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Exploration & Production

GENERAL SPECIFICATION
PIPELINES - RISERS
GS EP PLR 160

Design, fabrication and testing of subsea umbilicals

05

10/2009

General revision

04

10/2008

General revision

03

10/2007

General revision

02

10/2006

Revised 5.6, 5.20, 6.2.1, App. 1, App. 4

01

10/2005

Revised and rewritten to follow ISO 13628-5 structure Addition of "EP" root to GS identification

00

10/2004

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.

Exploration & Production


Date: 10/2009

General Specification

Rev: 05

GS EP PLR 160

Contents

1. Scope .......................................................................................................................4
2. Reference documents.............................................................................................4
3. Definitions and abbreviations ................................................................................6
3.1

Definitions ..........................................................................................................................6

3.2

Nomenclature and abbreviations .......................................................................................7

4. Applicability and limitations...................................................................................8


4.1

Applicability........................................................................................................................8

4.2

Interfaces with SPS General Specifications ......................................................................8

4.3

Basic principles................................................................................................................10

5. Design brief and deliverables ..............................................................................10


6. Design data............................................................................................................10
7. Design Methodology .............................................................................................10
7.1

General requirements ......................................................................................................10

7.2

Loads ...............................................................................................................................10

7.3

Analyses ..........................................................................................................................11

7.4

Electric cable design........................................................................................................16

7.5

Fibre optic design ............................................................................................................17

7.6

Steel tube design .............................................................................................................17

7.7

Termination interfaces .....................................................................................................19

7.8

Umbilical design...............................................................................................................20

7.9

Ancillary equipment design..............................................................................................22

8. Design Tools..........................................................................................................23
9. Qualification program ...........................................................................................23
9.1

General ............................................................................................................................23

9.2

Samples...........................................................................................................................23

9.3

Qualification procedure....................................................................................................24

9.4

Qualification tests on components...................................................................................24

9.5

Qualification tests on umbilical ........................................................................................25

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General Specification
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9.6

Date: 10/2009
Rev: 05

Qualification tests on ancillary equipment .......................................................................26

10. Manufacturing and testing ...................................................................................27


10.1

General requirements ......................................................................................................27

10.2

Electric cables..................................................................................................................29

10.3

Steel tube manufacturing and welding.............................................................................29

10.4

Terminations interfaces ...................................................................................................32

10.5

Umbilical ..........................................................................................................................32

10.6

Umbilical Factory Acceptance Tests (FATs)....................................................................33

10.7

Ancillary equipment .........................................................................................................33

11. Packaging and load out ........................................................................................34


11.1

Documentation.................................................................................................................34

11.2

Packaging ........................................................................................................................34

11.3

Load out...........................................................................................................................35

12. Operation and maintenance .................................................................................35


Appendix 1

Umbilical data sheet...........................................................................................36

Appendix 2

Guidance for Project Particular Specification (PPS) ..........................................40

Appendix 3

Reeling of small bore tubes ...............................................................................43

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General Specification

Rev: 05

GS EP PLR 160

1. Scope
This General Specification is applicable to the design, procurement, manufacturing and testing
of subsea umbilicals (the load out, transportation and installation are covered by
GS EP PLR 401, GS EP PLR 407 and GS EP PLR 408).
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.
Standards
Reference

Title

ASME Section IX

Code for welding and brazing qualification

ASME Section V

Non destructive methods of examination

ASTM A 370

Standard Test Methods and Definitions for Mechanical Testing of


Steel Products

ASTM A 450

Standard specification for General Requirements for Carbon,


Ferritic Alloy, and Austenitic Alloy Steel Tubes

ASTM E 562

Standard Test Method for Determining Volume Fraction by


Systematic Manual Point Count

DNV-OS-F101

Submarine pipeline systems

DNV-OS-F201

Dynamic risers

EN 473

General principles for qualification and certification of NDT


personnel

EN 10204

Types of inspection documents

EN 10257-2

Zinc or zinc alloy coated non-alloy steel wire for armouring either
power cables or telecommunication cables. Part 2: submarine
cables

ISO 4406

Hydraulic Fluid Power - Fluids - Method for Coding the Level of


Contamination by Solid Particles

ISO 13628-1

Petroleum and natural gas industries - Design and operation of


subsea production systems - Part 1: General requirements and
recommendations

ISO 13628-5

Petroleum and natural gas industries - Design and operation of


subsea production systems - Part 5: Subsea umbilicals

ISO 13628-6

Petroleum and natural gas industries - Design and operation of


subsea production systems - Part 6: Subsea Control Systems

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

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General Specification

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GS EP PLR 160

Reference

Title

ISO 13628-8

Petroleum and natural gas industries - Design and operation of


subsea production systems - Part 8: Design and operation of ROV
interfaces on subsea production systems

ISO/TS 29001

Quality Management Systems - Requirements

SAE AS 4059 E

Cleanliness classification for hydraulic fluids

Professional Documents
Reference

Title

API RP 2RD

Design of Risers for Floating Production Systems (FPSs) and


Tension-Leg Platforms (TLPs)

DNV-RP-C203

Fatigue design of offshore steel structures

DNV-RP-C205

Environmental Conditions and Environmental Loads

DNV-RP-F105

Free Spanning Pipelines

DNV-RP-F109

Stability of submarine pipelines

Regulations
Reference
DNV

Title
DNV Rules for Planning and Execution of Marine Operations

Codes
Reference

Title

Not applicable
Other documents
Reference

Title

Not applicable
Total General Specifications
Reference

Title

GS EP COR 100

Design of cathodic protection of offshore structures

GS EP COR 201

Supply of sacrificial anodes

GS EP COR 221

Three Layer Polypropylene external coating for pipelines

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General Specification

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GS EP PLR 160

Reference

Title

GS EP COR 350

External protection of offshore and coastal structures and


equipment by painting

GS EP COR 560

Physical and chemical treatment of hydrostatic test water

GS EP ELE 765

Subsea Cable

GS EP PLR 001

Documentation requirements

GS EP PLR 002

Organisation of the design works

GS EP PLR 100

Submarine pipeline systems

GS EP PLR 241

Fabrication of Super Duplex stainless steel small bore tubes for


umbilical

GS EP PLR 401

Installation of submarine pipelines

GS EP PLR 407

Load out of submarine cables, umbilical and flexible pipes

GS EP PLR 408

Transportation of submarine cables, umbilical and flexible pipes

GS EP PVV 614

Welding of Duplex and Super Duplex stainless steel

GS EP SPS 002

Design of subsea structures

GS EP SPS 009

Corrosion protection of subsea stations

GS EP SPS 019

Subsea production control system

GS EP SPS 021

Subsea mateable electrical/optical connectors

GS EP SPS 022

Environmental testing of subsea electronics

GS EP STR 301

Fabrication of Offshore steel structures

GS EP TEL 190

Engineering and installation of offshore optical fibres based


telecommunications

3. Definitions and abbreviations


Definitions and abbreviations used in this General Specification are in accordance with the
ISO 13628-5 except otherwise written. Modifications and additional terms are defined below.

3.1 Definitions
COMPANY

Total

SUPPLIER

The Umbilical supplier

The Design

Means all the studies and engineering tasks to be performed


either at a Pre-Project or a Project level as necessary for the
Works

The Project

Means the basic engineering, FEED, detailed engineering and


construction engineering

The Work

Means the construction of the System, including the site

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preparation, the precommissioning


reinstatement works

works,

and

the

site

Particular specification

Any particular specification based on Project requirements and


on instructions for the performance of the works. May be also
referred as job specification

Accumulated Plastic Strain

Sum of plastic strain from each strain cycle during the process
considered (manufacturing, handling, installation)

Dynamic section

Section of umbilical exposed to cyclically varying loads and


deflection during normal operation

Field proven solution

Umbilical system or part of the umbilical system previously


qualified or already in use assuring the giving function in similar
conditions to those of the project

Super Duplex

Refers to 25% Cr Ferritic/Austenitic stainless steel

Tie-in weld

Weld between two reels of components (steel tube, steel rod,


armouring, etc.) during the lay-up process of the umbilical

3.2 Nomenclature and abbreviations


APS

Accumulated Plastic Strain

CP

Cathodic protection

FAT

Factory Acceptance Test

FEED

Front End Engineering Design

FMECA

Failure Mode Engineered Critical assessment

FO

Fibre Optic

FPS

Floating Production System

GTAW

Gas Tungsten Arc Welding Process

HV

Hardness Vickers

ITP

Inspection and test plan

MQC

Multi Quick Coupling

MQP

Manufacturing Quality Plan

NDT

Non Destructive Test

PPS

Project Particular Specification

QCP

Quality Control Plan

QRA

Quantified Risk Analysis

SMYS

Specified Minimum Yield Stress

SCF

Stress Concentration Factor

SPS

Subsea Production System

SUT

Subsea Umbilical Termination

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Sw/OD

Submerged Weight over Outside Diameter ratio

TDP

Touch Down Point

TUT

Topside Umbilical Termination

VIV

Vortex Induced Vibration

WPQ

Weld Process Qualification

WPS

Weld Process Specification

Date: 10/2009
Rev: 05

4. Applicability and limitations


This specification covers the minimum requirements, provides recommendations and guidelines
as well as selects the reference documents for the design, procurement, manufacturing and
testing of subsea umbilical systems.

4.1 Applicability
This specification addresses both static and dynamic application of umbilicals.
This specification applies to subsea control, chemical injection, power, and gas-lift umbilicals.
Workover umbilicals are not covered by the present specification.
Activities addressed include design, procurement, manufacturing and testing which are
summarised as:
Engineering the umbilical structure, internal components and its ancillary equipment (end
terminations, terminations units, buoyancies, etc.), engineering the behaviour of the
umbilical during installation and in service, including defining the riser configuration
Procuring materials, manufacturing, assembling, inspecting, testing and storing all
umbilicals and associated equipment
Verifying that all goods and services to be delivered meet the specified requirements, and
providing adequate documentation.

4.2 Interfaces with SPS General Specifications


The present specification applies to the following components of the umbilical system:
Umbilical and components
Topside termination interface (or Topside hang-off)
Subsea termination interface
Bend restrictors
Bend stiffeners
Pull-in head
Topside electrical pigtail, hydraulic jumpers, hydraulic connectors
Subsea electrical pigtail, hydraulic tubes interface welding
Other ancillary equipment such as buoyancies, stabilisation or crossing features, repair
joints, I-tube seal, etc.

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General Specification

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GS EP PLR 160

Topside umbilical termination (TUT), subsea umbilical termination (SUT), subsea electrical
connectors and junction boxes, subsea hydraulic connectors are covered by GS EP SPS 002,
GS EP SPS 009, GS EP SPS 019, GS EP SPS 021, GS EP SPS 022.
Technical interfaces with above mentioned SPS general specifications shall be considered as
follows, if not specifically addressed through the project specifications:
Electrical/FO junction

Termination (GS EP SPS)

Hydraulic connector

TUT

Topside Umbilical
Termination

Hydraulic connector

Umbilical (GS EP PLR 160)

Topside Umbilical
Termination Interface
(Or Topside hang-off)
Anchoring area
I-tube

Bend stiffener

Topside interfaces

Subsea Umbilical
Termination Interface
Tube welding

Bend restrictor

Anchoring
area

Junction
area
Bolted flange

Umbilical (GS EP PLR 160)

Subsea Umbilical
Termination
Adaptator (if required)

SUT

Electrical/FO
connector

Hydraulic
connector
(MQC plate)

Termination (GS EP SPS)

Subsea interfaces

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4.3 Basic principles


The design, procurement, manufacturing and testing shall be performed according to the
ISO 13628-5, GS EP PLR 100, and GS EP PLR 002. The ISO 13628-5 shall be considered as
the Prime reference for the design, manufacturing and testing for the umbilical.
In addition, this General Specification amends, replaces, or supplements various sections of
ISO 13628-5.

5. Design brief and deliverables


The design of the umbilical system shall be documented in detail. Detailed drawings of the
umbilical cross section and ancillary equipment shall be disclosed.
Design documentation shall be provided according to GS EP PLR 001 and this General
Specification.
Prior to the start of design activities, a design basis shall be submitted to COMPANY for review
and approval.

6. Design data
The information required to design an umbilical is defined in ISO 13628-5 and Appendix 2.
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
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.

7.1 General requirements


The umbilical system shall be designed to withstand the loads induced by manufacturing,
transportation, installation, recovery where appropriated, and operation.
All material used in the umbilical system shall be documented and approved by COMPANY.
If the umbilical system is not a field proven solution, qualifications shall be conducted according
to ISO 13628-5 and this General Specification.
Any parameter of the umbilical system which can not be fully described and ascertained must
be determined by an appropriate test campaign.
All ROV interfaces shall be designed according to ISO 13628-8.

7.2 Loads
All analyses and cross section definition shall take into account the loads encountered during
the whole cycle life of the umbilical.

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ISO 13628-5 requirements shall be satisfied and in addition, special attention shall be paid to:
Loads generated during manufacturing and transpooling
Effect of buoyancy modules and attachments to the umbilical: local additional weight or
buoyancy loads shall be included. Computer models shall represent not only additional
weights but shall model hydrodynamic forces
Effect of additional equipment required for the installation
Hydrodynamic forces: for each wave and current direction, the phase shall be considered
to produce the maximum hydrodynamic horizontal force.

7.3 Analyses
SUPPLIER shall conduct umbilical analyses as per ISO 13628-5 requirements. In addition, the
following requirements shall be adhered:
7.3.1 Risk assessment
The risks shall be assessed in measurable terms - such as from QRA - and in the following
order of precedence: human, environmental, industrial.
This assessment shall be made for manufacture, installation/recovery and operation phases.
The risks shall be evaluated at the earlier phase of the design and shall be re-evaluated in the
course of the design at every occurrence of a significant change in the design conditions. Risk
mitigation measures shall be implemented as necessary.
At the end of the design, it shall be demonstrated that both the safety goals and the functional
requirements have been successfully reached.
7.3.2 Usage factors and capacity
Capacity curves shall be produced for each cross section (tension vs. curvature for a given
internal pressure) for installation and operation phase, with clear indication of limiting
component (e.g. tube, electric cable, etc.).
Maximum allowable stress/strain and usage factor for each component (tube, electric cable,
strength member, sheath, etc.) in installation, in place hydrotest and operation phase shall be
clearly indicated, justified and subject to COMPANY approval.
7.3.3 Structural analysis
Structural analyses of the umbilical shall be conducted in order to provide mechanical
characteristics required for the dynamic analyses and to calculate local stresses in components.
Particular attention shall be taken at the hang-off, sag bend, TDP and anchoring (if any) area.
As a minimum, the following shall be assessed and justified:
Loads distribution (tension, bending, torsion) between the components of the umbilical
Contact and friction loads between components, as well as the friction model used (clear
identification of stick/slip conditions). COMPANY is concerned that such friction loads
affects the fatigue life of the umbilical. Sensitivity studies shall be conducted on the friction
parameter in order to evaluate the impact on loads generated on components

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As a general requirement, any parameter or methodology which is not sufficiently accurately


covered by the design tools (see section 8) shall be subject to sensitivity studies.
7.3.4 Global Analysis
A complete Global Analysis shall be performed for dynamic umbilical.
Global Analysis shall include Dynamic, Interference and Fatigue Analysis.
The Global Analysis shall account for three-dimensional dynamic response, stochastic response
and non-linear effect.
The Design Basis shall present as a minimum:
Main design parameters for the Dynamic Analysis, Interference Analysis & Fatigue
Analysis
Load cases; including sensitivity analysis
Design philosophy
Methodology to be used
Software to be used.
The computer model, assumptions and results shall be fully documented.
The Global Analysis study shall provide as a minimum:
Quick overview of the input data
Independent tables for all the dynamic, interference & fatigue run for each line
Main outputs required to properly design the flexible, i.e. tension range, angle range and
curvature radius range
For each dynamic case, stress level in each component
Utilisation ratio for each component
Cumulated fatigue damage in each component.
7.3.4.1 Dynamic Analysis
The Dynamic Analysis of the umbilicals shall be performed using 3D finite element software
including environmental loads, i.e. waves, current, floating support motions.
The software selected for the analysis must include the axial, bending and torsion effects.
Load classes and load combinations used for Dynamic Analysis shall be in accordance with the
load cases defined and agreed in the Design Basis.
Sufficient parametric studies shall be performed and documented to check the sensitivity of the
analysis results to reasonable variation in input parameters. At least a parametric study on the
period selection and drag coefficients selection shall be conducted.
If simplified load distribution is used in the Dynamic Analysis (regular wave, time domain
analysis); the effect of the dynamic amplification or resonant response in the selection of wave
frequencies shall be evaluated. At least one irregular wave analysis shall be conducted and
compared to a regular analysis for each flexible riser configuration.

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Rev: 05

The significant response parameters which are required from Dynamic Analysis have to include
the following as a minimum:
Umbilicals angles at top side
Maximum and minimum effective tension distribution along the umbilicals
Maximum and minimum curvature along the umbilicals
Clearance between umbilicals and adjacent lines or structures
Angles and tensions at umbilicals extremities to design the bend stiffeners
Loads at bottom of the I-tubes and at subsea connections.
Marine Growth
The effect of the marine growth shall be taken into account (thickness to be applied on the outer
radius) along the flexible risers in the Global Analysis, including in the buoyant section.
The drag coefficients shall be adjusted according to the recommendations provided in
DNV-RP-C205.
Buoyancy modules
The configuration shall be demonstrated to be acceptable with the following buoyancy cases:
Initial buoyancy (as manufactured)
End of life buoyancy (loss of 5% buoyancy on every module / system)
Loss of 10% of buoyancy modules.
7.3.4.2 Interference Analysis
Interference Analysis shall be performed in order to avoid any contact or crossing between
umbilicals and other items, i.e. mooring lines, risers, structures, etc.
A no clashing criteria shall be used to provide details for riser arrangement, hang-off angle and
azimuth separation angles between adjacent risers.
Any possibility of clashing shall be thoroughly studied (energy of impact, location and probability
of occurrence) and shall be submitted to COMPANY for approval.
No interference or clashing is allowed at any time between the flexible riser and mooring lines.
Interference Analysis shall be performed with a configuration assuming that all lines are
installed.
Shield effect of two adjacent lines has to be evaluated and documented. Effect of the shield
may be modelled by adjusting the Cd value as suggested in the API RP 2RD.
SUPPLIER shall define the correct characteristics of the lines, in terms of Sw/OD ratio, stiffness
and length, in order to comply with the above requirements.
7.3.4.3 Fatigue Analysis
Detailed fatigue methodology shall be included in the design basis for COMPANY review and
approval.

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Rev: 05

General requirements
The Fatigue Analysis shall be done with the following input:
Internal Pressure: Max. Operating Pressure.
The fatigue contribution of each fatigue loading shall be determined:
Response to the wave frequency
Response due to low frequency excitation
Response due to vortex shedding.
The Fatigue Analysis shall be verified for the following phases:
Installation with contingencies considered (recovery). Particular attention shall be paid to
the vessel laying system and the TDP. Recommended practices to prevent increased
fatigue at TDP and overboard chute due to suspending installation operations shall be
given
In-place operation with intact mooring. Dedicated studies shall be performed for each
singular point (hang-off, sag, hog, and TDP) of each dynamic umbilical
In-place operation with damaged mooring (1 anchor line broken) for one year. This shall
be used to assess anchorage repair and robustness philosophy of umbilical design.
All components (tubes, electrical cables, armouring, rods, etc.) of the umbilical system shall be
verified for fatigue life.
The effect of residual stress and strain due to manufacturing process, mean stress, SCF,
internal friction between components, corrosion, temperature shall be taken into account.
The umbilicals shall be designed for the specific project service life with a safety factor of 10.
This shall include fatigue damages during component manufacture, umbilical fabrication, loadout, transportation, installation and operation.
Design fatigue curve
The design S-N curve used for the fatigue analysis of each component (tube, electric cable, rod,
etc.) shall be provided and subject to COMPANY approval. The S-N curve shall be qualified
against the following parameters:
Material
Manufacturer
Manufacturing process
Size/diameter
Wall thickness
Presence of a weld
Welding process
Pre-straining cycles according to the manufacturing process and load-out of the
component and umbilical, including contingencies (e.g. weld cut, re-spooling and re-weld).
In case of there is no design fatigue curve qualified against the parameters mentioned above,
fatigue tests shall be conducted.

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Design fatigue curve shall be documented and subject to COMPANY approval.


For welded Super Duplex tubes fatigue design, with a design temperature below 50C,
DNV-RP-C203 2.4.12 umbilical tubes S-N curve shall be used.
In case of operating temperature above 50C fatigue performance of the component shall be
documented and justified.
7.3.5 VIV analysis
The VIV analysis will demonstrate if VIV suppression devices are required for the dynamic part
of the umbilical. If required, they shall be included in the scope of design, supply and
installation.
Structural damping value considered for the analyses shall be justified and subject to
COMPANY approval.
7.3.6 On-bottom stability analysis
The on-bottom stability analysis shall be performed according to DNV-RP-F109.
The umbilical shall be stable on seabed in the following conditions:
Lateral stability due to current and wave
Longitudinal stability due to FPS motions and current.
The soil/umbilical lateral and longitudinal friction factor to be used shall be justified, unless
otherwise specified.
The dynamic section of the umbilical shall not transfer any tension to the SUT; i.e. even in far
conditions, the catenary horizontal tension shall be fully taken by soil friction before the first
SUT. If necessary, additional stabilization of the umbilical or anchoring devices shall be
provided.
7.3.7 Straining during manufacturing, transfer and installation
The level of strain and plastification of umbilical components during manufacturing, transfer and
installation phases shall be evaluated. Reference shall be made to section 7.6.3 for steel tubes.
In case spooling / unspooling operations after fabrication and storage of the umbilical (i.e.
during umbilical transfer, installation) induce plastification of a component, straighteners shall be
used.
7.3.8 Installation analysis
All transport, load transfer, lifting, subsea operations shall be performed according to
DNV Rules for Planning and Execution of Marine Operations.
Installation analysis shall demonstrate that suitable installation equipment (tensioners, pads,
chute, etc.) and procedures will be used to install the umbilical within design criteria. In
particular, load transfer, friction between umbilical components, crushing resistance, friction
between umbilical and pads, loads on termination interfaces and bend restrictors (and other
ancillary equipment) shall be evaluated and accounted for in the installation analysis.
In addition, a recovery analysis shall be performed. Conditions of recovery shall be identified.
The analysis will be conducted in the same way as the installation analysis. The utilisation
factors shall be taken identical to the installation case.

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Rev: 05

7.3.9 Free span analysis


For umbilicals laid on uneven seabed, free span analysis shall be conducted according to
DNV-RP-F105.
7.3.10 Requirement for protection
Additional protection may be required as a result of an accidental load impact assessment (e.g.
trawl gear, anchor line, dropped object, etc.) and such protection method can consist of:
A trenched section, with or without backfilling (natural or artificial)
An untrenched section of pipeline with a gravel dumping or mattress protection.
The assessment of the protection method shall demonstrate:
That the protection will remain in place for the service life, especially under strong sea
state and current conditions
That the generated loads on the umbilical will remain acceptable.

7.4 Electric cable design


7.4.1 General
Electric cable shall be supplied in one length, without any splice.
Depending on the umbilical length, if non feasibility of continuous electric cable is demonstrated,
and if approved by COMPANY, splices may be performed on individual component in static
section. Any repair that may be performed shall be subject to COMPANY approval. Repair
procedure shall be submitted.
In any case, no repair or splice shall be permitted in dynamic section.
7.4.2 Power cables above 3 kV
In addition to ISO 13628-5 and this specification requirements, power cables above 3 kV rating
shall be designed, manufactured as per GS EP ELE 765. Armouring and oversheath
requirements from GS EP ELE 765 may not be adhered to if it is demonstrated that the
surrounding components and the umbilical provide sufficient strength and protection.
The design and lay up of power cables within an umbilical shall consider electrical interference
and thermal effects. As a minimum the following specific analyses shall be conducted:
Electrical interference analyses between all components of the umbilical to demonstrate
that power supply, frequency, transmission data, and electrical equipment (e.g. pump)
functions are not affected.
Thermal analyses along the umbilical, from topside (I-tube) to subsea termination to
demonstrate that temperature will remain acceptable at any point of the umbilical, in
particular with respect to materials and coating systems selected within the umbilical.

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Rev: 05

7.4.2.1 DC conductor resistance


Value of cables DC conductor resistance shall include the followings corrections:
Temperature correction
Lay-up correction, e.g. the lay-up or assembly angle of the cores within a cable will affect
the value of the resistance obtained, i.e. high angle will give a higher resistance because
of the additional length of core/the lay-up of the cables within an umbilical will affect the
value of the core resistance's
Other corrections (e.g. effect of test leads when using a multimeter).
7.4.3 Crosstalk
If unscreened cable is proposed, evidence of a suitable lay-up length to minimize the crosstalk
between pairs/triples/quads to an acceptable level shall be provided.
7.4.4 Cable armouring
In all dynamic sections, electric cables shall be armoured with galvanized steel or aramid yarn
to provide tensile strength and fatigue resistance.
In static and dynamic section, electric cables shall not be exposed in case of damage of the
outer sheath that may occur during transportation and installation. As a minimum electric cables
shall be protected by surrounding metallic components, or fillers.
Galvanised steel armouring shall be performed according to EN 10257-2.
For galvanized steel armouring, grounding shall be detailed to avoid earth loops. Justification
shall be given about avoidance of armour corrosion.
7.4.5 Cable identification
Cables identification and colour coding shall be subject to COMPANY approval.
7.4.6 Interface with termination
The electric cable shall be designed and qualified for use in the connector or distribution box.
Insulation materials (on conductors and as outer sheath) shall be defined so that termination is
easily feasible. The materials selection shall consider also possible heating during potting
operation at the end of the umbilical.

7.5 Fibre optic design


In addition to ISO 13628-5 and this specification requirements, fibre optic shall be designed and
manufactured in accordance with GS EP TEL 190 requirements. The fibre optic shall be
armoured and have an extruded outer sheath.

7.6 Steel tube design


7.6.1 Material
If not specified by COMPANY, the choice of the base tube material shall be subject to
COMPANY approval. Unless otherwise specified in the PPS, tubes shall be seamless Super
Duplex 25% Cr: UNS 32750 (2507 type), UNS 32760 (Zeron 100 type) ASTM, UNS 39274
manufactured according to GS EP PLR 241.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

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GS EP PLR 160

Date: 10/2009
Rev: 05

7.6.1.1 Cleanliness
The umbilical shall be delivered with tubes verified to ISO 4406 class 15/12 (SAE AS 4059 class
6 B-F).
7.6.2 Mechanical design
Hoop stress shall be verified as per ISO 13628-5
Local buckling (Collapse, Ovality, Load combined criteria, Displacement controlled
criteria) shall be verified as per DNV-OS-F201 (for dynamic umbilicals) and DNV-OS-F101
(for static umbilicals), during manufacture, load-out, installation and operation phases. The
safety class shall be considered in accordance with DNV-OS-F101.
For operation design conditions, safety class HIGH shall be considered
Propagating buckling shall only be verified for installation and shall not be considered as a
design parameter.
Calculations shall be performed with extreme external - internal differential pressures. If
not specified, the minimum internal pressure shall be considered at 0 barg (full vacuum)
Contact pressures shall also be considered
Longitudinal and equivalent stress (functional and environmental loads) usage factor shall
not exceed 0.80 in operation.
Fatigue analysis shall be performed as per 7.3.4.3.
Where required by DNV-OS-F201 and DNV-OS-F101, the manufacturing tolerance shall be
taken as the most restricting values occurring during the manufacturing process.
In case of operating temperature above 50C, derating of the SMYS shall be quantified and
justified by the steel tube supplier.
7.6.3 Manufacturing analysis
Reeling / unreeling cycles during manufacturing (including termination integration works),
handling and installation shall be verified against the following criteria:
Strain during manufacturing: accumulated plastic strain and low cycle fatigue calculation.
Axial, bending and torsion strain shall be evaluated and their impact on the weld. It shall
be demonstrated that the following APS criteria are not exceeded during manufacturing,
handling and installation: Maximum allowable total APS level (manufacturing, handling,
installation) is 15%. The maximum allowable plastic strain level on 1 step (reeling or
unreeling) is 2%
Displacement controlled local buckling
Baushinger effect.
7.6.4 Corrosion/erosion protection
The internal corrosion risk shall be assessed for all transported fluids and for other piping fluids
in case of leakage.

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GS EP PLR 160

Date: 10/2009
Rev: 05

Compatibility with transported fluids shall be justified by previous qualification/experience in


comparable conditions or shall be subject to dedicated qualification testing, the programme of
which shall be submitted to COMPANY for approval.
The external corrosion risk, essentially crevice corrosion in seawater, shall be assessed and a
suitable material or coated material shall be selected. The proposed solution shall be submitted
and documented for COMPANY approval.
The tubes shall be separated by a polymer sheath or structure to prevent fretting, galvanic or
crevice corrosion and wear.
For 25Cr duplex stainless steel tubes, a three layer polypropylene coating in accordance with
GS EP COR 221 will be required if the design temperature is above 50C.

7.7 Termination interfaces


7.7.1 General
All steel structure used for SUT interfaces (in seawater) shall be protected against corrosion
according to GS EP SPS 009.
All steel structure used for TUT interfaces (in air) shall be protected against corrosion according
to GS EP COR 350.
All load bearing components (metallic tubes, armour, steel rods, etc.) shall be terminated with
end terminations (topside and subsea) with a minimum loading capacity equal to 1.5 times the
maximum applied load of the umbilical system (in installation or operation, whichever is the
highest).
7.7.2 Pull-in head
The umbilical pull-in head shall allow safe pulling of the umbilical and provide the interface with
the termination head. The pull-in feasibility through the I- or J-tube shall be demonstrated.
The pull-in head shall be easily removable to allow access to tube and cable tails for monitoring
purposes if required.
7.7.3 Topside termination interface
Topside termination interface shall be designed to transfer the umbilical installation and in-place
loads to the hang-off support. Refer to section 4.2 for schematic drawings.
The functional interface shall be as follows, except if otherwise specified:
Above the interface, tubes shall be terminated by hydraulic connectors (including boot
connector ready to be welded / crimped to topside piping). The type of connector shall be
subject to COMPANY approval
As a minimum, 5 m over-length of electric cable/fibre optic cable pigtail shall be provided
above the TUT interface. Each cable shall be sealed to prevent from water ingress at the
design water depth and shall allow connection of pre-commissioning tools. High Voltage
electrical termination shall be subject to COMPANY approval.
For each tube, additional segments of 3 m shall be supplied (length to be confirmed as part of
interface management), to be welded on topside piping (on adaptator piece, if required), and on
the boot connector.

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Rev: 05

GS EP PLR 160

7.7.4 Subsea termination interface


Subsea termination interface shall be designed to transfer the umbilical installation and in-place
loads to the termination structure. Refer to section 4.2 for schematic drawings.
This interface shall be designed with two distinct areas:
An anchoring area, where all load bearing components (armouring, tubes, rods, etc.) are
anchored, in order to transfer the loads to the interface structure. This area shall be
designed so that integrity and performance of every component is maintained
A junction area, where tubes are butt welded with tubes from the SUT. Tubes shall not be
welded in the anchoring area.
The SUT interface is connected to the SUT via a bolted flange.
The SUT Interface shall be equipped with bend limiter to prevent over-bending and kinking of
the umbilical during handling, installation and operation.
The functional interface shall be as follows, except if otherwise specified:
Electrical/fibre optic cables shall be supplied with minimum 5 m over-length after the SUT
interface, ready for connector/penetrator integration
For each tube, additional segments of 2 m shall be supplied (length to be confirmed as
part of interface management), to be welded inside the SUT (on adaptator piece, if
required), and in the junction area.

7.8 Umbilical design


7.8.1 General
The mechanical and material characteristics of the umbilical and its components shall be
provided according to Appendix 1.
All materials in the umbilical shall be compatible with the fluids, with seawater and with the
design temperature of components. In particular, gas lift tubes or power cables can lead to high
temperatures, which may drive polymer materials or coating system selection.
Temperature generated by the environment and by internal components (e.g. power cables, gas
lift tubes) shall be considered for the material selection of every component of the umbilical.
7.8.2 Free flooding
The umbilical shall have a free flooding design for the following reasons:
To pressure balance the umbilical and reduce friction loads for dynamic applications
To avoid air being entrapped that would get overpressure
To allows safe recovery of the umbilical.
Free flooding shall be obtained by holes in the extruded sheathes.
Free flooding requirement, holes spacing, flooding speed shall be assessed and justified.
7.8.3 Torque balance
The umbilical shall be torque balanced and designed to prevent rotation and minimise twisting
at the required loads.

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GS EP PLR 160

Date: 10/2009
Rev: 05

7.8.4 Cathodic protection


Continuity shall be ensured between the tubes, armours, steel members, connectors and to the
CP system. The umbilical and its ancillary equipments (terminations, I-tube, etc.) shall be
designed to be cathodically self protected for the design life, in seawater.
Tubes shall be connected to the CP system:
Topside, the electrical continuity shall be ensured between the tube and steel members of
the umbilical (if any), and with the topside termination, in order to connect the umbilical to
the platform CP system
Subsea, electrical continuity shall be ensured between each tube and the termination
interface flange, in order to connect the umbilical to the manifold/wellhead CP system.
Possible signal interference and corrosion between different materials in the umbilical (e.g.
carbon steel and Super Duplex steel) shall be addressed.
Possible corrosion between different materials in the umbilical (e.g. carbon steel and Super
Duplex steel) shall be addressed.
For termination interfaces, internal cathodic protection of stainless steel tubes shall be as
described in GS EP SPS 009 section 4.2.4.
7.8.5 Cross sectional arrangement
Cross-sectional arrangement shall consider all parameters of the umbilical installation and
operating conditions such as fatigue, crushing resistance, weight/diameter ratio, etc.
No metal to metal contact shall be allowed. All metallic components shall be separated by
coating, cables or polymer profiled shapes.
Solutions with combination of thermoplastic hoses and metallic tubes in the same umbilical are
not allowed.
7.8.6 Strength/weight components
Armouring, steel rods, steel ropes may be added in the umbilical to provide mechanical
strength, weight for stability or dynamic behaviour.
Galvanised steel armouring shall be designed according to EN 10257-2. Armouring layers shall
be separated from the other components by an extruded sheath.
Carbon steel rods and steel ropes shall be coated. The proposed coating shall be subject to
COMPANY approval.
7.8.7 Outer sheath
Outer sheath shall be made of thermoplastic extrusion. No roving shall be used.
Low density Polyethylene is not allowed for outer sheath material.
The umbilical shall be a bright colour (preferably yellow) for easier identification and recovery by
ROV.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

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General Specification
GS EP PLR 160

Date: 10/2009
Rev: 05

7.9 Ancillary equipment design


7.9.1 Bend stiffener
On dynamic applications, at I-tube bottom end, a bend stiffener shall be installed to prevent
overstress of the umbilical or excessive fatigue loading.
The choice of the bend stiffener material shall be made based on its ability to sustain loads, its
compatibility with surrounding fluids and its limited degradation due to ageing.
The bend stiffener shall be made of one continuous composite material. Repairs are not allowed
at any stage during the manufacturing of the bend stiffener.
Prior to being delivered to the FPS, all male parts shall be tested for interface with all female
parts to avoid any pairing requirement.
7.9.2 Bend limiter
A bend limiter shall be used at any transition between the umbilical and a rigid structure (e.g.
termination, transition piece, etc.) to prevent over-bending and kinking of the umbilical during
handling, installation and operation. The bend limiter shall be designed to withstand as a
minimum 1.5 times the maximum load in installation or operation, whichever is the highest.
The choice of material shall be made based on its ability to sustain loads and its limited
degradation due to ageing at operating temperature.
If made of steel, bend limiters shall be cathodically protected.
7.9.3 Buoyancy
Buoyancy modules shall be modelled using densities appropriate to the operating depth and
shall correctly take into account of the mass of mounting clamps and straps.
Buoyancy clamp shall be designed in order to prevent sliding under the maximum load in
installation or operation (whichever is the highest) with a minimum safety factor of 2.
The design and fabrication of buoyancy modules and materials shall meet the following
requirements:
Tri-axial hydrostatic crush pressure on buoyancy materials (incl. syntactic foam, micro /
macro spheres): max depth x 1.75
Loss of buoyancy after 20 years: < 5.0%. The loss of buoyancy shall be documented and
account for loss of volume due to elastic and inelastic compression and water absorption
at design water depth.
7.9.4 Joint box
The joint box shall allow for connection of all tubes, electric cables, optical fibre cables in case
of damage to any or all components of the umbilical. Each side of the joint box shall be
equipped with a bend limiter.
Joint box and associated repair procedures (including tube preparation and welding /
connection) shall be fully qualified and subject to COMPANY approval.

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General Specification
GS EP PLR 160

Date: 10/2009
Rev: 05

8. Design Tools
The design tools i.e. software, spreadsheets and computer models used in the design of
umbilical structure and end terminations 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
9.1 General
The cross-section and components to be manufactured shall be qualified according to this
General Specification and ISO 13628-5, if they are found not to be in compliance with the field
proven definition.
No extrapolation shall be made on the validity of a cross-section design, without COMPANY
approval.
This section provides general qualification requirements for all umbilical system components.
Unless authorized by COMPANY, all qualification programs shall be successfully completed
prior to the start of the manufacturing phase.
Test failures shall be documented and reported to COMPANY. Failure to meet any of the
specified requirements shall require modification of some or all of the design criteria, or the retest of the design. In the event of a re-test, the reason for the failure of the failed sample shall
be included as part of the supporting test documentation. The test in which the sample failed
shall be repeated satisfactorily for three new samples before the design is verified except the
tests including a complete umbilical. In the event of any redesign of the functional component as
a result of a failure, the verification tests shall be repeated in full for the new design before the
design can be verified.
Test report shall be reviewed by Company to determine whether the design is acceptable and
what steps need to be introduced to mitigate any potential problems that may arise when the
umbilical is put into service.
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.

9.2 Samples
Samples for qualification purposes shall be manufactured ahead of the final production, in the
same conditions, according to the same manufacturing and welding procedures and with the
same level of equipment as the final production.
Length to be manufactured shall be decided during detail engineering and submitted to
COMPANY for approval. This length shall not be less than 100m as a base case.

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GS EP PLR 160

Rev: 05

A contingency plan that can take into account redesign and qualification test failure shall be
provided.

9.3 Qualification procedure


A Quality Plan shall be in effect and agreed upon prior to any phase of the qualification.
COMPANY requires acceptance criteria for all qualification tests. A complete document shall be
issued to COMPANY prior to any qualification test, including:
Objective
Methodology and qualification principle
Detail program
Means
Deliverables
Acceptance criteria.
For qualification test that are not prone to an acceptance criteria, a tolerance criteria to which
the result of the test shall comply shall be defined.
For test results that may not fall within the tolerance range, the deviation shall be justified and
the results shall be submitted to COMPANY for approval.

9.4 Qualification tests on components


9.4.1 Electric cables
All verification tests required on electric cables in ISO 13628-5 shall be performed on cables to
be used for umbilical qualification prototype.
9.4.2 Steel tube
Steel tube manufacturing qualification shall be performed as per GS EP PLR 241, unless
otherwise specified in the PPS.
9.4.3 Steel tube fatigue test
If the steel tube is has not been previously qualified against requirements from section 7.3.4.3,
fatigue test shall be performed in order to validate the S-N curve selected.
Each type of tube (material x diameter x thickness x welding procedure) shall be tested
9 samples per type of tube shall be tested: 3 samples per stress range and 3 stress
ranges (100, 200 and 300 MPa)
Each sample shall include a weld performed in accordance with the welding procedure
qualification
All tubes shall have been subject to pre-straining cycles to the maximum allowable APS
specified, prior to fatigue testing (see section 7.6.3)
Tests shall be performed with a mean stress greater than the highest mean stress
calculated
High frequency pulsating test rig can be used (tensile or bending)

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

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General Specification

Rev: 05

GS EP PLR 160

Run out criteria: log Atest = log ADesign + 2 + 1.645 , where is the standard deviation of
the design S-N curve
Acceptance

criteria:

all

log Atest = log ADesign + 2 +

failures

1.645
n

shall

be

live

or

above

target

curve:

, where n is the number of specimen and the

standard deviation of the design S-N curve.


Fatigue test procedure shall be subject to COMPANY approval.

9.5 Qualification tests on umbilical


9.5.1 General
During all qualification tests, continuous monitoring of tubes pressure, electrical cables
insulation resistance or conductance and fibre optics shall be performed.
Fatigue and bending stiffness qualification tests on static sections are not required if fatigue
calculations demonstrate clearly that contingencies allow for recovery of all static section during
installation and sensitivity analyses have been performed during detail engineering on the
bending stiffness parameter.
The following qualification tests are required on the umbilical:
Qualification test

Applicable reference

Tensile test

Section 9.6.1

Bend stiffness test

ISO 13628-5

Crush test

ISO 13628-5

Installation simulation test

Section 9.5.2

Fatigue test

ISO 13628-5 and section 9.5.3

9.5.2 Installation simulation test


The purpose of this test is to demonstrate the suitability of the installation method and
parameters with the umbilical.
This test shall be performed with the pads similar to the ones used for the actual installation
(shape and tracks number). The tension applied shall be related to the length of the tracks used
for the test.
The objective of the test is to determine:
The maximum clamping force to avoid umbilical or components damage (crushing,
tearing, tubes ovalisation)
The minimum clamping force to avoid umbilicals or components slippage at the maximum
installation tension (including contingency cases) with a minimum safety factor of 1.5.
The tests shall be performed in both dry and wet conditions.

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GS EP PLR 160

Date: 10/2009
Rev: 05

Integrity and functionality of electric cables shall be ensured through continuity monitoring
during the tests and resistance / insulation resistance / high voltage DC tests after completion of
the tests.
9.5.3 Dynamic umbilical fatigue test
The dynamic umbilical shall be fatigue tested to a minimum of 1,5 million cycles with an
associated damage equal to 3 times the calculated damage obtained during the fatigue
analyses. Fatigue test loading matrix shall be consistent with fatigue load cases considered
during the design phase and shall be subject to COMPANY approval.
If the fatigue critical location is at hang-off location (bend stiffener area), test shall be performed
with the designed hang-off arrangement (i.e. termination interface and bend stiffener mounted).
All components shall be anchored as per termination interface design at the end of the sample.
The length of the sample shall be minimum 2 pitch length of the most fatigue sensitive tubes in
the umbilical.
If the fatigue critical location is located in another area, a specific test procedure and
arrangement shall be submitted to COMPANY for approval.
Acceptance at the completion of the fatigue test shall be based on the satisfactory performance
of FAT and verification of components integrity. The umbilical shall be stripped and inspected at
identified fatigue sensitive locations (tube inspection, X-Ray or dissection of electric cables,
etc.).

9.6 Qualification tests on ancillary equipment


9.6.1 Load test on termination interface
A load test shall be conducted to qualify each type of termination interface and verify the load
transfer from the umbilical to the termination through the anchoring of components. A load equal
to 1.5 times the maximum applied load on the umbilical system (in installation or operation,
whichever is the highest) shall be applied on the umbilical. This requirement applies as well for
any auxiliary equipment subject to installation or operation loading (hang-off, pull-in head, joint
box, etc.).
During the test, tubes or hoses shall be pressurised to the DWP, electric cables and optical fibre
cable shall be monitored. This test also qualifies the tensile strength and torsional stability of the
umbilical.
9.6.2 Bend limiter capacity test
Each type of bend limiter shall be tested for bending capacity at 1.5 times the maximum load
and angle combination in installation or operation, whichever is the highest.
9.6.3 Buoyancy clamps
The minimal and maximal diameter of the umbilical shall be calculated, taking into account as a
minimum:
Fabrication tolerances
Maximum and minimum tension loads
Maximum and minimum external pressures
Maximum and minimum temperatures.

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Rev: 05

The buoyancy clamp shall be designed (size, inner diameter, clamping load, etc.) for the
minimal and maximal umbilical diameter.
An axial loading test shall be performed on a buoyancy clamp fitted on 2 mandrels (1 with
minimum and 1 with maximum umbilical outer diameter calculated). The mandrels shall be
coated with a material which has lower friction than the umbilical external sheath.
The buoyancy clamp shall be able to withstand an axial load greater than 2 x buoyancy load at
maximum water depth, without any slippage.
In addition, it shall be verified that the clamp will not damage the umbilical by crushing.
9.6.4 Buoyancy modules
Hydrostatic pressure test at 1.5 x the maximum water depth shall be performed on each type of
buoyancy module.

10. Manufacturing and testing


10.1 General requirements
Manufacturing and testing of umbilicals shall be performed according to ISO 13628-5
requirements and this General Specification.
This section defines additional requirements to be satisfied.
Prior to start of the manufacturing activities a manufacturing kick-off meeting shall be organised.
10.1.1 Quality Assurance Requirements
The quality assurance system shall be ISO/TS 29001 compliant and shall be certified. The
Certifying Authority reports and conclusions shall be issued to COMPANY.
COMPANY is concerned by potential deviations between the characteristics of the umbilical and
its components used in the design and the final product resulting from the manufacturing
process. At all levels of the manufacturing process, clear evidence of the compliance of
components, intermediate and final product to the design parameters shall be produced.
Corrective measures shall be undertaken in case of deviation from the design parameters.
10.1.2 Documentation
10.1.2.1 Procurement Plan
Based on the overall delivery schedule, a procurement plan shall be prepared for all materials
required including specific equipment for testing.
The procurement activities shall be co-ordinated and corrective actions initiated in order to
ensure that the requirements of the procurement plan are met.
During the procurement phase, a progress report shall be issued on a regular basis, with
particular emphasis on performance of quality control and acceptance testing.

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General Specification
GS EP PLR 160

Date: 10/2009
Rev: 05

10.1.2.2 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
fabrication process, working procedures and repair procedures to be used during the
fabrication and assembly of the umbilical lengths and associated termination parts
A Control Inspection Plan, defining all inspections, verifications and controls to be carried
out during the fabrication and assembly phases, together with references to the relevant
documents containing the associated acceptance criteria
A Factory Acceptance Testing (FAT) Procedure, defining all tests to be carried out during
the fabrication and assembly phases.
Witness and hold points during fabrication shall be indicated.
The MQP shall be submitted for review, comments and approval by the COMPANY, prior to
start fabrication.
All specific requirements indicated in the sections below shall be included in the MQP and
identified by the code "Client Requirements".
A progress report of the manufactured umbilicals shall be issued on a weekly basis. This report
shall include a list of all the non conformities (internal and external) raised during the
manufacturing of the line.
10.1.3 Certifying Authority
Independent verification agent approved by Company Certifying Authority shall witness and
shall certify the manufacturing of the umbilical.
10.1.4 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.
More generally, 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.
10.1.5 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.
For umbilical lengths, a proper identification system shall be implemented, to ensure that the
umbilical, and section if relevant, can be quickly identified at any time during the fabrication
process.
10.1.6 Control and Inspection
QCP and ITP for each component of the umbilical system shall be submitted to COMPANY for
approval. The fabrication and assembly controls and inspections shall be performed in

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GS EP PLR 160

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Rev: 05

accordance with the QCP and ITP. COMPANY shall be granted unrestricted access to the
fabrication, assembly and/or testing sites, as well as to all documentation and control/inspection
data.
All metallic components of the umbilical (metallic tubes, armouring, rods, etc.) shall have an
inspection certificate level 3.2 according to EN 10204.
To ensure quality and dimensional tolerances (diameter, thickness, length), the following
minimum inspections shall be performed:
During each fabrication phase of the components and the umbilical, the entire length shall
be monitored with an indication and record of any particular points or repairs
Length tolerance for umbilicals shall not exceed -0.0/+1.0% of the required overall length
as previously determined. No negative tolerance shall be accepted.

10.2 Electric cables


10.2.1 General
During manufacturing phases, special care will be taken to the cleanliness of extrusion
machines in order to avoid metallic particles to pollute the dielectric material.
10.2.2 Insulation resistance and High Voltage DC acceptance test
Acceptance of the complete conductor lengths shall be based on the following tests:
Samples of 10 m length shall be extracted from each manufactured batch of insulated
conductor (core) and shall be tested to hydrostatic pressure at maximum service depth. Three
(3) samples shall be taken at the beginning, the middle and the end of each batch. The test
shall be performed in accordance with ISO 13628-5 section 7.7.4 and 7.7.5.
All completed insulated conductor reels shall be tested to a hydrostatic pressure of 3.5 MPa.
A single insulated conductor reel will be tested to hydrostatic pressure at maximum service
depth.
Insulation resistance shall be measured between conductors in the same pair or quad, between
each conductor and the corresponding shield, between shields and electrical cable armour, if
any. This applies also to all subsequent tests required by ISO 13628-5 (e.g. load out tests).

10.3 Steel tube manufacturing and welding


Steel tube manufacturing shall be performed as per GS EP PLR 241, unless otherwise specified
in the PPS.
10.3.1 General
The supplier shall at all times ensure that no contact of the hollows and tubes with any material
leading to contamination such as carbon steel, copper, etc., in order to prevent parent
corrosion.
The dynamic section shall be manufactured without any tie-in weld, i.e. the length of tube on the
lay-up reels shall be sufficient to manufacture one complete umbilical dynamic section.
Welding, inspection and testing procedures, including acceptance criteria related to the tubes
manufacturing and welding shall be submitted to COMPANY for approval.

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GS EP PLR 160

Full traceability of each tube shall be provided to COMPANY. This includes, but shall not be
limited to:
Material
Manufacturing process main parameters
Welding inspection: WPS, WPQ, welding parameters control, non destructive testing
inspection and report, destructive tests on production tests
Weld repairs (cut and re-weld)
Reel used for spooling after welding.
10.3.2 Strain control during manufacturing
Plastic strain imposed on the tubes of the umbilicals shall be subject to COMPANY approval
prior to manufacturing.
As specified in section 7.6.3 the maximum allowable total APS level in metallic component
(manufacturing, handling, installation) is 15%. The maximum plastic strain level in metallic
component on 1 cycle is 2%.
The following general rules shall be applied:
Limitation of number of spooling
Spooling of tubes on as large as possible drum reels
Reels for lay-up machine with as large as possible drums
Use of carousels during manufacturing as much as possible
If tubes are coated, spooling of tubes after welding shall be done on as large as possible
reels that may be different from the reels to be fitted on the lay-up machine.
10.3.3 Welding
Welding qualification and welding of Super Duplex tubes and fittings shall be in accordance with
GS EP PVV 614.
10.3.3.1 Amendments to GS EP PVV 614
All line production welds shall be performed using orbital automated GTAW (Gas
Tungsten Arc Welding) process
Termination end and tie-in welds may be performed using manual GTAW
Welding procedures shall be subject to COMPANY approval before production start
Section 4.1: Use of nitrogen instead of argon as backing gas is acceptable provided that
the same "system" (flow rate, purge arrangement and set-up) is used during welding
procedure qualification test and production
Section 6.2: Stamping of welder or welding operator identification number is not required,
but full traceability (welder identification to weld number) shall be achieved during
production

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Ferrite content in the weld: The ferrite content measurement test shall be based on
ASTM E 562 with content within the range 35% - 65% in the weld. The duplex structure
shall be homogeneously distributed.
10.3.3.2 Welding qualification
WPS shall be subject to COMPANY approval before starting the production.
WPQ shall be made on the project product, with the welding machine(s) of the manufacturer
and on the manufacturing line(s).
10.3.3.3 Welding procedure
All welding and non destructive procedures shall be submitted to COMPANY for approval before
starting the production.
All these documents shall be demonstrated at site manufacturer for COMPANY approval prior to
production start.
10.3.3.4 Production inspection
Welding parameters shall be checked at least one time per shift and per welding machine.
After welding, continuous X-ray inspection by level II minimum inspectors according to EN 473
shall be performed. An independent review of the welds by Level II inspectors according to
EN 473 is required on all welds and shall be completed prior to start of next manufacturing step:
coating of the tube or lay-up.
10.3.4 Tubes delivery and hydrotest
Tubes shall be delivered by tube supplier/manufacturer on reels or straight lengths at umbilical
manufacturing site as per Appendix 3 requirements.
After tube manufacturing, reeling and welding, and before coating or lay-up, a pressure test
shall be performed in accordance with GS EP PLR 241 section 12.1 for a minimum of 4 hours.
All straight tubes lengths shall be pressure tested. For straight tubes smaller than 2OD
(60.3 mm), pressure test may be replaced by EMI. These tubes shall be clearly identified and
marked.
All tubes shall be dried after hydrotest and before tie-in welding.
10.3.5 Coating
The following concerning tube coating shall be documented and subject to COMPANY
approval:
Material
Tube preparation
Size of reels used for spooling the tube
High and low temperature limitations: e.g. if at low temperature the coating crack. The
chosen material shall be compatible with manufacturing, storage, installation and in place
conditions

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GS EP PLR 160

Inspection process for defect of coating arrangement


Repair procedure.
No defect is accepted on the tube.
Coating repair procedure shall take into account the accumulated plastic strain limitations.

10.4 Terminations interfaces


10.4.1 General
Materials selection, fabrication and welding procedures of termination structure shall be
performed in accordance with GS EP STR 301. Amendments to this specification may be
proposed and shall be subject COMPANY approval.
10.4.2 Resin for umbilical termination interface
It shall be ensured that the exothermic reaction during resin curing will not affect the
performance or damage the components.
For each resin / hardener batch, prior to pour the mix in the termination interface piece, tests
shall be conducted in order to ensure the correct mixing, identify maximum curing temperature
and pouring volume steps.
Historic test data shall not be accepted.
10.4.3 Steel tubes tie-in at termination interface
Tube cold bending shall performed in a controlled manner with dedicated equipment, in
accordance with section 7.6.3 requirements.
No socket weld shall be used for tubes tie-in in termination interfaces. Butt weld shall be
required.
Umbilical tubes tie-in welds with SUT tubes shall be performed inside the termination interface,
in a dedicated junction area, after the anchoring area.

10.5 Umbilical
10.5.1 Strength/weight components manufacturing
All metallic strength/weight components shall be:
Welded according to ASME IX
Tested according to ASTM A 370 and ASTM A 450. As a minimum, the following tests
shall be performed: tensile tests, hardness HV5, impact test (at minimum design
temperature, or 0C, whichever is the lowest), side bends (on samples including a weld).
10.5.2 Inner/outer sheath manufacturing
The bundle shall be separated from the inner sheath by polyester (or equivalent) tape or a
polymer structure to prevent from penetration or melting with components during extrusion.
10.5.3 Marking
The complete length shall be marked with a straight line indicating any twisting of the umbilical
when reeled and/or deployed.

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At the extremities all components shall be marked to indicate as a minimum:


Service
Duty rating: design working pressure/voltage
Connectors shall be colour coded.

10.6 Umbilical Factory Acceptance Tests (FATs)


10.6.1 General
Before the FAT, all umbilicals functions shall be clearly identified, marked and functionnaly
tested to avoid any mismatch.
FAT shall be carried out on the umbilical after fitment of terminations, before load-out and, as
required, after loading onto shipping/installation reel or carousel. Some test may be performed
before fitment of termination only if justified and approved by COMPANY. FAT shall be carried
out as per ISO 13628-5.
All performances required in the PPS shall be demonstrated, including the maximum pressure
drop allowed for every tube (as part of the flow test).
10.6.2 Cathodic protection continuity
A test shall be conducted to ensure electrical continuity between metallic components and
terminations. The resistance measured shall not be greater than 0.01 ohm.

10.7 Ancillary equipment


10.7.1 General
During storage and transportation, ancillary equipment (buoyancy modules, bend limiters, bend
stiffeners, etc.) shall be adequately protected against cold/direct sunlight, which may affect their
performances.
10.7.2 Buoyancy modules internal clamps
The following tests shall be conducted at the completion of clamps fabrication:
Acceptance test

Frequency

Density of the clamp body

Every Batch

Mechanical properties of the clamp body, notably tensile strength on


sample

Every Batch

Visual and functional check entire connection system

Every Clamp

Weight in air and in water

Every Clamp

Fit-up test for extreme pipe diameter (min / max)

Every Clamp

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GS EP PLR 160

10.7.3 Buoyancy modules


The following tests shall be conducted during and at the completion of buoyancy modules
fabrication:
Fabrication control / acceptance test

Frequency

Number of macro-spheres/micro-spheres introduced in the mould

Every Module

Pressure on macro-sphere/micro-sphere

Every Batch

Tensile / compressive strength and hydrostatic crush pressure on foam


samples

Every Batch

Weight and water absorption tests on foam samples

Every Batch

Module weight in air

Every Module

Module volume and buoyancy

Every 10 Modules

Fit-up test on standard clamp

Every Module

11. Packaging and load out


11.1 Documentation
Each delivery shall be accompanied by a document containing all necessary information, such
as:
Type and number of reels/carousels
Length of umbilical on each reel/carousel
Terminations, bend restrictors mounted on each reel/carousel
Weight of each reel/carousel
Factory acceptance tests, etc.

11.2 Packaging
Umbilicals shall be delivered packed onto the installation reels or ready for load out onto
installation or transport vessel carousel in the following conditions:
Terminations, bend stiffeners and bend restrictors mounted (or partially for bend
restrictors)
Tubes filled with fluids approved by COMPANY, and pressurized
Pre-load out test completed, including cleanliness check
With monitoring equipment mounted
All electrical cable ends (whether terminated or not) and connectors shall be sealed and
protected from environmental ingress
Non terminated cable ends (e.g. hang-off pigtail) shall be protected with long term caps
designed to the maximum installation depth

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GS EP PLR 160

Rev: 05

Bleed valves shall be mounted at hydraulic connectors at 1 end termination unit for
pressure compensation (fluid expansion due to temperature variation).
As a minimum, reel or carousel packaging shall meet the following requirements:
Reel / carousel sides shall be plated
The umbilicals shall not be exposed to sharp edges
Tension shall be locked in to the umbilical at both ends (drum side and outer layer) by use
of Chinese fingers and chain blocks
Back tension shall be maintained and monitored during reeling
Soft ropes / belts shall not be used for terminations fastening
The umbilicals shall be protected against UV
The umbilicals shall not be reeled one above the other.
On each side of the reels, an identification plate shall indicate:
Place and country of delivery
Job name
Line name or code
Reel number/Total number of reels for the job
Customer name
Contract reference
Diameter and length
Net and gross weights.
All additional equipment shall be adequately protected and properly boxed for delivery. All
boxes shall be properly identified (see above list of indications), and a boxing list shall be
provided.
Accessories and spare parts shall be delivered together with the associated umbilicals.
If the umbilical system is stored following manufacture and FAT for a period in excess of
3 months, additional FAT shall be implemented before load out.

11.3 Load out


Cleanliness of tubes shall be verified after load out of reels or transpooling from carousels,
when the transportation barge or lay vessel is still on the quay.

12. Operation and maintenance


Inspection and maintenance requirements shall be provided.

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GS EP PLR 160

Appendix 1

Appendix 1

Umbilical data sheet

Data sheet to be provided by umbilical manufacturer to COMPANY.


For each umbilical, the following data shall be provided, in SI units.
Umbilical general data
Cross section drawing including dimensions in and tolerances
Umbilical outside diameter

mm

Weight in air empty

kg/m

Weight in air fluid filled

kg/m

Weight in water empty

kgf/m

Weight in water fluid filled

kgf/m

Weight in water fluid filled and flooded

kgf/m

Submerged weight to diameter ratio

N/m/mm

Maximum allowable load under tension (no bending)

kN

Minimum breaking load under tension (no bending)

kN

Maximum allowable crushing load

kN/m

Axial stiffness

kN

Bending stiffness at 20C and 4C

kN.m

Torsion stiffness

kN.m

Minimum bending radius for storage, handling

Minimum bending radius for installation

Minimum bending radius for operation

Capacity curve for installation and operation (tension vs.


curvature)

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Rev: 05

GS EP PLR 160

Appendix 1

Hoses data
Construction

Liner material
Reinforcement material and type
Sheath material

Size

Inside diameter

mm

Number off
Design pressure
Maximum pressure drop allowed at defined flowrate with service
fluid

bar
bar

Metallic tubes data


Material
characteristics

Material
Youngs modulus

MPa

Specified minimum yield strength

MPa

Tensile strength

MPa

Thermal expansion

1/C

Poissons ratio
Size

Inside diameter

mm

Number off

Coating

Nominal wall thickness

mm

Wall thickness manufacturing tolerance

% mm

Design pressure

bar

Material and type

Maximum pressure drop allowed at defined flowrate with service


fluid

bar

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Rev: 05

GS EP PLR 160

Appendix 1

Electrical cables data


Construction

Type
Number off
Conductor size and number of strands (cross
sectional area)

mm

Conductor material
Conductor insulation material
Conductor insulation thickness

mm

Cable outer sheath material


Cable outer sheath thickness

mm

Shield
Braiding
Electrical
characteristics

Voltage rating

kV

Loop resistance @ DC and communication


frequency

/km

Capacitance @ DC and communication


frequency

nF/km

Inductance @ DC and communication


frequency

mH/km

Conductance @ DC and communication


frequency

S/km

Attenuation @ communication frequency

dB/km

Cross talk @ communication frequency

dB/km

Insulation resistance @ 1000 VDC

M.km

Characteristic impedance @ communication


frequency

/km

Optical fibre cable data


Construction

Tube type
Number off
Number of fibres per tube

Characteristics

Mode
Wavelength

nm

Attenuation

dB/km

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GS EP PLR 160

Date: 10/2009
Rev: 05
Appendix 1

Strength/weight component data


Construction

Type (Armouring, rod, rope, etc.)


Number of layers
Directions of windings

Material
characteristics

Size

Material
Youngs modulus

MPa

Specified minimum yield strength

MPa

Tensile strength

MPa

Thermal expansion

1/C

Outside diameter

mm

Number off
Coating

Material and type

Fillers
Type
Material
Density

kg/m3

Extruded sheathes
Type
Material
Thickness

mm

Density

kg/m3

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

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Rev: 05

GS EP PLR 160

Appendix 2

Appendix 2

Guidance for Project Particular Specification (PPS)

The objective of this section is to provide a non exhaustive guideline to COMPANY for the
Project Particular Specification (PPS).
The PPS shall be written as per ISO 13628-5 Annex A requirements. Additional
recommendations and requirements are provided hereunder.

1. Functional specification
Functional diagram, layout and lengths, termination concepts of umbilical system shall be
defined.
The number and size of components in the umbilical shall take into account redundancy
required to satisfy reliability, accessibility and maintainability criteria acceptable for the project.
Functional requirements for each component should be gathered in datasheets as follows:
Tubes/hoses

Service
Material
Inside diameter
Maximum/minimum design pressure at reference level
Maximum/minimum design temperature
Fluid at delivery / in operation
Fluid density
Cleanliness level at delivery

Electrical cable

Duty
Type
Voltage
Cross sectional area
Transmission data (Attenuation, Characteristic impedance,
Capacitance, Inductance, Insulation resistance, Cross talk) at
the required communication frequency (nominal or range)
Shielding requirement

Optical fibre bundle

Duty
Number of fibres
Size
Transmission data (Mode, wave length, transfer rate)

Recommendations for tubes/hoses


Metallic tubes/hoses sizes, pressure shall be determined with respect to subsea control
requirements, flow assurance and pressure drop considerations.

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Appendix 2

The tube type (hose or metallic tube) and material shall be specified by COMPANY with a due
consideration to:
Compatibility with service fluids
Corrosion resistance (metallic tube)
Cleanliness class requirements
Dynamic response requirements (subsea control functionality)
Mechanical strength, fatigue resistance, minimum bend radius, collapse resistance
Weldability (metallic tube)
Overall reliability requirements.
As a base case, Super Duplex Seamless tubes shall be specified.
Fluid at delivery shall be compatible with fluid in operations. To this respect, the fluid shall be
defined in accordance with operations requirements.
Cleanliness class for control lines shall be equal or better than 6BF as per SAE AS 4059.
Cleanliness class for chemical injection (including methanol) lines shall be equal or better than
8BF as per SAE AS 4059 if subsea dosing valves are installed, 10 BF otherwise. As a base
case, the umbilicals shall be delivered with tubes verified to ISO 4406 class 15/12
(SAE AS 4059 class 6 B-F).
Recommendations for electric cables
Electric cable properties shall be defined by subsea equipment requirements.
The need to shielding electrical/communication conductors shall be addressed with respect to
crosstalk requirements and potential triggering of submarine fauna.

2. Environmental data
The following data shall be gathered for analyses, as part of the design basis:
Met-ocean data
Geotechnical and geophysical data
FPS motions characteristics (for dynamic umbilicals)
FPS hang off locations.

3. Spare part requirements


Repair (umbilical / network functionality), maintenance and sparing philosophy shall be defined
for the project, based on a FMECA.
Spare components, equipment and umbilicals, when required, shall be specified.

4. Site integration tests


In addition to ISO 13628-5, and this General Specification, site integration tests should be
required to ensure the installation and functionality of the complete system. The intention is to
demonstrate the physical interfaces between the umbilical, the SUT, the installation rigging, the
manifold, the X-mas tree, the flying leads, the ROV and the connecting tools.

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Date: 10/2009
Rev: 05
Appendix 2

This test should be described in the PPS and should include as a minimum:
Test performed in shallow water
Umbilical short lengths with terminations
Electric, optic and hydraulic connections, according to installation schedule.

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Rev: 05

GS EP PLR 160

Appendix 3

Appendix 3

Reeling of small bore tubes

This appendix is applicable to small bore tube smaller than 2OD (60.3 mm) reeling, prior to
umbilical manufacturing. These requirements shall be read in conjunction with welding
requirements.

1. Protection against contamination


Each reel shall be coated to ensure no contact between tubing and carbon steel (paint is not
sufficient).
Prior to shipment, each reel shall be equipped for outside storage and adequately protected
against pollution, water ingress and potential contact with carbon steel.

2. Reeling conditions
Tubing shall be wound on the reels in uniform even layers at touch pitch (i.e. gaps between
adjacent tubes are not permitted and no additional packaging shall be used between
subsequent layers of tubes). Any reels with unacceptable quality of reeling shall not be
delivered to the umbilical manufacturing site.
Back tension on reel shall be continuously maintained.
All reeling, de-reeling and umbilical fabrication reeling and de-reeling conditions shall not allow
the small bore tube to exceed a plastic bending strain of 2%.
Total accumulated plastic strain (APS) from tube manufacturing up to umbilical installation
(included) shall not exceed 15%.

3. Marking
Each reel shall be identified in legible weather resistant manner with the following information:
Manufacturer name
Company P.O. reference
Company project reference
Reel identification number.

4. Hydrotest
Each tube reel shall be hydrostatically tested in accordance with GS EP PLR 241 section 12.1
for a minimum of 4 hours.

5. Cleaning
Each tube reel shall be cleaned as per the following requirements:
The fluid shall be circulated at the highest achievable velocity commensurate with the
stipulated pressure rating of the tube
The fluid shall be treated in accordance with the requirements of GS EP COR 560

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Appendix 3

The fluid volume shall be displaced a minimum of three times prior to taking samples
Three samples shall be taken and shall be examined and meet ISO 4406 class 15/12
requirements (SAE AS 4059 class 6 B-F).

6. Drying
Each tube reel shall be dried as per the following requirements:
The fluid shall be flushed out of each string or spool
The spool shall be dried with nitrogen at -20C
The spool shall then capped and pressurised to a maximum of 1 Barg
A valve shall be left on one end of the spool for verification of a nitrogen charge
Tubes ends shall be tagged N2 atmosphere 0.7 to 1.0 Barg.
The end of tube string, including plugging valve, shall not exceed the envelope of the reel flange
and the end fitting shall be protected to avoid any damage on the adjacent layer of tube.

7. Documentation
As a minimum the following documents shall be provided for each reel:
Dedicated material testing report
Certificate of conformity
Production log
Factory acceptance tests.

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