as well as in FPSO (Floating Production, Storage, and Offloading) and FSO (Floating Storage and Offloading) installations, where internal pressure, motion, bending, and environmental loads interact.

Materials and Architecture: Innovation Happens Inside the Hose

A marine hose does not derive its properties from a single material. In bonded constructions, the different layers serve to contain the fluid, provide reinforcement, and offer external protection. The selection of these layers must be based on the fluid being transferred, pressure, temperature, required flexibility, mechanical stresses, and environmental conditions.

Composite materials and multilayer configurations allow for fine-tuning the balance between strength, flexibility, and mass, but “advanced material” does not mean a universally superior material. The right solution is one that has been designed, qualified, and tested for the conditions of the intended service.

For hoses used in offshore mooring applications, GMPHOM, published by the Oil Companies International Marine Forum (OCIMF), remains a technical reference. The fifth edition, published in 2009, includes requirements related to construction, acceptance testing, inspection, and prototype approval; for the latter, dynamic bending, tensile, and torsion tests are specified.

In 2019, OCIMF published a specific update to the dynamic torsion test and continues to work on the revision of GMPHOM. The update to these criteria reflects the changes the industry is incorporating into the design, specification, and evaluation of hoses.

Cryogenic hoses: when temperature changes, technology changes

The marine transport of Liquefied Natural Gas (LNG) is one of the areas where technological advancements are most evident. Cryogenic temperatures require careful consideration of materials, insulation, flexibility, connections, handling, and—depending on the configuration—additional containment or detection systems.

ISO 16904-2:2024 establishes guidelines for the design, material selection, qualification, certification, and testing of hose assemblies intended for the marine transfer of LNG. Among the main types described are corrugated metal hoses, multilayer thermoplastic composite hoses, and hose-in-hose configurations.

The standard also covers optional components such as leak detection systems, insulation, intermediate barriers, devices to control curvature, and buoyancy elements. In cryogenic composite hoses, polymer films and textile layers are combined with helical wires to provide containment and structural strength. The design must be tailored to the anticipated cryogenic and operational conditions and cannot be directly adapted from a conventional application.

This development is also directly linked to specialized companies such as IOCS Srl, which offers cryogenic composite hoses as part of its range of solutions for the oil and gas industry, along with other equipment and components for transfer systems.

From a passive approach to data-driven monitoring

The integration of instrumentation makes it possible to record operational variables and subsequently correlate them with tests, inspections, and service history. A sensor generates data; to use this data in a condition assessment, it must be interpreted in conjunction with operating conditions and other available evidence.

In this area, the company has explained that it works with hose manufacturers that incorporate pressure and temperature sensors. The information obtained can support decision-making, but its usefulness depends on maintaining the operational context and correlating it with other evidence regarding the condition of the hose.

For LNG applications, ISO 16904-2:2024 also covers optional leak detection systems and hose-in-hose configurations in which the annular space can serve isolation, buoyancy, or detection functions. The usefulness of this instrumentation depends on how the data obtained is integrated with the observed condition, test results, and the hose’s operational history.

Condition monitoring: Data becomes valuable when it has a history

A single measurement describes a single point in time; a series of comparable readings allows us to observe trends. In offshore hoses, this distinction is important because pressure, environmental exposure, movement, and transfer conditions change during service. Monitoring can complement inspections and tests, but it does not automatically replace them.

The IOCS Service Life Monitoring Program uses field data records and test results obtained during the operational period and periodic testing, supplemented by results from hoses removed from service after an agreed-upon period. Comparing these records makes it possible to track changes in condition between evaluations and provides historical information to support future decisions.

Evidence-Based Monitoring: A Decade of Experience

During SLOM 2025, Davide Contino presented a case study from Italy in which certain hoses remained in operation for approximately 10 years under periodic monitoring. Depending on the case, selected components were removed approximately every two years to undergo physical testing and to compare the results with previous records.

That period should not be interpreted as a service life applicable to other facilities. This case demonstrates how historical data and subsequent testing can support decisions regarding continued operation or replacement, without relying solely on the component’s age.

The following video expands on this approach and shows how digitization, periodic inspections, and condition monitoring are integrated into the management of offshore systems.

Simulation and Testing: Complementary Technologies

Innovation also comes into play before a hose is installed. Simulation tools make it possible to study a planned configuration and analyze its response under the conditions represented in the model.

As part of its engineering services, IOCS uses OrcaFlex®, marine dynamics software developed by Orcina Ltd., to perform static and dynamic analyses of floating and subsea hose strings. For mooring systems, it uses OPTIMOOR, developed by Tension Technology International (TTI), a tool that evaluates the response of different configurations to conditions such as wind, current, waves, tides, and changes in draft.

Modeling provides information prior to installation by allowing for an assessment of the configuration’s expected response, while monitoring, inspection, and testing generate evidence during and after service. These are distinct sources of information that can be used in a complementary manner to evaluate the hose’s performance.

An instrumented or digitally modeled hose still requires qualification and verification. Hydrostatic, vacuum, electrical, and mechanical tests provide answers to different questions about the component. IOCS includes several of these tests as part of its services for new and used hoses and hose strings.

From Innovation to the System the Operator Needs

The incorporation of a specialized material, a sensor, or a numerical model must meet specific requirements regarding compatibility, performance, safety, availability, or condition management.

As part of its vision, IOCS is committed to finding technological and innovative solutions and coordinating with multiple suppliers to provide end users with a comprehensive and functional package. Its operations combine the supply, design, engineering, and support of equipment for the oil and gas industry, while in the field of hoses, it works with specialized manufacturers and suppliers.

For the operator, the decision involves determining which marine hose technology is truly suited to the operating conditions and what evidence will be needed to verify its performance during operation.

Do you need to evaluate a hose solution for an offshore operation? IOCS Srl offers technical support to design transfer solutions based on system requirements, operating conditions, and project needs. Contact their team directly to evaluate your application.

Conclusions

Selecting a hose for offshore transfers today requires considering more factors than just pressure, diameter, and compatibility with the product. Materials, construction, cryogenic conditions, instrumentation, simulation, and test results all provide different insights into how the component will perform during operation.

New generation marine hoses are designed precisely to provide a better understanding of that behavior before and during service. The value of these technologies lies in providing information that allows for better hose specification, verification of performance, and data-driven decisions regarding the hose’s condition.

References

1. IOCS Srl. Products – Hoses & Ancillaries Equipment Supply for Oil & Gas Industry. 
2. IOCS Srl. Engineering Services; Service Life and Re-certification of Marine Hoses. 
3. OCIMF. Guide to Manufacturing and Purchasing Hoses for Offshore Moorings (GMPHOM), 5th Edition, 2009. 
4. OCIMF. Dynamic Torsion Load Tests for Offshore Hoses: An Update to GMPHOM 2009, Section 3.4.10.3, 1st Edition, 2019. 
5. ISO. ISO 16904-2:2024 – Installation and equipment for liquefied natural gas – Design and testing of marine transfer systems – Part 2: Design and testing of transfer hoses. 
6. Amaechi, C. V., Wang, F., Ja’e, I. A., Aboshio, A., Odijie, A. C. & Ye, J. A literature review on the technologies of bonded hoses for marine applications. Ships and Offshore Structures, 17(12), 2819–2850, 2022.
7. Orcina Ltd. OrcaFlex Documentation – Static and Dynamic Analysis of Offshore Systems.
8. Tension Technology International (TTI). OPTIMOOR – Mooring Analysis Software

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