GS Ep PLR 160 en

GENERAL SPECIFICATION
PIPELINES - RISERS
GS EP PLR 160
Design, fabrication and testing of Subsea Umbilicals
07 10/2012 Section 7.6.4: requirement for coating continuity

General revision: Topside connection, derating for
06 01/2012 temperature, crossing and interference, reel storage and
seafastening
05 10/2009 General revision
04 10/2008 General revision
00 10/2004 First issue
Rev. Date Purpose of the revision
Owning entity: DEV/TEC Managing entity: DEV/TEC/PLR
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party,
reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
General Specification GS EP PLR 160
Rev.: 07 Effective date: 10/2012 Page: 2 of 47
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 ................................................................................... 7

4.1 Applicability ..................................................................................................................... 7
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.......................................................................................................... 18
7.6 Steel tube design .......................................................................................................... 18
7.7 Termination interfaces................................................................................................... 20
7.8 Umbilical design ............................................................................................................ 22
7.9 Ancillary equipment design ........................................................................................... 23
8. Design Tools.......................................................................................................... 24
9. Qualification program ........................................................................................... 25

9.1 General ......................................................................................................................... 25
9.2 Samples ........................................................................................................................ 25
9.3 Qualification procedure ................................................................................................. 25
9.4 Qualification tests on components................................................................................. 26
9.5 Qualification tests on umbilical ...................................................................................... 27
9.6 Qualification tests on ancillary equipment ..................................................................... 28
10. Manufacturing and testing ................................................................................... 29

10.1 General requirements ................................................................................................... 29
10.2 Electric cables ............................................................................................................... 31
10.3 Steel tube manufacturing and welding .......................................................................... 31
10.4 Terminations interfaces ................................................................................................. 34
10.5 Umbilical ....................................................................................................................... 35
10.6 Umbilical Factory Acceptance Tests (FATs).................................................................. 35
10.7 Ancillary equipment ....................................................................................................... 36
11. Packaging and load out ........................................................................................ 37

11.1 Documentation .............................................................................................................. 37
11.2 Packaging of line on reel or carroussel ......................................................................... 37
11.3 Load out ........................................................................................................................ 38
11.4 Real seafastening ......................................................................................................... 38
12. Operation and maintenance ................................................................................. 38

Appendix 1 Umbilical data sheet ........................................................................................ 39
Appendix 2 Guidance for Project Particular Specification (PPS) ........................................ 43
Appendix 3 Reeling of small bore tubes ............................................................................. 46
1. Scope
This General Specification is applicable to the design, procurement, manufacturing, testing, load
out, and transportation of subsea electrical cables and umbilicals. The installation is covered by
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.
External Documents
Unless otherwise stipulated, the applicable version of these documents, including relevant
appendices and supplements, is the latest revision published at the effective date of this
document.
Reference Title
API RP 2RD Design of Risers for Floating Production Systems (FPSs) and
Tension-Leg Platforms (TLPs)
ASME Section IX Code for welding and brazing qualification
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 DNV Rules for Planning and Execution of Marine Operations
DNV-OS-F101 Submarine pipeline systems
DNV-OS-F201 Dynamic risers
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
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 13628 (Parts 5; 8) Petroleum and natural gas industries - Design and operation of
subsea production systems - Parts 5; 8
Reference Title
ISO 4406 Hydraulic Fluid Power - Fluids - Method for Coding the Level of
Contamination by Solid Particles
ISO 9712 Non-destructive testing - Qualification and certification of NDT
personnel
ISO/TS 29001 Quality Management Systems - Requirements
SAE AS 4059 E Cleanliness classification for hydraulic fluids
Total General Specifications

Unless otherwise stipulated, the applicable version of these documents, including relevant
appendices and supplements, is the latest revision published in the applicable yearly collection.
Reference Title
GS EP COR 100 Design of cathodic protection of offshore structures
GS EP COR 221 Three layer polypropylene external coating for pipelines
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 cables
GS EP PLR 001 Documentation requirements
GS EP PLR 002 Organization 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 PVV 614 Welding of duplex and superduplex 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 SPS 029 Metallic Materials for Subsea Production Facilities
GS EP STR 301 Fabrication of offshore steel structures
Reference Title
GS EP STR 401 Loadout, seafastening, transportation and installation of offshore
structures
GS EP TEL 190 Design 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
preparation, the precommissioning works, and the site
reinstatement works
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
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
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.
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)
TUT Hydraulic connector
Hydraulic connector Umbilical (GS EP PLR 160)

Topside Umbilical
Termination
Topside Umbilical
Termination Interface
(Or Topside hang-off)
Anchoring area
I-tube
Bend stiffener
Topside interfaces
Subsea Umbilical
Subsea Umbilical
Termination
Termination Interface
Adaptator (if required)
Tube welding
SUT
Bend restrictor
Anchoring Junction
area area Electrical/FO Hydraulic
connector connector
Bolted flange
(MQC plate)
Umbilical (GS EP PLR 160) Termination (GS EP SPS)
Subsea interfaces
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.
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).. Sensitivity studies shall be conducted on the friction
parameter in order to evaluate the impact on loads generated on components
• Effect of temperature on component shall be assessed for temperature above 50°C and
below -30°C, i.e. mechanical properties de rating, ageing... De rating curve for super
duplex mechanical properties proposed in DNV–OS-F101 or in the DNV–OS-F201 should
not be used. Impact of temperature on tube shall be defined based on testing performed
at similar or higher tube design temperature.
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 umbilical configuration.
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 accordingly and documented. Recommendations
provided in DNV-RP-C205 could be used.
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.
For hydrodynamic calculation, effect of buoyancy elements shall be assessed as per
methodology described in the DNV-RP-C205 section 6.11.
7.3.4.2 Interference Analysis

In any conditions, it is not allowed that umbilical, crosses above or below any other dynamic
lines, i.e. flexible, steel risers, umbilicals and mooring lines
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.
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.
General requirements
The Fatigue Analysis shall be done with the following input:
• Internal Pressure: Max. Operating Pressure.
• Temperature of components along the line for temperature above 50°C.
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 umbilical 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, load-out,
transportation, installation, including one recovery and re installation phase, 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.
Design fatigue curve shall be documented and subject to Company approval.
For welded Super Duplex tubes fatigue design, with a design temperature below 50°C,
DNV-RP-C203 § 2.4.12 umbilical tubes S-N curve shall be used.
In case of operating temperature above 50°C fatigue performance of the component shall be
documented and justified for Company approval. If data are not available or applicable to the
given service, specific test program shall be developed and submitted for approval to Company,
to either derive a new SN curve or knock down factor at the given operating temperature.
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.
Any devices to be added for on bottom stability or loads transfer shall be review and approved
by Company.
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.
In case of presence of buoyancy modules clamped on the umbilical cross section, i.e. lazy wave
configuration, hydrodynamics load induced during deployment phase shall be evaluated, i.e.
slamming, and taken into consideration for the friction clamp design.
7.3.9 Free span analysis

For umbilical 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
Splicing:
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.
Mechanical design:
Elongation within core components shall be calculated considering loading on the cable.
Design criteria for the maximum allowable elongation in the cable shall be documented.
Capacity curve of the umbilical shall be drawn taken into account copper performance.
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.
Ageing is considered to be part of this analysis.
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), manufactured according to GS EP PLR 241.
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

• Mechanical design of the tube shall be performed according 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.
• 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 50°C, 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.
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 50°C.
In case where three layer polypropylene coating is applied, no discontinuity of the coating is
allowed (coated section adjacent to uncoated section) if the temperature is above 30°C.
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:
- For control fluid, tubes shall be terminated by hydraulic connectors (including connector
ready to be welded / crimped to topside piping). The type of connector shall be subject
to Company approval.
- For methanol, manifolding of the tubes inside the termination head with grayloc type
connector for topside connection shall be the base case solution (See graph below).
Other alternate could be proposed for review and approval by Company.
- For gas, hydraulic connectors are forbidden and tubes shall be manifolded inside the
termination head with grayloc type connector for topside connection (See graph below).
• 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.
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.
• Internal tubing of the subsea termination interface shall be designed to allow subsea
inspection by ROV.
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.
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.
Cathodic protection system shall be designed according requirement of the GS EP COR 100.
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 4.2.3, 4.2.4 and 4.3 and GS EP SPS 029 section 7.1.5
and 9.
In case of cold bend super duplex tube, effect of cathodic protection and risk of HIC shall be
assessed by existing documentation or testing, considering tube straining.
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.
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.
Bend limiters shall be made of steel and 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.
Joint box are not allowed on dynamic section.
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 re-
test 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 100 m as a base case.
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 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)
• Run out criteria: log Atest = log ADesign + 2σ + 1.645σ , where σ is the standard deviation of
the design S-N curve
• Acceptance criteria: all failures shall be live or above target curve:

1.645σ
log Atest = log ADesign + 2σ + , where n is the number of specimen and σ the
n
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.
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.
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.
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
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 7.9.9.4 and 7.2.9.5.
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.
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 5: The qualification of welding operators shall be carried out on using base
materials and consumables intended for use in the actual production of the tubing strings.
The equipment used shall be that intended for actual production. Welding operators shall
be qualified on the basis of five (5) welds for each applicable WPS. Macrography
examination shall be carried out on at least one (1) weld.
• 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.
• 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.
• Production tests: Test sampling shall be done before the production weld is performed,
and shall consist of five (5) welds as a minimum, obtained by welding tube samples on the
string in the same condition as the production welds. Only production tubing is to be used
for these tests. The tests required on the samples welds are one tensile test sample, one
macrographie examination and one G48 Test. Prior to the First (1), third (3rd), ninth (9th),
fifteenth (15th) fiftieth (50th) and every one hundredth, production welds, a sample weld
will be made for testing in accordance with the tests detailed above. The samples shall be
traceable to the welder and/or welding operator, as well as each individual tube number.
In case of one test is found not acceptable the sequence should be restarted from the
beginning.
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 made available 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 ISO 9712
shall be performed. An independent review of the welds by Level II inspectors according to
ISO 9712 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 2”OD
(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
• 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.
Historical 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 0°C, 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.
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 Every Batch
sample
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
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 Every Batch
samples
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 of line on reel or carroussel

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
• Bleed valves shall be mounted at hydraulic connectors at 1 end termination unit for
pressure compensation (fluid expansion due to temperature variation).
• For spooling operation or storage at low temperature, effect of temperature combined with
bending on components shall be assessed.
As a minimum, reel or carousel packaging shall meet the following requirements:
• Reel / carousel sides shall be flat
• The umbilical 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.
Reel storage area:
For the reel storage area, a no-flooding area, clean, flat and guarded shall be selected.
Protection shall be retained or restored, in particular protection against exposure to ultra-violet
rays or end fitting protection. Where there is a risk of frost, insulation shall be provided.
Any works requiring high temperature or welding shall be prohibited in the surrounding of reels
without specific protection.
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.
Reels must be handled together with their supporting frame.
11.4 Real seafastening

Reels shall be sea fastened, on deck and in the hold, in such way that the reels are least
affected by the stresses during transportation. The sea fastening shall comply with the
specification GS EP STR 401.
Cables and turnbuckles shall not be used for sea fastening.
The installation and welding of fastenings shall take into account the sensitivity of the line to
temperature and stresses.
12. Operation and maintenance

Inspection and maintenance requirements shall be provided.
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 kg/m
Weight in water fluid filled kg/m
Weight in water fluid filled and flooded kg/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 max, min design and max, min operating kN.m²
temperature
Torsion stiffness kN.m²
Minimum bending radius for storage, handling m
Minimum bending radius for installation m
Minimum bending radius for operation m
Capacity curve for installation and operation (tension vs.
curvature) based on the weakest element of the umbilical cross
section
Appendix 1
Hoses data
Construction Liner material

Reinforcement material and type
Sheath material
Size Inside diameter mm
Number off
Design pressure bar
Maximum pressure drop allowed at defined flowrate with service bar
fluid
Metallic tubes data
Material Material
characteristics
Young’s modulus MPa
Specified minimum yield strength MPa
Tensile strength MPa
Thermal expansion 1/°C
Poisson’s ratio
Size Inside diameter mm
Number off
Nominal wall thickness mm
Wall thickness manufacturing tolerance % mm
Design pressure bar
Coating Material and type
Maximum pressure drop allowed at defined flowrate with service bar
fluid
Appendix 1
Electrical cables data
Construction Type
Number off
Conductor size and number of strands (cross mm²
sectional area)
Conductor material
Conductor insulation material
Conductor insulation thickness mm
Cable outer sheath material
Cable outer sheath thickness mm
Shield
Braiding
Electrical Voltage rating kV
characteristics
Loop resistance @ DC and communication Ω/km
frequency
Capacitance @ DC and communication nF/km
frequency
Inductance @ DC and communication mH/km
frequency
Conductance @ DC and communication μS/km
frequency
Attenuation @ communication frequency dB/km
Cross talk @ communication frequency dB/km
Insulation resistance @ 1000 VDC MΩ.km
Characteristic impedance @ communication Ω/km
frequency
Optical fibre cable data
Construction Tube type

Number off
Number of fibres per tube
Characteristics Mode
Wavelength nm
Attenuation dB/km
Appendix 1
Strength/weight component data
Construction Type (Armouring, rod, rope, etc.)

Number of layers
Directions of windings
Material Material
characteristics
Young’s modulus MPa
Specified minimum yield strength MPa
Tensile strength MPa
Thermal expansion 1/°C
Size Outside diameter mm
Number off
Coating Material and type
Fillers
Type
Material
Density kg/m3
Extruded sheathes
Type
Material
Thickness mm
Density kg/m3
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.
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.
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.
Appendix 3
Appendix 3 Reeling of small bore tubes
This appendix is applicable to small bore tube smaller than 2”OD (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
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 -20°C
• 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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GENERAL SPECIFICATION

Design, fabrication and testing of Subsea Umbilicals

07 10/2012 Section 7.6.4: requirement for coating continuity

Owning entity: DEV/TEC Managing entity: DEV/TEC/PLR

Design, fabrication and testing of Subsea Umbilicals

Rev.: 07 Effective date: 10/2012 Page: 2 of 47

2. Reference documents ............................................................................................. 4

3. Definitions and abbreviations ................................................................................ 6

4. Applicability and limitations ................................................................................... 7

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

6. Design data ............................................................................................................ 10

7. Design Methodology ............................................................................................. 10

9. Qualification program ........................................................................................... 25

Design, fabrication and testing of Subsea Umbilicals

Rev.: 07 Effective date: 10/2012 Page: 3 of 47

9.6 Qualification tests on ancillary equipment ..................................................................... 28

10. Manufacturing and testing ................................................................................... 29

11. Packaging and load out ........................................................................................ 37

12. Operation and maintenance ................................................................................. 38

Design, fabrication and testing of Subsea Umbilicals

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Design, fabrication and testing of Subsea Umbilicals

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Total General Specifications

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3. Definitions and abbreviations

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3.2 Nomenclature and abbreviations

4. Applicability and limitations

Design, fabrication and testing of Subsea Umbilicals

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4.2 Interfaces with SPS General Specifications

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Hydraulic connector Umbilical (GS EP PLR 160)

Umbilical (GS EP PLR 160) Termination (GS EP SPS)

Design, fabrication and testing of Subsea Umbilicals

Rev.: 07 Effective date: 10/2012 Page: 10 of 47

4.3 Basic principles

5. Design brief and deliverables

7.1 General requirements

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7.3.1 Risk assessment

7.3.2 Usage factors and capacity

7.3.3 Structural analysis

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7.3.4 Global Analysis

7.3.4.1 Dynamic Analysis

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7.3.4.2 Interference Analysis

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7.3.4.3 Fatigue Analysis

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7.3.5 VIV analysis

7.3.6 On-bottom stability analysis

Design, fabrication and testing of Subsea Umbilicals