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GENERAL SPECIFICATION
PIPELINES - RISERS
GS EP PLR 109
07
10/2009
General review
06
10/2008
General review
05
10/2007
General review
04
10/2006
General review
03
10/2005
02
10/2004
General review
01
10/2003
00
10/2002
First Issue
Rev.
Date
Notes
This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.
Date: 10/2009
GS EP PLR 109
Rev: 07
Contents
1. Scope .......................................................................................................................3
2. Reference documents.............................................................................................3
3. Definitions and abbreviations ................................................................................4
3.1
Definitions ..........................................................................................................................4
3.2
Abbreviations .....................................................................................................................4
7.2
7.3
Loads .................................................................................................................................9
7.4
8. Design Tools..........................................................................................................11
9. Qualification program ...........................................................................................11
10. Certification of the design by a Third Party ........................................................12
11. Manufacturing and testing ...................................................................................12
11.1
11.2
11.3
11.4
Delivery............................................................................................................................17
12.2
12.3
12.4
Appendix 1
Appendix 2
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GS EP PLR 109
Rev: 07
1. Scope
This General Specification is applicable to the design, procurement, manufacturing and testing
of flexible pipes (the installation is covered by the GS EP PLR 401).
Further information on the Scope is provided in section 4 hereof.
2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant appendices
and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT.
In case of conflict with listed data, GS EP PLR 109 shall apply.
Standards
Reference
Title
ISO 13628-2
ISO 9001 or ISO/TS 29001 Petroleum, petrochemical and natural gas industries - Sectorspecific quality management systems - Requirements for product
and service supply organizations
The API SPEC 17J shall be considered as the Prime Reference for the design and construction
of the flexible riser.
Professional Documents
Reference
Title
API RP 2RD
API RP 17B
DNV-RP-F206
Regulations
Reference
Title
Not applicable
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GS EP PLR 109
Rev: 07
Codes
Reference
Title
Not applicable
Other documents
Reference
Title
Not applicable
Total General Specifications
Reference
Title
GS EP EXP 311
GS EP PLR 001
Documentation requirements
GS EP PLR 002
GS EP PLR 100
GS EP PLR 401
GS EP PVV 611
GS EP SAF 337
The space between the internal pressure sheath and the outer sheath.
Bore
3.2 Abbreviations
The following technical definitions and abbreviations are used in this document:
FMECA
BSF
Bend Stiffener
NCR
COC
Certificate of Conformance
PFP
FAT
PPS
Project Specification
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IRC
PT
MBR
UV
MQP
VIV
NCR
PFP
PPS
Project Specification
PT
UV
VIV
Date: 10/2009
Rev: 07
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6. Design data
The information required to design a flexible pipe is defined in the GS EP PLR 100 and the
API SPEC 17J.
The information shall be collected prior to start of design activities and gathered into the design
basis document as required in the GS EP PLR 100 and in the GS EP PLR 001.
7. Design Methodology
Although it is understood that the design of flexible pipe involves an iterative process combining
the selection of material type, grade and thickness for each layer and the definition of the
configuration (static behaviour, dynamic riser: free-hanging, lazy-wave, etc.) it has been decided
to separate the two issues for clarity purposes.
In the following sections, when testing is required, it shall be understood that COMPANY may
relax this requirement if tests have already been conducted in conditions at least as onerous as
the conditions of the project development under consideration. Full details of the test protocol,
test results and justification for the validity of the existing tests to cover the project development
conditions shall be provided to COMPANY for approval.
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Rev: 07
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7.3 Loads
In order to address the requirements from the two previous sections, all analyses and structure
definition shall take into account the loads encountered during the whole cycle life of the flexible
pipe.
Loads cases shall be combined with manufacturing tolerances of the steel and plastic layers.
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8. Design Tools
The design tools i.e. software, spreadsheets and computer models used in the design of flexible
pipe structure and end fittings shall have been validated and calibrated upon small and full scale
tests:
Tests conditions shall cover the design ones
Supportive documentation shall be made available to COMPANY
Design tools shall have been certified by a Certifying Authority approved by COMPANY.
Certificate and associated reports and comments shall be made available to COMPANY.
9. Qualification program
For all flexible pipes under consideration, design and operational condition shall be compared
with qualification program already performed or with field proven track record on similar flexible
structure (cross section, internal diameter, material).
The following aspects of the design shall be addressed:
Bursting performance for pipe sample that includes welds
Hydrostatic collapse performance in straight and bent configuration
Flexible pipe behaviour under tensile and pressure loads
Flexible pipe behaviour under high compressive loads due to hydrostatic pressure or
mechanical compression, combined with cyclic bending
Flexible pipe behaviour under installation loads (contact with gutter under tension and
crushing loads in caterpillar)
Flexible pipe thermal behaviour
Properties and ageing of material, polymers and high strength tapes, used within the
proposed structure under design and operational conditions shall be documented, i.e.
abrasion, creeping, blistering, hydrolysis, crack propagation, etc.
End fitting sealing system shall be demonstrated to be suitable under foreseen conditions
Subsea vent valves performance
Anchoring performance of the tensile armours in the end fitting
Polymer sheath creeping due to hydrostatic or mechanical pressure
Fatigue performance of the pressure and tensile armours.
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When qualification requirements defined in sections 6 and 7 are not satisfied, a detailed
qualification program shall be prepared according to API SPEC 17J, section 6.2 and
ISO 13628-2, section 6.2 and submitted to COMPANY for review and approval.
During the tender phase, supplier shall provide a qualification status report demonstrating the
proposed flexibles are within its qualified range, (design, material and installability), and/or
highlighting the need for further qualification.
This report shall also described the design tools and validation (software and spread sheet).
If scaling of available test data is considered then it shall be submitted to COMPANY for review
and approval.
In all cases, the qualification programs, including test specifications and procedures with
acceptance criteria, shall be submitted to COMPANY for approval prior to the implementation of
the components, materials or technologies in the design.
The resulting qualification reports, reproducing the original qualification program together with
the achieved results, shall be issued to COMPANY as part of the final documentation.
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For approval when the final product will be non conform to the MQP or when a non
qualified repair is proposed. In that case NCR must be approved by COMPANY prior to
starting the next manufacturing phase or the repair.
All NCRs submitted to COMPANY during manufacturing shall be including during the final data
book.
Weekly progress report shall be provided to COMPANY and its representative. The report shall
include, at least:
Procurement progress
Manufacturing progress
List of all NCR issued, with their respective status
Forecast for the coming week.
11.1.2 Documentation
11.1.2.1 Procurement Plan
Based on the overall delivery schedule, a procurement plan shall be prepared for all materials
required including specific equipment for testing.
Specifications for wires and polymer materials procurements shall be provided to COMPANY for
review. Details of the material characteristics (SMYS, UTS, hardness, dimension, chemistry,
folding capacity) and associated tolerances shall be produced.
11.1.2.2 Manufacturing Quality Plan
The Manufacturing Quality Plan (MQP) shall contain as a minimum:
Detailed fabrication and assembly procedures, including a step by step description of the
raw material fabrication, welding, flexible pipes fabrication process and tolerances for all
layers, working procedures and repair procedures to be used during the fabrication and
assembly of the flexible lengths and associated termination parts
A Control Inspection Plan, defining all inspections, verifications and controls to be carried
out prior to start off production i.e. on raw material during the fabrication and assembly
phases, together with references to the relevant documents containing the associated
acceptance criteria
The COMPANY and third party Inspection Points
A Factory Acceptance Testing (FAT) Procedure, defining all tests to be carried out during
the fabrication and assembly phases.
The MQP shall be submitted for review, comments and approval by the COMPANY prior to
fabrication start off.
All specific requirements indicated in the sections below shall be included in the MQP and
identified as "Client Requirements".
11.1.3 Certifying Authority
Independent verification agent approved by COMPANY Certifying Authority shall certify the
flexible line. A Certificate of Conformance (CoC) shall be produced.
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11.1.4 Storage
Detailed storage instructions shall be provided taking into account the nature of the goods and
their vulnerability to high or low temperatures, dust, impact, moisture, light (sunlight), corrosion,
oxidation, magnetism, theft, etc.
The Manufacturer shall be fully responsible for the proper organisation of his warehouses and
stocks, including clear, unambiguous marking of the goods for their identification and location.
All equipment forming part of the final delivery, as well as any component thereof, shall remain
the full responsibility of the Manufacturer until the complete job has been delivered and
accepted.
11.1.5 Traceability
Throughout the fabrication and assembly process, all components shall be clearly identified and
marked with a unique reference code, which must be quoted in all associated documentation. In
particular, when furnace is employed in the manufacturing process of the wires, each coil shall
given a metallically identification tag to maintain traceability.
For flexible lengths, a proper identification system shall be implemented, to ensure that the line,
and section if relevant, can be quickly identified at any time during the fabrication process.
11.1.6 Control and Inspection
The fabrication, assembly controls and inspections shall be performed in accordance with the
Control Inspection Plan approved by COMPANY.
COMPANY site representatives shall have full access to Factory with no restrictions in areas
where Companies product is being Manufactured / Tested / Stored, as well as to all
documentation and control / inspection data.
COMPANY reserves the right for photographs of Non-Conformities, requested by COMPANY
representatives.
Wires manufacturing:
Upon fabrication of the first batch of wires, variations of the mechanical characteristics and
associated SSC/HIC tests shall be determined along the whole length of one coil, i.e. 3 samples
per coil.
For welds produced by the wire manufacturer, variations of the mechanical characteristics and
associated SSC/HIC tests shall be determined by WPS/WPQR.
When furnace is employed for heat treatment, the above variation shall also be established to
capture the influence of coils locations in the furnace, i.e. 3 samples per coil.
All wires shall be checked by Eddy currents and 100% graphically recorded. Calibration
samples shall be machined with defects covering 100% of the wire surface. Inspection report
shall be made available to COMPANY for review.
All recorded Eddy currents indications shall be identified and marked on wires (spray painted).
All welds shall be identified and recorded by permanent marking on the wires. Marking shall be
completed immediately upon welding performance.
When furnace is employed in the manufacturing process, maps of coils locations in the furnace
shall be produced and recorded.
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Upon first coil manufacturing weldability tests shall be performed to ensure mechanical
characteristics and corrosion requirements are satisfied.
Flexible pipe manufacturing:
To ensure quality and dimensional tolerances (diameter, thickness and length), the following
minimum inspections shall be performed:
Continuous measurement of diameters during all stages of fabrication:
- If continuous measurement is not possible, the flexible diameter shall be checked every
10 meters and at shorter intervals in the event of problems or at any COMPANY
representative's request.
Continuous measurement of thickness of the pressure sheath and any other leakproof
sheath.
For subsequent sheaths, continuous measurement shall be carried out at the beginning of
the extrusion process, then discontinuous measurements shall be taken every 10 meters
at four points at 90 (with an offset of 30 between two consecutive series of
measurements)
Electronic files on CD-ROM records shall be included in the as built data documentation.
Measurement of the pitch during wire laying.
During the fabrication phase, the entire length of the various flexible lines shall be
monitored with an indication and record of any particular points or repairs.
No negative tolerance is accepted on the final length..
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GS EP PLR 109
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Vent port that does not meet the above criteria shall be clearly identified by red paint.
11.4 Delivery
11.4.1 Marking
Marking procedure shall be prepared and submitted COMPANY for review and approval at least
6 months prior to delivery. It shall address as a minimum the length marking, identification code
and position of any specific ancillary or feature
11.4.2 Packing
Packing procedure and drawings shall be prepared and submitted COMPANY for review and
approval at least 6 months prior to delivery.
The reel characteristics shall be in accordance with the laying requirements.
The lines shall be reeled under tension and protected against UV. Slack is NOT allowed.
Vent ports shall be obtruded and a label with instructions for fitting shall be applied.
All sections of line in contact with the shipping reel outer edge plates shall be protected.
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Accessories and spare parts (bolts and gaskets) shall be delivered together with the associated
flexible lines.
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To summarize, this manual shall list the main information from the project design data:
Data sheets, design basis, main findings from design reports
Manufacturing data relevant for re-assessment of the risers.
In addition, acceptance criterion for all the measurements from the installed monitoring system
shall be clearly defined in the operating manual.
In case one of this criterion is infringed, the operating manual shall clearly document the
subsequent course of actions. Procedures shall be developed to handle observations outside
acceptance criteria.
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For flexible risers that are pulled in a J or I tube, a visual inspection through a video
camera shall be carried out from the surface. At a minimum, access inside the tube shall
be provided.
A baseline survey shall be completed before the pipe is brought in service as a reference for
condition monitoring and inspection during service.
The detailed features/design of the whole monitoring system shall be submitted to COMPANY
for approval.
12.4.1 Polymer Coupon Monitoring System - for oil and gas risers
A Company polymer specialist shall be involved to determine, during the pre-project phase,
which risers require a polymer coupon monitoring system.
As a minimum, the polymer coupon monitoring system shall consist in:
Polymer coupon samples located in the vicinity (5 m Max) of flexible riser. The associated
detailed specifications for the frequency of the sample removal and the analysis of
collected material (viscosity) shall be defined by the flexible pipe SUPPLIER.
Record of operating temperatures & pressures in the vicinity (5 m Max) of the coupon
holder system shall be completed in conjunction with fluid composition (water) and
injected chemicals.
These data are required for the analysis of the coupon sample.
12.4.2 Annulus Vent Gas Monitoring System - for oil and gas risers
The requirement for Annulus Vent Gas Monitoring System shall be evaluated for all flexible
risers at the pre-project phase and validated by a Company flexible pipe specialist.
Monitoring the gas from the annulus has three objectives:
Validate the diffusion calculation results employed in the design
Monitor and record the vented gas flowrate. This shall help to detect any damage to the
external sheath of the pipe, as any water ingress will induce a sudden change in the gas
flowrate
Monitor and record the composition of the diffused gas. Research for hydrogen in the gas
vented from the annulus shall be carried out to identify damage of the external sheath.
The monitoring system selected for the project under development shall satisfy the three
objectives required above.
In addition, the associated detailed specifications for tests and analysis to be performed with
collected data (for e.g. diffusion calculations, fatigue load verification and re-analysis) shall be
produced.
12.4.3 Annulus Vacuum Testing
In order to investigate the status of the risers annulus and gas drainage system, riser annulus
testing shall be carried out.
Vacuum volume shall be calibrated by performing a volume measurement during the FAT
(Factory Acceptance Test) to establish a baseline.
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A vacuum test shall be completed after Installation to ensure that the external sheath has not
been damaged during installation.
During service, the vacuum test will allow to draw a partial vacuum in the annulus space and to
determine water presence by measuring free volume.
Once test is completed, the vacuum in the annulus is then filled with a pre-defined quantity of
Nitrogen to ensure that dry gas is re-injected.
Detailed procedures for testing at the factory, offshore after installation and in-service shall be
produced. Emphasis shall be made on the reconciliation between the data collected from these
three phases tests to ensure the integrity of the external sheath.
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Appendix 1
Appendix 1
The following topics are Project specific details that shall be specified by the COMPANY in a
dedicated Project Specification (PPS):
Specific thermal requirements
Detailed Pigging requirements
Installation / Pre-com requirements
Depressurisaton Rates
Definition of subsea and topsides types of connection between flexibles and between
flexible and rigid pipes
Definition of the type of connections for jumpers.
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Appendix 2
Appendix 2
The following topics shall be specified, by SUPPLIER, for each manufactured flexible pipe, in a
dedicated Operating Manual:
1. Introduction
Project Name
Geographical zone
Field description
Etc.
2. Abbreviations
3. References
4. Flexible pipes description
Design Service Life
Pipe characteristics
Line Description
Service: Production, Water Injection, Gas Injection, Oil Export, etc.
ID - OD
Structure Supplier Identification Number
Quantity
Length
Application: Static or Dynamic
Sweet or Sour
Design & Operating Pressures
Design & Operating Temperatures
Design Water Depth
MBR for Storage
Weight in air & empty
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Appendix 2
End-fittings
Design Temperature
Material
Type (Grayloc, API flange, etc.)
Size
Gasket
Gas draining (FPU piping, plugs, GRVs, No venting, etc.)
Insulation
Corrosion protection
Ancillary equipments
Bending restrictors
Bending stiffeners
Buoyancy modules
Etc.
As-built documents
Document references
Monitoring systems
Description of each specific systems to monitor the operating conditions of each flexible
pipes
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Appendix 2
6. Operating conditions
Internal fluid operational limits
Temperature and pressure limits (Minimum & Maximum)
Pipe Empty acceptable?
Minimum allowable internal pressure
7. Inspection plan
Description of monitoring systems and inspection plan
Visual inspection
For each inspection tasks and monitoring systems, defined in the GS EP EXP 311:
Recommended frequency
Acceptance criteria for each items and further Actions to be defined.
As an example for the outer sheath:
Item
Acceptance Criteria
- xx mm
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Appendix 2
Acceptance Criteria
Armour annulus not flooded
Acceptance Criteria
No significant wear
Monitoring systems
Minimum requirements for the monitoring systems are listed below. This list shall be amended
at project stage by:
Definition of the items to be monitored
Recommended frequency for each measured items
Definition of the acceptance criterion for the measurements from the monitoring system
In case one of this last criterion is infringed, flexible pipe supplier shall clearly document
the subsequent course of actions.
As an example, for the Polymer coupons monitoring:
Polymer
coupons
Recommended frequency
for coupon retrieval
Comments and
Actions
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Appendix 2
Recommended frequency
of measurement
Flowrate range
Comments and
Actions
Gas
composition
Comments and
Actions
To be amended
End fittings
Specific maintenance requirements
Bending stiffeners
Specific maintenance requirements
Monitoring systems
Specific maintenance requirements
Buoyancy modules
Specific maintenance requirements
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