NI-2409

N-2409 ENGLISH AUG / 94

PROPERTY OF PETROBRAS 48 pages

FLEXIBLE PIPE

Specif icat ion

CONTEC Mnadatory requirement is indicated by imperative verbs such as: shall andequivalent expressions like is to...., is required to...., it is required that....,

Comissão de Normas has to....., only.... is permitted and it is necessary... .Recommended practiceTécnicas (not mandatory) is expressed by advisory forms, such as: should and

equivalente expressions like it is recommended that.... or ought to.... .

.

SC - 21 Materials and Equipment

for Oil Drilling andProduction

Suggested revisions of this standard shall be submitted to the respectiveCONTEC subcommission, indicating standard alphanumeric identification,identification of the revision, clause(s) to be revised and technical/economicjustification for the revision. Such proposals will be considered for the nextrevision of the standard

Any decision taken regarding the use of thisstandard is not theresponsability of the CONTEC subcommision. Its concern is with theinterpretation of the contents of this standard.

According to ISO directives a comma is used in the place of a decimalperiod.

Presentation

PETROBRAS Technical Standards Commission (CONTEC) refer directly to theCompany Executive Directory. Is is constituted by a Plenary Assembly (made up of representatives ofSuperintendency Organs users of technical standards), Local Representatives (industrialunits representatives, engineering enterprises, and technical departments), SpecializedSubcommissions - SC (formed by technicians from common engineering area wich representthe users Organs of PETROBRAS standards) and Work Groups - GT’s (formed by specialistson each standard subject). CONTEC objective is to plain, elaborate, approve, divulge and toupdate PETROBRAS technical standards.


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SUMMARY

1 PURPOSE .............................................................................................................. 5

2 COMPLEMENTARY DOCUMENTS....................................................................... 5

3 LIST OF ABBREVIATIONS AND SYMBOLS USED IN THIS SPECIFICATION ... 6

4 DEFINITIONS ......................................................................................................... 74.1 FLEXIBLE PIPE APPLICATIONS ................................................................................................................ 7

4.1.1 Flowline....................................................................................................................................... 74.1.2 Static Flexible Riser ..................................................................................................................... 74.1.3 Dynamic Flexible Riser................................................................................................................ 74.1.4 Jumper......................................................................................................................................... 7

4.2 PIPE LAYERS ......................................................................................................................................... 74.2.1 Structural Layer ........................................................................................................................... 7

4.2.1.1 Carcass................................................................................................................................ 74.2.1.2 Tensile Armor ..................................................................................................................... 74.2.1.3 Pressure Armor.................................................................................................................... 84.2.1.4 Laying Angle....................................................................................................................... 84.2.1.5 Fishscaling .......................................................................................................................... 8

4.2.2 Others.......................................................................................................................................... 84.2.2.1 Pressure Barrier ................................................................................................................... 84.2.2.2 Anti-wear Layer................................................................................................................... 94.2.2.3 Holding Bandage ................................................................................................................. 94.2.2.4 Outer Sheath........................................................................................................................ 94.2.2.5 Insulating Layer................................................................................................................... 94.2.2.6 Thermal Exchange Coefficient - TEC.................................................................................. 9

4.3 PIPE ACCESSORIES................................................................................................................................. 94.3.1 Bend Restricter ............................................................................................................................ 94.3.2 Bend Stiffener.............................................................................................................................. 94.3.3 Buoyancy Device........................................................................................................................ 104.3.4 End Fitting ................................................................................................................................ 104.3.5 Connector .................................................................................................................................. 104.3.6 Termination............................................................................................................................... 104.3.7 Outerwrap.................................................................................................................................. 10

4.4 CONFIGURATIONS AND STATIC POSITIONS OF THE RISER ....................................................................... 104.4.1 Geometrical Configuration of Pipe ............................................................................................. 10

4.4.1.1 Pliant Wave ....................................................................................................................... 104.4.2 Neutral Position ......................................................................................................................... 114.4.3 Far Position ............................................................................................................................... 114.4.4 Near Position ............................................................................................................................. 114.4.5 Offset......................................................................................................................................... 11

4.5 CONSTRUCTIVE TYPES......................................................................................................................... 124.5.1 Rough Bore Flexible Pipe........................................................................................................... 124.5.2 Smooth Bore Flexible Pipe......................................................................................................... 124.5.3 Unbonded Flexible Pipe ............................................................................................................. 12

4.6 QUALITY TERMINOLOGY ..................................................................................................................... 124.7 OPERATING CONDITIONS OF THE FLOATING UNIT ................................................................................. 13

4.7.1 Normal Condition ...................................................................................................................... 134.7.2 Extreme Condition..................................................................................................................... 13

4.8 MECHANICAL LOADS........................................................................................................................... 134.8.1 Design Pressure ......................................................................................................................... 13


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4.8.2 Design External Pressure ........................................................................................................... 134.8.3 Design Tension.......................................................................................................................... 134.8.4 Operating Loads ........................................................................................................................ 134.8.5 Operating Pressure..................................................................................................................... 134.8.6 Operating Tension ..................................................................................................................... 144.8.7 Extreme Loads........................................................................................................................... 144.8.8 Shutdown Internal Pressure........................................................................................................ 144.8.9 Minimum Internal Pressure........................................................................................................ 144.8.10 Pressure Differential ................................................................................................................ 144.8.11 Maximum Pressure Differential ............................................................................................... 144.8.12 Installation and Retrieval Loads ............................................................................................... 14

4.8.12.1 Laying Tension................................................................................................................ 144.8.12.2 Crushing Loads ............................................................................................................... 14

4.8.13 Minimum Bending Radius - MBR............................................................................................ 15

5 DESIGN REQUIREMENTS AND RECOMMENDATIONS.................................... 155.1 GENERAL ............................................................................................................................................ 155.2 FAILURE MODES.................................................................................................................................. 15

5.2.1 Structural Layers........................................................................................................................ 165.2.2 Pressure Barrier ......................................................................................................................... 165.2.3 End Fitting ................................................................................................................................ 175.2.4 Pipe Clogging ............................................................................................................................. 18

5.3 MECHANICAL LOADS........................................................................................................................... 185.3.1 General ...................................................................................................................................... 185.3.2 Operating Loads and Extreme Loads.......................................................................................... 185.3.3 Installation and Retrievel Loads ................................................................................................. 195.3.4 Other Loads ............................................................................................................................... 19

5.4 CONVEYED FLUID AND EXTERNAL ENVIRONMENT ................................................................................ 195.5 GLOBAL ANALYSIS.............................................................................................................................. 20

5.5.1 General ...................................................................................................................................... 205.5.2 Considerations about Internal Forces on Flexible Pipe and Conditions when Laying .................. 215.5.3 Considerations about Internal Forces and Conditions for Installed Pipe...................................... 21

5.5.3.1 Flowlines........................................................................................................................... 215.5.3.2 Static Risers....................................................................................................................... 215.5.3.3 Dynamic Risers on Semisubmersible Units ........................................................................ 225.5.3.4 Dynamic Risers on other Floating Units............................................................................. 225.5.3.5 Dynamic Risers on Fixed Platforms ................................................................................... 22

5.6 THERMAL INSULATION ......................................................................................................................... 225.7 MATERIAL SELECTION AND QUALIFICATION ......................................................................................... 23

5.7.1 General ...................................................................................................................................... 235.7.2 Steels ......................................................................................................................................... 235.7.3 Polymers.................................................................................................................................... 245.7.4 Fibers and Composite Materials ................................................................................................. 245.7.5 Strength Determination of Structural Materials for Design Purpose ........................................... 245.7.6 Materials for Use in Sealing Systems ......................................................................................... 255.7.7 Materials for Use in Buoyancy Modules ..................................................................................... 25

5.8 SAFETY REQUIREMENTS ...................................................................................................................... 255.8.1 Safety Requirements for Structural Layer ................................................................................... 25

5.8.1.1 Safety Factors for Failure Mode of Item 5.2.1.1.................................................................. 255.8.1.2 Safety Factor for Failure Mode of Item 5.2.1.2 ................................................................... 255.8.1.3 Safety Factor for the Failure Mode of Item 5.2.1.3 ............................................................. 265.8.1.4 Safety Factor for the Failure Mode of Item 5.2.1.4 ............................................................. 265.8.1.5 Safety Factor for the Failure Mode of Item 5.2.1.5 ............................................................. 265.8.1.6 Safety Requirement for the Failure Mode of Item 5.2.1.6 ................................................... 265.8.1.7 Safety Requirement for the Failure Mode of Item 5.2.1.7 ................................................... 265.8.1.8 Safety Requirement for the Failure Mode of Item 5.2.1.8 ................................................... 27


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5.8.1.9 Safety Requirement for the Failure Mode of Item 5.2.1.9 ................................................... 275.8.2 Safety Requirements for Pressure Barrier ................................................................................... 27

5.8.2.1 Safety Requirement for the Failure Mode of Item 5.2.2.1 ................................................... 275.8.2.2 Safety Requirement for the Failure Mode of Item 5.2.2.2 ................................................... 275.8.2.3 Safety Requirement for the Failure Mode of Item 5.2.2.3 ................................................... 275.8.2.4 Safety Requirement for the Failure Mode of Item 5.2.2.4 ................................................... 275.8.2.5 Safety Requirement for the Failure Mode of Item 5.2.2.5 ................................................... 285.8.2.6 Safety Requirement for the Failure Mode of Item 5.2.2.6 ................................................... 285.8.2.7 Safety Requirement for the Failure Mode of Item 5.2.2.7 ................................................... 285.8.2.8 Safety Requirement for the Failure Mode of Item 5.2.2.8 ................................................... 285.8.2.9 Safety Requirement for the Failure Mode of Item 5.2.2.9 ................................................... 28

5.8.3 Safety Requirements for End Fitting .......................................................................................... 285.8.3.1 Safety Factors and Requirements for the Failure Mode of Items 5.2.3.1, 5.2.3.2, and 5.2.3.3285.8.3.2 Safety Requirement for the Failure Mode of Item 5.2.3.4 ................................................... 285.8.3.3 Safety Requirement for the Failure Mode of Item 5.2.3.5 ................................................... 295.8.3.4 Safety Requirement for the Failure Mode of Item 5.2.3.6 ................................................... 295.8.3.5 Safety Requirement for the Failure Mode of Items 5.2.3.7, 5.2.3.8, 5.2.3.9, and 5.2.3.10 ... 295.8.3.6 Safety Requirement for the Failure Mode of Item 5.2.3.11 ................................................. 29

5.8.4 Safety Requirement for Pipe Clogging........................................................................................ 295.9 DESIGN VERIFICATION......................................................................................................................... 29

6 ACCESSORIES DESIGN ..................................................................................... 306.1 BEND STIFFNER................................................................................................................................... 30

6.2 Buoyancy Modules........................................................................................................................ 306.3 OUTERWRAP ....................................................................................................................................... 306.4 HANDLING ACCESSORIES FOR INSTALLATION........................................................................................ 31

7 MANUFACTURING AND CONTROL................................................................... 317.1 SPECIAL PROCESSES ............................................................................................................................ 31

7.1.1 Welding..................................................................................................................................... 317.1.1.1 Wires/Strips of Layers ....................................................................................................... 327.1.1.2 End Fittings....................................................................................................................... 327.1.1.3 Outer Sheath...................................................................................................................... 32

7.1.2 Coating...................................................................................................................................... 327.1.3 Non Destructive Examination .................................................................................................... 32

7.2 REPAIRS.............................................................................................ERRO! INDICADOR NÃO DEFINIDO.7.3 PROCESS CONTROL AND CHECKING...................................................................................................... 34

7.3.1 Pipe ........................................................................................................................................... 347.3.2 Manufacturing Tolerances ......................................................................................................... 357.3.3 Polymeric Layers (extrusion)...................................................................................................... 367.3.4 Metallic Layers .......................................................................................................................... 367.3.5 Accessories ................................................................................................................................ 37

7.4 CONTROL OF THE MANUFACTURED PIPE/ACCESSORY............................................................................ 377.4.2 Data Book.................................................................................................................................. 38

8 HANDLING, STORAGE, PACKAGE, INSTALLATION, SERVICING ANDOPERATION ...................................................................................................... 38

9 IDENTIFICATION OF DOCUMENTS ................................................................... 39

ANNEX A - PROCEDURE FOR DYNAMIC GLOBAL ANALYSIS OF FLEXIBLEPIPES .................................................................................................. 40

ANNEX B - QUALIFICATION TESTS ...................................................................... 42


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1 PURPOSE

1.1 Specification applies to submarine high pressure non-bonded flexible pipes, composed oflayers made of polymeric, metallic, fabric or composite materials, used in the offshore oilindustry, for transportation of petroleum and its fractions, in the liquid and/or gaseous phases,and completion fluid as well as for water and gas injection, gas lift, and chemical productsinjection.

1.2 The purpose of this Specification is to establish technical requirements to be met by thesupplier when quoting or supplying flexible pipes and accessories to PETROBRAS (hereinafterreferred to as purchaser). In case of omission, the Complementary Documents shall beadopted.

1.3 This Specification should also be considered when suppliers are developing new flexiblepipe concepts (e.g. using new materials and new wire profiles). However, alternative methodsand criteria may be used for new developments, if previously agreed upon by the parties.

1.4 The concepts included herein may also be used in the evaluation of flexible pipes in serviceor in the evaluation of damaged flexible pipes.

1.5 This Standard is applied to projects begun on the date of its edition.

2 COMPLEMENTARY DOCUMENTS

When applying this standard it is necessary to consult:

API RP 17B - Recommended Practice for Flexible PipeASTM C 177 - Test Method for Steady-State Heat Flux

Measurement and Thermal TransmissionProperties by means of the Guarded-Hot-Plate Apparatus

ASTM C 335 - Test Method for Steady-State HeatTransfer Properties of Horizontal PipeInsulations

BUREAU VERITAS-NI 364 DTO ROO E - Non-Bonded Flexible Steel Pipes used asFlow-Lines

VERITEC - Guidelines for Flexible PipesDNV - Standard for Insurance Warranty Surveys

in Marine Operations - Part 2: RP5-Lifting

NACE MR-01-75 - Sulfide stress cracking resistant metallicmaterials for oil field equipment


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NACE RP-01-75 - Control of internal corrosion in steelpipelines and piping systems

NACE TM-01-77 - Testing of materials for resistance tosulfide stress cracking at ambienttemperature

ISO 8402 - Quality Vocabulary

3 LIST OF ABBREVIATIONS AND SYMBOLS USED IN THISSPECIFICATION

COG - Center of GravityCOM - Center of MotionDAF - Dynamic Amplification FactorH - Wave HightHmax - Maximum Wave HightHs - Significant Wave HightID - Inside DiameterIDi - Inside Diameter of Layer ik - Wave NumberKi - Thermal Conductivity of Layer iMBL - Minimum Breaking LoadMBR - Minimum Bending RadiusNDE - Non Destructive ExaminationOD - Outside DiameterODi - Outside Diameter of Layer iODi+1 -Outside Diameter of Adjacent External LayerRAO - Response Amplitude OperatorRMS - Root Mean SquareSr - Response SpectrumSw - Wave SpectrumSWL - Safe Working LoadT - Wave PeriodTDP - Touch Down PointTEC - Thermal Exchange CoefficientTF - Transfer Functionti - Thickness of Layer iTz - Zero Up Crossing PeriodTLP - Tension Leg PlatformUTS - Ultimate Tensile StrenghtUV - Ultra Violetw - Angular FrequencyYS - Yield Strenght; Yield Pointλλp - Pipe Insulation Thermal Conductivity


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4 DEFINITIONS

4.1 Flexible Pipe Applications

4.1.1 Flowline

Flexible pipe laid on the seafloor or buried, used to link two subsea equipment, subseaequipment to flexible riser or even to interconnect flexible risers.

4.1.2 Static Flexible Riser

Flexible pipe generally used to link a rigid or a flexible pipe on the seafloor level to aproduction plant of a fixed platform, above the surface, passing through an “I” or “J” tube orclamped on the platform structure.

4.1.3 Dynamic Flexible Riser

Flexible pipe generally used to connect a subsea equipment, including pipes, to a floating unitor a fixed platform on the surface or a floating unit to a fixed unit or even two floating units.

4.1.4 Jumper

Short section of flexible pipe. It may need additional design requirements, according to itsapplication, wich are not included within the scope of this specification.

4.2 Pipe Layers

4.2.1 Structural Layer

4.2.1.1 Carcass

Structural layer that gives support to the polymeric pressure barrier. It also withstands, totallyor partially, the external pressure and mechanical crushing loads.

4.2.1.2 Tensile Armor

Structural layer composed of several wires/strips (metallic or not) arranged helically side byside. Usually, the tensile armors are wound in pairs. The tensile armors withstand the axialloads (tension and torsion) applied on the pipe and take, partially or entirely, the internalpressure load.


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4.2.1.3 Pressure Armor

Structural layer that increases the resistance of the flexible pipe to the internal and externalpressure and mechanical crushing loads.

4.2.1.4 Laying Angle

See definition in API RP 17B.

4.2.1.5 Fishscaling

a) For a tensile armor, on a pipe cross section.The angle α between the tangent of the pipe section and the orientation of thewidth, at the centroid of the wires/strips section - See FIGURE 1a;

b) For a presure armor, on a longitudinal pipe section.The angle β between the wires/strips, in its width direction, and the pipe cylindricalgeneratrixat, at the centroid of the wires/strip section - See FIGURE 1b.

-1 a- -1 b-

α

β

FIGURE 1 - FISHSCALING

4.2.2 Others

4.2.2.1 Pressure Barrier

Polymeric layer that makes the pipe leakproof.


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4.2.2.2 Anti-wear Layer

Non metallic layer used to avoid friction between structural layers.

4.2.2.3 Holding Bandage

Strong bandage made of polymeric, fabric or fiber reinforced tape wound around the tensilearmors, compressing and attaching their wires/strips against the pipe body to avoid buckling ofthese wires/strips (birdcaging).

4.2.2.4 Outer Sheath

Non metallic layer used to protect pipe against corrosion, the penetration of sea water, and thetensile armors against abrasion and mechanical damage, and to keep the tensile armors inposition after forming.

4.2.2.5 Insulating Layer

Layer used to increase the thermal insulation of the flexible pipe.

4.2.2.6 Thermal Exchange Coefficient - TEC

This coefficient provides the heat loss (Watts) of 1 m of pipe when subjected to 1°C differencebetween the internal and the external surface of pipe. For multilayer insulation this coefficientis obtained as follows:

TECKi ODi IDi

=∑

2

1

π[( / )ln( / )]

4.3 Pipe Accessories

4.3.1 Bend Restricter

Same as bend limiter; see definition in API RP 17B.

4.3.2 Bend Stiffener

See definition in PAI RP 17B.


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4.3.3 Buoyancy Device

See definition in VERITEC - Guidelines for Flexible Pipes.

4.3.4 End Fitting


4.3.5 Connector


4.3.6 Termination


4.3.7 Outerwrap

Anti-abrasive protection of dynamic risers in the TDP region. It is generally an externalmatallic carcass.

4.4 Configurations and Static Positions of the Riser

4.4.1 Geometrical Configuration of Pipe

Shape of the riser (or flowline, during its installation) which varies according to the distributionof weight and buoyancy along it and to the boundary condition of its extremities. Commonconfigurations as defined in API RP 17B are free hanging, Lazy S, Steep S, Lazy wave, andSteep wave.

4.4.1.1 Pliant Wave

Variation of the lazy wave configuration in wich the displacements of the TDP region arerestricted by dead weight attached to this part of the pipe - See FIGURE 2.


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FIGURE 2 - PLIANT WAVE CONFIGURATION

4.4.2 Neutral Position

Static position of the riser top correspondent to the position of the floating units without theinfluence of winds, currents or waves - See FIGURE 3.

4.4.3 Far Position

Static position of the riser when the floating unit is displaced in the riser plane, in anorientation which causes the maximum stretch of the riser. In such situation riser top is farfrom riser bottom - See FIGURE 3.

4.4.4 Near Position

Static position of the riser when the platform is displaced in the riser plane, in an orientationwhich causes the minimum stretch of the riser. In such situation riser top is near riser bottom -See FIGURE 3.

4.4.5 Offset

Static displacement in relation to the neutral position - See FIGURE 3.


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OFFSET OFFSET

FIGURE 3 - POSITION OF THE RISERS

4.5 Constructive Types

4.5.1 Rough Bore Flexible Pipe

See definition in VERITEC - Guideline for Flexible Pipes.

4.5.2 Smooth Bore Flexible Pipe

See definition in VERITEC - Guideline for Flexible Pipes. It is used for liquid products with nogas, when there is no risk of collapse of pressure barrier.

4.5.3 Unbonded Flexible Pipe

Same as non-bonded Flexible Pipe. See definition in API RP 17B.

4.6 Quality Terminology

The meaning of terms such as special process, traceability, subcontractor, supplier, nonconformity, quality plan, and design verification adopted in ISO series 8402 are valid in thisspecification and in the scope of its application.


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4.7 Operating Conditions of the Floating Unit

4.7.1 Normal Condition

Condition in wich effects such as excessive acceleration or excessive inclination of the floatingunit, that would cause sistem shut, do not occur.

4.7.2 Extreme Condition

Condition in wich the specified limit of the normal condition are exceeded (see item 5.5.3.3).

4.8 Mechanical Loads

4.8.1 Design Pressure


4.8.2 Design External Pressure

Maximum hydrostatic external pressure to which the flexible pipe will be subjected during itslife, which varies according to the maximum water depth specified for the pipe.

4.8.3 Design Tension

Maximum tensile load to which the flexible pipe will be subjected during its life. Generally,flowlines will be subjected to significant tensile loads only during installation. In this case, thedesign tension will be determined by the most critical laying conditions. In case of risers, thedesign tension is the most critical tension for the operating or laying condition.

4.8.4 Operating Loads

Loads imposed on the flexible pipe under normal operating conditions such as, the operatingpressure and the operating tension.

4.8.5 Operating Pressure

See definition in API RP 17B.


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4.8.6 Operating Tension

Maximum tension to which a flexible riser is subjected under normal operating conditions ofthe floating unit.

4.8.7 Extreme Loads

Loads imposed on the flexible riser under extreme conditions.

4.8.8 Shutdown Internal Pressure

Internal pressureof a flexible pipe when the limit enviromental condition is exceeded and theproduction system is shutdown.

4.8.9 Minimum Internal Pressure

Minimum specified internal pressure to which the pipe will be subjected since it is installed(including the installation phase).

4.8.10 Pressure Differential

For a given cross section along the pipe, is the difference between the external pressure and theminimum internal pressure.

4.8.11 Maximum Pressure Differential

Difference between the design external pressure and the minimum internal pressure for a givenpipe cross section.

4.8.12 Installation and Retrieval Loads

4.8.12.1 Laying Tension

Maximum tensile load to which the flexible pipe is subjected during its laying or retrievaloperation.

4.8.12.2 Crushing Loads

Compressive loads imposed during installation and retrieval by laying equipment such astensioners, sheave or chute (or gutter). The effect of these loads may be more critical when thepipe is under tension and subjected to squeezing effect to the tensile armors.


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4.8.13 Minimum Bending Radius - MBR

See definition in API RP 17.

5 DESIGN REQUIREMENTS AND RECOMMENDATIONS

5.1 General

5.1.1 As a general directive, the flexible pipe design shall consider the failure modes describedin 5.2 and include the safety requirement of item 5.8. The feasibility of flexible pipemanufacture, handling, transportation, and installation shall also be considered.

5.1.2 THe failure modes considered are those cuased by chemical, physical or mechanicalagents acting on the pipe. The compatibility of materials considering chemical and physicalagents shall be evaluated by the supplier based on available technical literature or testing,during the early development phase.

5.1.3 Some failures caused by mechanical agents, such as rupture of layers (or yield of endfitting), rupture by fatigue, excessive deformation, collapse, and birdcaging are evaluated afterthe results of the pipe global analysis are available.

5.1.4 Theoretical models for local analysis provide the stress, deformation, and contactpressure valves in layers when pipe is subjected to mechanical loads. An evaluation of failurerisk is performed based on these values.

5.1.5 For other failures modes caused by mechanical agents, such as loss of interlocking,fatigue, wear, polymer extrusion, blistering, relative displacement between pipe layer and endfitting, and damage of end fitting sealing system or resin, theoretical models may not beavailable. In these cases, simplified or empirical formulas, adjusted by tests, should be used. Ifeven empirical formulas are not available , specific tests should be necessary for evaluating thefailure risk.

5.2 Failure Modes

This item defines various modes which lead flexible pipe to failure (defined as the event orunoperable state in wich the pipe or a part of it, does not perform as specified). The failuresdescribed herein do not include those caused by non conformities resulting from manufacturing(of raw material or pipe) or pipe misuse.


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5.2.1 Structural Layers

5.2.1.1 Rupture of any structural layer strip caused by tension (in tensile armor), internalpressure (in tensile armor or pressure armor), radial compression (in carcass or pressurearmor), torsion, curvature or by the combination of some of these loads.

5.2.1.2 Rupture by fatigue of the material constituent of a structural layer.

5.2.1.3 Excessive permanent (or residual) or temporary deformation (axial, radial or torsional)of layer caused by any load.

5.2.1.4 Collapse of carcass or pressure armor caused by external pressure applied on anywaterlight polymeric layer.

5.2.1.5 Collapse of carcass or pressure armor caused by squeezing effect of the tensile armor,associated or not with any other radial compressive load acting on pipe simultaneously.

5.2.1.6 Birdcaging of tensile armor caused by friction between two structural layers.

5.2.1.7 Loss of interlocking of any interlocked structural layer caused by excessive bending,excessive torsion, and “kink” or axial compression during installation or operation.

5.2.1.8 Excessive wear caused by friction between two structural layers.

5.2.1.9 Excessive corrosion, chemical degradation, biological degradation or abrasion of anystructural layer caused by galvanic phenomena, aggressive or abrasive conveyed fluids or bythe external environment in contact with the structural layer.

5.2.2 Pressure Barrier

5.2.2.1 Rupture caused by inner pressure, tension, torsion, bending or by the combination ofsome of these loads.

5.2.2.2 Excessive extrusion of the pressure barrier through the gaps between the wires/stripsof the adjacent structural layer, caused by the pressure effect, for the considered temperaturerange, including the short and long term deformations. The latter is referred to as creepextrusion.


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5.2.2.3 Material rupture by fatigue.

5.2.2.4 Excessive wear caused by friction with other layer.

5.2.2.5 Layer damage due to intermolecular or interlamellar tearing of the material, caused bythe despressurization of diffused gas in the polymeric pressure barrier material (blistering).

5.2.2.6 Excessive chemical degradation caused by the action of the conveyed fluid or externalenvironment.

5.2.2.7 Loss of physical properties caused by the temperature of the inner fluid or externalenvironment.

5.2.2.8 Excessive erosion caused by the conveyed fluid or abrasion caused by pig running(applicable to smooth bore flexible pipe).

5.2.2.9 Excessive gas diffusion caused by ageing, blistering, fatigue/wear, or erosion.

5.2.3 End Fitting

5.2.3.1 Yield of any structural part of the end fitting caused by tension, pressure, bending,torsion or by the combination of some of these loads.

5.2.3.2 Hydrostatic collapse of end fitting structure.

5.2.3.3 Rupture of end fitting structure due to fatigue.

5.2.3.4 Excessive corrosion or chemical degradation of any structural part of the end fittingcaused by the action of the conveyed fluid or external environment.

5.2.3.5 Loss of physical properties of any structural part of the end fitting induced by thetemperature of the inner fluid or external environment (it includes brittleness induced by lowtemperature and stree concentration).

5.2.3.6 Loss of the anchoring system of tensile armors caused by tension, pressure, bending,torsion or by the combination of some of these loads.


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5.2.3.7 Excessive relative displacement between the edges of layers and the end fitting body.

5.2.3.8 Leakage through the sealing system (internal or external) observed when tension,pressure, bending or torsion are applied.

5.2.3.9 Damage of sealing system (internal or external) due to fatigue.

5.2.3.10 Damage of the region of the pressure barrier in contact with the end fitting caused bythe action of tension, pressure, bending, torsion or by the combination of some of these loads.

5.2.3.11 Long or short term degradation of sealing system (internal or external) or filling resincaused by corrosive, chemical, physical agents and temperature of the conveyed fluid orexternal environment.

5.2.4 Pipe Clogging

It may be caused by wax or other organic deposits.

5.3 Mechanical Loads

5.3.1 General

The machanical loads to be considered in the flexible pipe design shall include the followingloads:

a) design pressure;b) design external pressure;c) desgin tension;d) MBR;e) operating loads;f) extreme loads;g) pressure differential;h) maximum pressure differential;i) installation and retrieval loads.

5.3.2 Operating Loads and Extreme Loads

The design shall consider the operating loads, as well as the extreme loads imposed on thepipe.


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5.3.3 Installation and Retrieval Loads

Some loads applied on the flexible pipe during its installation and/or retrieval can be criticaland may, therefore, determine some characteristics of the pipe structure. The supplier shalltaze into consideration all aspects of the installation method, the specific features of thehardware (vessel and laying equipment) and the boundary conditions (environment, waterdepth and sea floor profile). The main loads included in such classification are laying tensionand the crushing loads, as defined in 4.8.12.1 and 4.8.12.2.

5.3.4 Other Loads

Flexible pipes may be subjected to other sources of loads during the phases of manufacturing,handling, transportation or storage. Supplier shall verify if those phases are critical andconsider them in the design.

5.4 Conveyed Fluid and External Environment

5.4.1 The flexible pipe design shall consider the characteristics of the conveyed fluid, andexpected flow conditions as follows:

- Type of fluid (gas, oil, water);- Chemical composition;- Pressure;- pH;- Temperature;- Specific gravity;- Viscosity;- Flow rate and regime;- Thermal properties;- Sand Contents;- Gas oil ratio;- Gas liquid ratio;- Basic sediment and water;- Corrosive agents sucha as:

- bacteria;- carbon dioxide;- chlorides;- hydrogen sulfide;- organic acids;- oxygen;- solids or precipitates;- sulfur bearing compounds;

- Chemical products injected during pipe operation (such as drag reducers inhibitors,demulsifiers).


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5.4.2 The external environment is specified in terms of:

- Sea water salinity;- Sea water temperature;- Air temperature;- UV radiation incidence;- Marine growth occurrence;- Soil characteristics/presence of coral /bottom topography;- Bacteria.

5.5 Global Analysis

5.5.1 General

5.5.1.1 This item presents some requirements and recommendations for determinig theinternal forces and moments (tension, moment/curvature, and torsion) acting on pipe duringinstallation, operation, and extreme condition. These internal forces are used to verify the pipestructure.

5.5.1.2 The global analysis includes the determination of the pipe geometrical configuration tobe analyzed, followed by dynamic simulations of the pipe in that configuration for a set ofconditions. THe geometry of the configuration has to be adjusted in the static or even in thedynamic phase of the analysis, whenever necessary, to avoid interference of the flexible pipewith the floating unit or its mooring lines, lengthwise compression and bending radius lowerthan the MBR.

5.5.1.3 The least complex models accepted for these calculations are based on cablemachanical behavior equations, taking into account the axial and bending stiffness. Thesemodels shall include hydrodynamic simulation of drag and inertial loads caused by regularwaves, currents, and any other source of relative velocity between pipe and fluid, including themovements imposed by the floating units. They shall also take into consideration the effect ofbuoys and anchor blocks attached to the pipe. The friction between the pipe and the seafloorshall be considered on both axial and lateral directions.

5.5.1.4 The model shall have full three dimensional capability to represent the loading, theboundary conditions, the riser configuration and responses.

5.5.1.5 The analysis shall be performed using programs adjusted and improved by comparisonwith other recognized programs or physical tests.

5.5.1.6 An irregular wave analysis in the time domain (to take in account the nonlineardynamic behavior) is preferable. The design wave spectrum shall consider the project locationand the exposure time of pipe.


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5.5.1.7 Annex A presents two other alternative approaches for performing the dynamic globalanalysis. Other methodologies may be used as long as the designer is able to demonstrate theirconsistency and accuracy.

5.5.2 Considerations about Internal Forces on Flexible Pipe and Conditions whenLaying

5.5.2.1 Parameters such as laying angle (top angle), boundary constraints on top (which areboth governed by the type of laying system), internal fluid density, pipe weight, pipe diameter,pipe axial and bending stiffness, MBR, water depth, oceanographic data (currents and waves),and laying vessel movements shall be taken into account when analyzing the laying operation.

5.5.2.2 Once all these parameters are defined, static and dynamic analysis are performed todetermine the most critical internal forces and moments: tension (generally on the top) andmoments/curvature (generally near the TDP or in curved regions due to the presence of buoysor concentrated dead weights).

5.5.2.3 The dynamic analysis shall be performed using one-year return period for theoceanographic loads. A regular sea with currents, waves, and vessel heading taken in the samedirection shall be used, unless otherwise specified. A significant wave (Hs and associatedperiod) is generally accepted.

5.5.2.4 Stability of pipe during laying shall be evaluated by designer considering the ratio“pipe OD/pipe weight” and the specific installation conditions, in order to avoid excessive pipedisplacement due to current effect.

5.5.3 Considerations about Internal Forces and Conditions for Installed Pipe

5.5.3.1 Flowlines

Internal and external pressure are the main mechanical loads acting on flexible flowline underits normal operating conditions. Vibration induced by vortex, in case of pipe free span, shall beevaluated. Pipe on-bottom stability shall be considered as per API RP 17B.

5.5.3.2 Static Risers

Static flexible risers are not subjected to a strong influence of currents, waves, and platformmovements. In the design of such risers, at least, the static weight, buoyancy and curvature(special care shall be taken when detailing the bottom of “J” or “I” tubes) shall be considered.


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5.5.3.3 Dynamic Risers on Semisubmersible Units

Such risers are subjected to quasi-static displacements and dynamic motions. Suchdisplacements are the specified platform offset (both with the mooring system intact ordamaged) due to current, wind and second order wave action. The dynamic top motions aredue to the first order motions of the platform. The riser shall be analyzed for the near and farpositions. The direction and orientation of the waves and currents shall be considered the sameas those of the riser top offset. A set of oceanographic data (waves and currents) and quasi-static offset shall be adopted for the normal condition of the floating unit and another set for itsextreme condition. Unless otherwise specified, the normal condition of the floating unit isassociated with a 10-year return period, and the extreme condition is associated with a 100-year return period. A 1-year current associated with a 10-year wave or vice-versa, whichever isthe worst, may be accepted for the 10-year return period case and a 1-year current associatedwith a 100-year wave or vice-versa, whichever is the worst, may be accepted for the 100-yearcase. Hmax and associated period are required for a regular wave analysis.

5.5.3.4 Dynamic Risers on other Floating Units

Flexible dynamic risers may be used in other types of floating vessels, such as TLP, productionships, and monobuoys. THe behavior of these floating units will differ from that of thesemisubmersible in terms of displacements (offsets) and motions, but the same basicmethodology should be used.

5.5.3.5 Dynamic Risers on Fixed Platforms

The same approach described for the semisubmersible units may be used for dynamic risers onfixed platforms. Special attention shall be given to possible interference between the riser andthe platform structure.

5.6 Thermal Insulation

5.6.1 When thermal insulation characteristics are specified for the pipe, the following itemsshall be considered.

5.6.2 For determining the pipe TEC, the insulation due to metallic layer, as well as the contactresistance between layers shall be disregarded, unless justified by recognized methods. Thethermal conductivity of plastic materials shall be determined as per ASTM C177.

5.6.3 TEC may be determined directly by test as per ASTM C335. From this test, the value ofpipe thermal conductivity - λp is obtained, and the TEC is calculated by the following relation:

TECp OD ID

=2

1

πλ( / )ln( / )


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5.6.4 A value of TEC bellow the one specified shall be guaranteed throughout the pipe servicelife, taking into consideration the reduction of insulating properties due to effects such asreduction of insulating layer thickness (caused by hydrostatic external pressure, crushing,handling loads, or war), water absorption, and ageing.

5.7 Material Selection and Qualification

5.7.1 General

The physical, chemical, mechanical, and performance characteristics of all materials to beapplied in the flexible pipe and accessories shall be verified through a documented qualificationprogram. This program shall confirm the adequacy of each material based on tests results andanalysis which shall demonstrate the materials fitness for use throughout the specified servicelife of the flexible pipe. Testing methods and accpetance criteria should be based oninternationally recognized standards, whenever available. When standards are not available thesupplier may use his own methods/criteria or other ones developed by the raw materialsubcontractor. In all cases such methods/criteria should be correlated with the specific materialapplication on pipe, as provided in the design. For material selection and qualification, thesupplier shall take into account all loads (including cyclic loads), conditions, and agents actingon pipe and accessories during the pipe service line such as those mentioned in items 5.2, 5.3,and 5.4. The qualification of materials by testing shall consider all processes (and theirvariation) adopted to produce the pipe, which may impair the properties and characteristicscalled for by the design. Wear during operation shall also be verified in the qualificationprogram. It includes wear due to friction between two adjacent pipe layers made of anymaterial (e.g. polymer, steel, and fiber) and abrasion of the materials applied on dynamic risers(or on outerwrap) when they are in contact with the seafloor (e.g. in the region of TDP).

5.7.2 Steels

The qualification program shall include a complete evaluation of fatigue, corrosion, and stresscorrosion cracking phenomena on structural layers made of steels. When applicable, therequirements of NACE MR-01-75, RP-01-75 and TM-01-77 shall be considered. Thesusceptibility of steels to brittle fracture shall be investigated, specially in case of those used asstructural parts of end fittings and in which failure induced by low temperature or notch-brittlebehavior can appear during operation. Such materials shall be qualified by notched-bar impacttesting. If structural full penetration welds of these materials are foreseen during the accessorymanufacturing process, a similar investigation shall be carried out in welded samples in orderto qualify the weldig process.


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5.7.3 Polymers

The adequacy of polymers in relation to phenomena such as ageing, fatigue, creep,environmental stress cracking, excessive swelling due to water/oil absorption, UV lightdegradation, excessive wear/abrasion, and blistering shall be verified under the qualificationtests program, as applicable. The ageing phenomenon shall be evaluated considering the agentswhich contribute to the polymer chemical degradation, e.g. conveyed fluid, temperature, andexternal environment, as applicable. Degradation of the pressure barrier material according tothe operating temperature and service life shall be considered. The pressure barrierqualification test program shall also evaluate the creep extrusion phenomenon. The evaluationof pressure barrier resistance to blistering shall include tests which evaluate the influence ofconveyed fluid, pressure, number of decompression cycles, and temperature.

5.7.4 Fibers and Composite Materials

Fibers, matrices using fibers, and composite materials in general used in structural layers shallbe qualified in the final processed condition. Tests shall be performed in order to determine thetensile strength, elastic modules, and Poison’s ratio. Fatigue, creep, and wear shall also beinvestigated by testing.

5.7.5 Strength Determination of Structural Materials for Design Purpose

The determination of mechanical properties based on test results shall be subjected to astatistical approach. It includes the determination of the strength of materials and layers,including welds, as applicable. All possible variations coming from the manufacturingprocesses shall be considered. The determination of any mechanical property shall be obtainedby testing samples of representative lot/batch of material/layer. The value of the property to beadopted by the designer shall be based on the most conservative of the 5% or the 95% of thetest results. The influence of welded wires/strips in structural layer strength shall be evaluatedby testing pipe samples. In such analysis, parameters sucha as decrease of strip resistance, thenumber of wires/strips on layer, and the distance between welds shall be considered whendefining layer strength and manufacturing procedures (e.g. minimum allowable distancebetween welds). Two requirements to be observed when determining the strength of thestructural layers are prescribed below:

a) Guaranteed StrengthWhen the designer is sinzing the structural layers of the pipe, the material strengthvalue (e.g. YS and UTS) adopted shall be that one guaranteed by the raw materialmanufacturer;

b) Increased StrengthIn some cases the designer may consider the resistance of a metallic layer (thecarcass, for example) taking into account the increase in strip/wire strength resultingfrom the manufacture forming processes. In this case, the determination of the layerresistance should be obtained by testing the formed material. Alternatively,mechanical/physical properties of the whole layer may be obtained through test in afirst step, and then converted in terms of layer strength. All possible origins of errorsshall be taken into account.


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5.7.6 Materials for Use in Sealing Systems

The qualification of the sealing system materials and filling resin of the end fitting shall includeverification of chemical and physical degradation of the sealing system considering, asapplicable, agents such as conveyed fluid, external environment and their temperature, andapplied strain/stress. The investigation of the effects of corrosion on metallic materials shall becovered by the qualification program, as applicable.

5.7.7 Materials for Use in Buoyancy Modules

Such materials shall be qualified by tests in order to confirm their resistance to hydrostaticpressure (for the specified water depth) and their performance considering the maximumallowable water absorption called for in the design for the specified service life.

5.8 Safety Requirements

5.8.1 Safety Requirements for Structural Layer

The safety factors presented below are applicable for metallic materials. In case of non-metallicstructural layers, different safety factors may be necessary to keep the same safety level.

5.8.1.1 Safety Factors for Failure Mode of Item 5.2.1.1

a) Operating LoadsStresses caused by combined operating loads (operating tension and operatingpressure) shall be limited to a maximum of 0,50 x UTS and be lower than YS.

b) Non Operating LoadsStresses caused by non operating loads (design pressure, extreme loads, installationand retrieval loads, and other loads - item 5.3.4) shall be limited to a maximum of0,72 x UTS and be lower than YS.

Note: Exceptions may be accepted for radial compression caused by pipe passage throughtensioner or sheave, during installation of pipes with carcass and at least one pressurearmor. In this situation, yield in one of these structural layers may be reached, providedthat the stress(es) on the structural layer(s) do(es) not exceeded 0,72 x UTS, and allother safety requirements be maintained for the deformed pipe (after loada application),specially the requirement of item 5.8.1.4.

5.8.1.2 Safety Factor for Failure Mode of Item 5.2.1.2

Accumulated damage (Miner’s rule) due to fatigue of the structural layer is limited to amaximum 0f 30%, for the specified service life.


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5.8.1.3 Safety Factor for the Failure Mode of Item 5.2.1.3

Maximum permanent deformation for both the longitudinal (caused by initial accomodation,for example) and radial (caused by mechanical compression during installation, for example)directions of pipe shall be limited to 1,0%. Maximum permanent torsional deformation shall belimited to 0,2 degrees/m. Deformations under load shall be limited to a maximum of threetimes the limits defined for permanent deformations.


The maximum pressure differential applied on pipe shall be limited to a maximum of 0,67 ofthe hydrostatic collapse pressure of the carcass or pressure armor, considering the combinedresistance of these structural layers. The external pressure shall be considered acting on themost unfavorable leakproof layer (i.e., outer sheath or any other leakproof layer where externalpressure may act on, in case of water penetration).


The maximum pressure caused by squeezing effect of the tensile armor, associated or not withany other radial compressive load, plus the correspondent pressure differential (acting on themost unfavorable leakproof layer) shall be limited to a maximum of 0,67 of the hydrostaticcollpase pressure of the carcass oe pressure armor considering the combined resistance ofthese structural layers.

5.8.1.6 Safety Requirement for the Failure Mode of Item 5.2.1.6

The riser configuration shall be determined avoiding axial compression (negative effecttension), except when a specific design methodology is available. The same is applicable forpipes during installation. Special pipes should require some kind of protection, such as aholding bandage or an additional thickness of the outer sheath, to avoid damage caused byaxial compression.


Design fo pressure armors and carcass shall take into consideration the shape of the wireprofiles, in order to allow accommodation resulting from deformations (axial, radial, andtorsional), bending, or dimensional variations of innermost layers coming from the allowablemanufacturing tolerances, without loss of interlocking.


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Dynamic flexible pipes shall be designed considering the possibility of thickness reduction dueto wear. In case an anti-wear layer is not used between the tensile armor and the pressurearmor or between two adjacent tensile armor layers, an extra thickness allowance shall beconsidered. A typical value is a 10% thickness increase. Lubricant or thin polymeric layers(wound tape, which functions as lubricant) may reduce wear effect.


Any structural layer which may deteriorate due to the internal or external environment shall becomposed of proper resistant material or be designed with sufficient thickness allowance.When applicable, the requirements and recommendations of NACE MR-0175 and RP-01-75shall be considered. When different metallic materials are used in pipe layers, electricdiscontinuity between these layers shall be guaranteed in order to avoid galvanic corrosion.

5.8.2 Safety Requirements for Pressure Barrier


Pipe design shall establish the maximum allowable radial gaps to limit the pressure barrierdeformation when the design internal pressure is applied. Deformations caused by torsion andbending shall be limited in the design, considering the mechanical characteristics of thematerial.


The ratio referred to as “gap between wires/pressure barrier thickness) shall be properlychosen to avoid barrier extrusion through the gaps of the pressure armor or tensile armor, asapplicable, caused by the internal pressure effect. The chosen ratio referred to as “gap betweenwires/pressure barrier thickness” shall be appropriate so as to avoid extrusion of the pressurebarrier through the gaps of the carcass wires/strips, caused by the external pressure effect.

5.8.2.3 Safety Requirement for the Failure Mode of Item 5.2.2.3Erro! Indicador nãodefinido.

Variations in internal pressure may cause fatigue in the pressure barrier material. Designer shallevaluate this possibility and avoid risks of damage by fatigue, considering the specified servicelife. The established maximum allowable radial gaps (item 5.8.2.1) shall be checked so as toavoid damage to the pressure barrier caused by fatigue.


Designer shall avoid excessive wear in dynamic risers, considering the specified service life.


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Pressure barrier of pipes specified for fluids with gas contents shall be made of materialsresistant to blistering.


The pressure barrier material shall be chemically resistant to the action of the conveyed fluidand external environment for the specified operating temperature range, considering thespecified service life.


The pressure barrier material shall not deteriorate within the specified temperature range,considering the specified service life.


When high erosion or abrasion rates are expected, it shall be considered adding a thicknessallowance.


Excessive gas diffusion shall be avoided throughout pipe service life, considering the possibilityof ageing, blistering, fatigue, wear, or erosion.

5.8.3 Safety Requirements for End FittingErro! Indicador não definido.

5.8.3.1 Safety Factors and Requirements for the Failure Mode of Items 5.2.3.1, 5.2.3.2,and 5.2.3.3

End fittings shall be designed in order to withstand the tension, torsion, pressure and bendingmoments, using the requirements of BUREAU VERITAS NI 364 DTO ROOO E. For nonoperating loads, as defined in item 5.8.1.1, less conservative safety factors may be adopted.Cyclic loads shall be considered for the fatigue calculations. A maximum of 30% accumulateddamage (Miner’s rule) shall be adopted, considering the specified service life.


End fittings shall be designed in order to guarantee that they will not be damaged by corrosionduring their service life, when immersed in sea water or when exposed to marine atmosphere(in case it is installed above sea level). Treatments other than nickel intermolecular diffusionshall be used after proper qualification. Likewise, end fitting internals shall not be corroded ordegraded by inner fluids. When applicable, the requirements and recommendations ofNACE MR-01-75 and RP-01-75 shall be considered.


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End fittings shall be designed considering their performance within the specified operatingtemperature range. When applicable, the requirements of BUREAU VERITAS NI 364 DTOROO E - for end fitting materials shall be considered. When checking the possibility of failureby brittle fracture, attention shall be given to the influence of notches and the state of stress,besides temperature.


Supplier shall make sure, by means of specific tests, that the end fitting conception is notsubjected to such type of failure for all conditions and loads during its service life.

5.8.3.5 Safety Requirement for the Failure Mode of Items 5.2.3.7, 5.2.3.8, 5.2.3.9, and5.2.3.10

All these mechanical failure modes may cause leakage in the end fitting region. To be sure thatthe end fitting concept is safe and not subjected to such type of failures, supplier shall performmechanical tests in the end fitting, simulating all the conditions and loads that may lead the endfitting to these failure modes (in all phases of its life, such as handling, installation, andoperating). Expansion caused by temperature shall be included in such evaluation. End fittingconcept/design shall be suitable for resin filling without allowing voids that could causepressure barrier failure by lack of its support by inner pressure effects.


Specific tests shall be performed to demonstrate that the end fitting sealing system and fillingresin are not subjected to such failures, for the specified service life.

5.8.4 Safety Requirement for Pipe Clogging

When specified, supplier shall guarntee the thermal insulation properties of pipe to avoid pipeclogging, as per item 5.6.4.

5.9 Design Verification

5.9.1 During development or optimization phases, supplier shall verify all models, methods,criteria, and technologies involved in pipe design, by means of prototype tests (includingcorrelation tests for comparison of theoretical and test results), and comparison withalternative calculations. Such verification shall include the investigation of weak points such aswelds, repairs, and process variations.


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5.9.2 Qualification tests are performed on representative samples aiming to demonstrate:

a) The capability of manufacured pipe/accessory to withstand the specified loads andconditions to which it may be subjected during its service life;

b) The capability of the manufacturing process to produce flexible pipes andaccessories, in compliance with design.

5.9.3 Standard qualification tests are defined in Annex B. For a specific pipe, the scope oftests may be adjusted, depending on previous experience with similar pipe or level innovation.

6 ACCESSORIES DESIGN

6.1 Bend Stiffner

6.1.1 The bend stiffner design shall consider the cyclic bending loads expected for theoperating phase. It shall be sized in order to guarantee that it will keep the bending radius ofthe riser within acceptable limits, for the specified service life, under the expected loadingconditions.

6.1.2 It is recommended that the bend stiffner be a single piece, made of polymeric materialresistant to UV light (for the specified service life), reinforced or not by metallic wires.

6.1.3 The bend stiffener shall preferably be clamped to the end fitting. When it is necessary toclamp it directly to the pipe, special attention shall be given to the clamping system design,which shall guarantee the attachment without damaging or overstressing the pipe.

6.2 Buoyancy Modules

They shall withstand the specified external pressure without collapsing or losing negativeweight, by water absorption, for the specified service life. Its assembly system shall allow quickinstallation on board laying vessel. The fixing device of the modules to the pipe shall resistchemical attack and corrosion by sea water, shall not become slack or lose adhesion, and shallnot damage or overstress the pipe.

6.3 Outerwrap

In designing the outerwrap, supplier shall consider the specified soil characteristics, the relativedisplacement between pipe TDP and seafloor, the submerged pipe plus outerwrap weght, andthe abrasion resistance of the outerwrap material.


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6.4 Handling Accessories for Installation

6.4.1 Handling accessories (such as chinese fingers, handling collars, pulling heads, padeyes,shackles, and slings) used during pipe installation shall be designed for the dynamic loadsacting on pipe during the laying process. For determination of SWL a DAF of 1,4 shall be usedunless a greater amplification factor is found in the dynamic analysis. In such case, this newvalue shall be considered.

6.4.2 Chinese fingers, shackles, and slings shall be qualified by load tests. The test shallcontinue until accessory failure. Breaking load shall be greater than MBL, as per DNV -Standard for Insurance Warranty Surveys in Marine Operations - Part 2: RP5 - Lifting.

7 MANUFACTURING AND CONTROL

7.1 Special Processes

The procedures for special processes of manufacturing and control, and the personnel involvedin their execution, shall be qualified. Under the scope of this specification, welding, extrusion,coating, non-destructive examination, and heat treatments are to be considered specialprocesses. Procedures to perform special processes shall define the essential variables (whichinfluence the material properties) as well as their allowable variation ranges. A newprocess/personnel qualification will be required if any modification of these ranges or ofprocess equipment is carried out. The equipment used in the qualification of special processesshall be representative of the producing configuration. In addition, when material is subjectedto tests in order to qualify processes, the samples shall be produced considering all theprocesses which may influence their properties and are involved in the actual manufacturingprocess. The acceptance criteria for such tests shall be in accordance with pipe/accessorydesign and adequate for all pipe application (i.e. handling, storage, installation, and operationphases). In case of tests aiming to evaluate mechanical properties, the value of the property tobe used for evaluating the process adequacy shall be based on the most conservative of the 5%or 95% of the test results.

7.1.1 Welding

When applicable, the tests aiming to qualify such procedures shall include, tension test,bending test, hardness test, micrography (the latter, in case of welding steels), magneticparticle test (or dye penetrant test), and x/gramma ray test (or ultrasonic test).


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7.1.1.1 Wires/Strips of Layers

When internationally recognized standards do not exist as a guide for the welding procedures,the range of essential variables, such as chamical composition and strength of the base material,material thickness or dimension (i.e. wire/strip cross section), heat treatment conditions,welding voltage and amperage, and filler material specifications shall be defined, as applicable.In case of pipes using stainless strip/wire, the effects of corrosion in the weld and in the heataffected zone shall be evaluated.

7.1.1.2 End Fittings

In case of butt-joints, the qualification of the welding procedures to be used in the structuralsteels of end fittings shall also include the evaluation of welds by impact tests, whenever thebase material is susceptible to brittle fracture as mentioned in item 5.7.2.

7.1.1.3 Outer Sheath

Qualification of welding procedures to be used in order to repair the outer sheath of the pipeshall also include the verification of the flexibility and tensile properties of the welded area andof the long term effects UV light, cyclic loads (fatigue), and degradation by seawater. Therepaired area shall have a service life similar to the one specified for the pipe.

7.1.2 Coating

The procedure for qualification of the metallic coating processes to be applied on pipeaccessories shall specify at least the following controls/checks:

a) bath composition;b) control of temperature and time for heat treatments;c) hardness test of coating;d) adhesion test of coating;e) optical microscopy or a similar method recommended to analyze the cross section of

the coated surface;f) coating thickness measurement;g) testing to confirm the resistance of coating to corrosion agents (e.g. seawater and

CO2;h) checking surface coating for flaws.

7.1.3 Non Destructive Examination

Qualification of NDE procedures and of the operators involved in the execution of suchprocedures is mandatory. In case of tests/checking performed by subcontractors, thequalification records shall be included in the data book of the pipe to be supplied.


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7.2 Repairs

7.2.1 When applicable, the investigation of the influence of repairs on pipe/accessoryperformance, including strength or life expectancy, shall be confirmed by testing samples.

7.2.2 When repair procedures involve special processes, the procedures to perform suchprocesses shall be qualified as per item 7.1.

7.2.3 Repair procedures shall define the maximum dimension of the area to be repaired(length, depth, and width), the minimum allowable distance between two adjacent repairs, andall restrictions regarding their use.

7.2.4 Repairs in the pressure barrier layer are not allowed. However, sand blasting ormachining may be carried out in order to eliminate superficial discontinuities or to adjustlocalized excessive thickness, provided that the final thickness complies with the specified layertolerance and that a proper surface finish is assured.

7.2.5 All repairs and inspections performed in repaired areas shall be recorded. Theirtraceability shall be assured.

7.3 Process Control and Checking

7.3.1 Pipe

7.3.1.1 All inspections, tests, and chacking to be performed during the manufacturing processof each pipe and each accessory shall be foreseen in the Quality Plan. Such Plan shall includean Inspection Plan, for each phase of the pipe/accessory manufacture, defining the applicableexamination/testing procedures, the correspondent acceptance criteria, the part/portion to bechacked, the sampling plans, and the documents to be issued in order to record/certify qualitycharacteristics.

7.3.1.2 During manufacturing, the dimensions of each pipe layer shall be measured, at least, atevery 10 m of layer length. The measurements performed in each pipe layer shall be taken atthe same pipe transversal cross section. A maximum error of ± 10 cm in the pipe cross sectionlocation is acceptable.

7.3.1.3 The frequency mentioned above (i.e. measurement at every 10 m of layer length) maybe reduced, if the supplier, based on records sucha as control charts and previous experience inmanufacturing similar pipe, demonstrates that the procedures adopted to control the processesare adequate.


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7.3.1.4 The manufacturing tolerances shall be determined based on the foreseen pipeapplication and justified by the design methods/criteria. The tolerances for control of thegap/interference between two consecutive pipe layers, the pitch of structural layer, the ovalityof carcass or pressure armor, and fishscaling shall be determined by design, considering theaspects which could impair the specific pipe performance.

7.3.1.5 In order to assure that the manufacturing processes are under control and to avoidsupply of defective pipe, control charts are required for continous processes (i.e. average andrange charts for the main dimensions of the extruded plastics and of the formed wire/strips).They shall be drawn for the structural layers, the pressure barrier and the outer sheath. Themonitored dimensions shall include, at least, the layer thickness and diameter of the polymericlayers and, for structural layers,the diameter, the pitch (for presure and tensile armors), andthickness (for carcass).

7.3.1.6 In order to avoid damages to the pipe, the supplier shall have procedures for pipehandling during manufacture. Such procedures shall include recommendations to avoidexcessive pipe torsion, bending or crushing when winding/unwinding pipe on reels or duringthe end fitting assembly.

7.3.1.7 The supplier shall record every non conformity verified during manufacuting. Suchrecords shall allow the supplier to locate such findings on pipe/accessory.

7.3.2 Manufacturing Tolerances

Some tolerances to be applied during pipe manufacturing are presented below. Sucha valuesare limits to be used by the supplier for pipe acceptance or refusal. More restrictive values shallbe adopted by the supplier and included in the Quality Plan when ever required by the designmethods/criteria. In this case, the new tolerances shall prevail over the ones listed below:

a) Carcass ID:- 0%/+2,0% (in relation to the specified value; measured at least in both extremities,indirectly measured by OD control);

b) Thickness of polymeric layers:- ± 20% of the nominal value;

c) Clearance between two adjacent wires/strips of the tensile armor layers:- two times the strip width, at the most;

d) Pipe OD:- ± 5% of the nominal value;

e) Pipe length:- for pipe having total length up to 750 m: +15m/-0m- for pipe having total length greater than 750 m: +20m/-0m.


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7.3.3 Polymeric Layers (extrusion)

7.3.3.1 Control procedures for use during storage of raw material and during pipemanufacturing shall assure that the raw material moisture content does not exceed the limitsrecommended by the raw material subcontractor.

7.3.3.2 During manufacturing, the layer thickness shall be controled at the bottom, at the topand at both sides of the layer cross section. The outside diameter of the layer shall be measuredin the horizontal and vertical directions.

7.3.3.3 The supplier shall adopt procedures to assure that there will be no inclusion ofimpurities in extruded pipe layers during manufacturing. For layers extruded over an adjacentinternal layer. Provision shall be made to guarantee that the internal one is kept clean duringthe extrusion process. Equipment such as extruder, feed system, storage reels, and pipesupports shall be cleaned on a regular basis. The feed system shall be protected from air byinert gas injection if the quality of the extruded material can be impaired when in contact withair.

7.3.3.4 Full visual inspection of the extruded material during manufacturing is required for thepressure barrier and the outer sheath layers. Manufacturer shall stablish a criteria foracceptance of bubbles, impurities, and flaws.

7.3.3.5 Raw material to be used in pressure barrier manufacturing shall be a virgin materialwhich does not contain re-granulated, recycled, reprocessed, reused or other similar material.

7.3.4 Metallic Layers

7.3.4.1 The procedure for wire/strip reel storage shall assure that these materials are protectedagainst corrosion.

7.3.4.2 Defects in wire/strip (which appear in raw material or occur after forming it on thepipe) which can damage non metallic layers are not allowed.

7.3.4.3 Diameter, ovality, pitch, and thickness of the layer cross section shall be measured. Asan additional verification of the preforming process, the fishscaling and clearances between twoadjacent strips/wires of tension or pressure armors (after their laying on pipe) shall also bechecked.

7.3.4.4 The interference or gap between two adjacent layers, as foreseen in the pipe designconception, shall be controlled and measured.


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7.3.4.5 Besides the visual inspection, another method of NDE is required to check buttweldsin pressure or tensile armor strips/wires for cracks.

7.3.5 Accessories

7.3.5.1 The raw material of forged structural steels of the end fitting/end connector shall benon destructively inspected against flaws/cracks after the last heat treatment or forming isperformed. Visual, magnetic particle, and x-ray (or gamma-ray, or ultrasonic) inspection shallbe performed in 100% of the material/surface.

7.3.5.2 For the metallic coating of end fittings and other accessories, the adhesion andhardness tests, the thickness checking and the examination/inspection of coating flaws/cracksshall be performed and reported, in addition to the visual inspection.

7.3.5.3 All existing buttwelds of the end fitting/end connector shall be 100% tested by visual,magnetic particle (or by dye penetrant) and x-ray (or gamma-ray) methods.

7.3.5.4 If resin is used in the end fitting, the process shall be qualified in order to guarantee aproper filling (i.e. without voids). Control by means of x-ray or gamma-ray testing should beavoided.

7.4 Control of the Manufactured Pipe/Accessory

7.4.1 Acceptance Test - Pigging and Hydrostatic Testing

7.4.1.1 Each pipe (with the end fittings assembled on it) to be supplied shall be subjected topigging and hydrostatic testing. The supplier’s test procedure shall encompass the followingsteps:

a) A gauging pig, for checking the specified pipe inside diameter, shall be inserted intoone extremity and run inside the pipe. Until it is removed from the other end;

b) Pipe shall be filled with water and complete air removal shall be assured;c) With the help of a hydraulic system composed of a pump and a pressure recorder,

the pipe shall be pressurized to a pressure equal to or greater than 1,5 times dedesign pressure (but not greater than 1,65 times the design pressure). In order tocheck for any failure of the main pressure gauge, a second redundant pressuregauge shall also be maintained coupled to the system during the whole test period;

d) After pressure stabilization, pipe shall be kept under a pressure equal to or greaterthan 1,5 times the design pressure for a 24 h period. During this time, pipe shall bedisconnected and isolated from the pressure system. Repressurization shall not beallowed during this period, as well as pressure drops greater than 4% in relation tothe pressure considered in the begining of the 24 h period. No leaks to the outsideor between pipe layers are permitted during this period.


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7.4.2 Data Book

Manufacturing data book shall be retained by supplier for a period equal to the specifiedservice life and will be supplied to the purchaser on request. The data book shall include atleast the following documents:

a) raw material certificates (pipe and accessories);b) certificate and records of pig passage and hydrostatic test (acceptance test - item

7.4.1);c) inspection/testing records, including x/gamma rays in buttweld, tensile testing results

of structural steels/fibers, heat treatment records, and test/inspection results incoatings (end fittings);

d) “as built” data sheet of pipe: pipe length, inside diameter, thickness, and outsidediameter of each pipe layer, including the maximum, minimum, and average valuesfound for these dimensions;

e) certificate of conformity (pipe assembly);f) traceability regarding non conformities/repairs and reports mentioning repair

procedures and checks after repair, if any.

8 HANDLING, STORAGE, PACKAGE, INSTALLATION, SERVICING ANDOPERATION

8.1 The supplier shall present to the purchaser, for each pipe supply, a user’s manualcontaining all necessary instructions, requirements, and recommendations applicable forpipe/accessory handling, storage, preservation, installation, operation, maintenance, and“in situ” testing. Special recommendations in the event of extreme conditions shall be included.

8.2 Unless otherwise specified, the package to be provided by the supplier shall allow the pipeto be store in a non protected area during at least six months.

8.3 In addition, supplier shall include instructions in user’s manual on how to avoid excessivetorsion during pipe unwinding/winding on reels or relative displacements between layers ofpipe. Restrictions regarding pipe storage in non protected area shall also be included.

8.4 As to the pipe installation, supplier shall be aware of the methods specified by thepurchaser and inform the critical parameters and requirements in the installation phase whichwill be considered for preparing the laying procedure.

8.5 In order to speed up solutions regarding pipe/accessory damage which may occur duringpipe/accessory storage, handling, installation, and operation, supplier shall have procedures forrepairing it in such situations, whenever possible. The scope of such procedures, which shall beproper for use in a non-protected area and on board, shall cover. At least end fittinginstallation and repair of the outer sheath layer. The execution of any repair in a pipe sectionshorter than 0,5 m shall not take more than 8 h, and the end fitting assembly shall not takemore than 24 h, under normal conditions. The requirements mentioned in item 7.2 areapplicable for repairing pipe during handling, storage, installation, and operation.


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9 IDENTIFICATION OF DOCUMENTS

Each pipe/accessory design shall be specifically identified by supplier. The identification systemof documents (e.g. data sheet, drawing) shall allow a quick recognition of its pipe/accessorydesign. New identification is required if any modification in product design or manufacturingprocess is made.

___________

/ANNEX A


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ANNEX A - PROCEDURE FOR DYNAMIC GLOBAL ANALYSISOF FLEXIBLE PIPES

A-1 INTRODUCTION

The dynamic internal forces and moments, to be determined by dynamic global analysis, arecaused by:

a) the static offsets and motions of the floating units at the top extremity of the pipe;b) the hydrodynamic loads of waves and currents acting directly on the riser.

Two methodologies are suggested to represent the sea state: regular wave approach andirregular wave approach.

A-2 METHODOLOGY 1 (Regular Wave Approach)

a) Step 1: A design wave, characterized by its height (H) and period (T), is selected forthe considered condition;

b) Step 2: The motion amplitudes and phases of the floating unit are obtained by theRAO and phase curves. For the wave period (T), the amplitude given by the RAOcurve is multiplied by the wave amplitude (H/2) to give the actual motion amplitude.The motion phase of the floating unit is obtained directly by the phase curve. Thisshall be done for all relevant degrees of freedom. It shall be noted that the RAO’s arecalculated at the COG or COM of the floating unit;

c) Step 3: The motion amplitudes and phases of the top end of the riser are obtained bytransferring the motion amplitudes and phase of the floating unit at COG or COM tothe riser connection position;

d) Step 4: The dynamic loads acting along the pipe are calculated by a proper algorithmwhich takes into consideration the top end motions, quasi-static, and environmentalloading acting directly on the riser.

A-3 METHODOLOGY 2 (Iregular Wave Approach)

a) Step 1: Several wave period values are selected in order to cover the period range ofthe design wave spectrum. The number of such values shall guarantee sufficientaccuracy on final results;

b) Step 2: The transfer function (TF) for a chosen response (effective top tension, forexample) is calculated as follows:

- For each selected wave period, a regular wave analysis (methodology 1) isperfomed. The wave height to be associated to each period and used in thecalculation is to be taken from the following steepness relation:

k x H / ,2 0 1=

where: k = wave number = w2/g


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Note: This steepness relation, for practical purposes, may be used for water depths > = 50 m,without current effect. Corrections for shallower waters, or to take in account thecurrents, shall be introduced where their influence is deemed relevant. Otherwise, ifspecific site data are available, they may be used instead of the above relation. Eachcalculated response shall be divided by the respective wave height (or amplitude) usedin the calculation.

c) Step 3: The response spectrum, for the chosen parameter (effective top tension, forexample), is obtained by performing the spectral crossing of the wave spectrum of thestorm case to be considered (defined by Hs and Tz) and TF. The spectral crossing isdone by means of the following formula:

Sr Sw x TF= ( )2

d) Step 4: The significant response and the most probable largest double amplitude areobtained after calculating the RMS value for the response spectrum of step 3, i.e. thesquare root of the area under the response spectrum:

- Significant response (double amplitude) = 4 x RMS- Most probable largest double amplitude = f x 4 x RMS

where f x N= 0 5, log , and

N = number of observed waves;For a 3 hour duration storm in the Campos Basis, f is approximately 1,87.

/ANNEX B


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ANNEX B - QUALIFICATION TESTS

B-1 GENERAL

B-1.1 Test samples shall represent the actual product to be supplied, considering both designand manufacturing procedures. Operators, processes, and machines used to produce samplesand derived products shall be the same. The purchaser may require the inclusion of weakpoints (such as weld, repairs, or process variations) on samples.

B-1.2 Before testing, supplier shall issue a detailed test procedure including at least thefollowing items:

a) type of tests to be performed;b) schedule of tests;c) test descriptions (including sketches and equipment set up);d) type and size of samples to be tested;e) equipment descriptions (including accuracy and sensitivity);f) data forms to be filled in, during the tests;g) acceptance criteria;h) predicted results and failure modes, when applicable;i) references.

B-1.3 After testing, supplier shall present a detailed test report including, at least, thefollowing items:

a) gathered data and final results;b) comparisons between predicted and observed values;c) conclusions.

B-1.4 Pipe dissection shall be done whenever sample fails. Failure evaluations andabnormalities shall be reported.

B-1.5 In order to verify pipe performance, the tests shall simulate typical and extreme loadsand boundary conditions to which the pipe is subjected during its installation or operationphases.

B-1.6 The necessity of cycling the sample, by internal pressure, before testing shall beevaluated by the suplier, for each case, when structure accommodation can affect the results.

B-2 INTERNAL PRESSURE TEST

B-2.1 The purpose of this test is to evaluate the flexible pipe (with end fittings assembled)resistance to internal pressure.


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B-2.2 Test sample shall have a minimum length of 20 (twenty) times the inside diameter,excluding both end fittings.

B-2.3 Internal pressure shall be continuously monitored and registered, during the whole testperiod.

B-2.4 Pipe sample shall be suspended/laid out, full of water, on a device that allows its freerotation and longitudinal and radial deformations. One sample end shall be clamped, and theother one free to move.

B-2.5 Test sample is pressurized until failure, at a rate not exceeding 10 MPa/min. The burstpressure, failure mechanism, and location shall be recorded.

B-2.6 During pressurization, for pipe at design pressure, and with no pressure (residualvalues), the following measurements are required:

a) sample overall longitudinal deformation (each mark shall be positioned at a minimumdistance of 2 (two) diameters from the respective end termination);

b) outside diameter deformations measured in the middle of the sample and taken attwo positions 90° apart;

c) sample free end rotation.

B-2.7 The burst pressure shall be greater than 2 (two) times the design pressure. Before thispressure level is reached, no leaks are accepted.

B-2.8 Additional acceptance criteria (when deformation measurements are required) for thesample longitudinal deformation (ld), its mean diametric deformation (mdd), and its rotation(r), for loaded and unloaded sample (residual values) are:

ld mdd (O.D.) rloaded ± 2% ± 1,5% ± 0,6 °/m

unloaded ± 1,0% ± 0,5% ± 0,2 °/m

B-3 EXTERNAL PRESSURE TEST

B-3.1 The purpose of this test is to evaluate the flexible pipe resistance to external pressure.This test can also verify the adequacy of the end fitting sealing system.

B-3.2 The test sample shall have a minimum length of 10 (ten) times the inside diameter andbe placed, empty, inside a hyperbaric chamber.


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B-3.3 Supplier shall guarantee that the external pressure is acting directly on the pressurebarrier. A cylindrical piece of the outer sheath, with a width of 1 (one) diameter, shall beremoved from the sample, leaving the outermost structural layer exposed. If the sample hasintermediary polymeric layers, between the outermost structural layer and the pressure barrier,holes or cuts shall be bored on these layers.

Note: In case smooth bore pipes, the external pressure shall act on the leakproof intermediarypolymeric layer which resists the external pressure, when that is required.

B-3.4 The chamber is pressurized, with water, until a value between 1,0 and 1,2 times themaximum pressure differential is reached. The pressure is kept within this range during aminimum period of 24 (twenty-four) hours, after a period of initial stabilization. During thewhole test period the test pressure shall never drop to a value less than the maximum pressuredifferential, and no leakage is accepted.

B-3.5 The test proceeds with the chamber being pressurized, at a rate not exceeding10 MPa/min., until the collapse of the sample. The collapse pressure, failure description, andlocation shall be recorded. Collapse pressure shall be greater than 1,5 times the maximumpressure differential.

B-4 TENSILE TEST

B-4.1 The purpose of this test is to evaluate the resistance of flexible pipe to tension, withassociated bending, simulating the passage through the sheave of the laying vessel.

B-4.2 The test sample shall have a minimum length of 20 (twenty) times the inside diameter,excluding both end fittings.

B-4.3 Test sample shall be positioned, empty, without internal pressure, on a special devicethat simulates the pipe laying sheave of the vessel, with the same bend radius and transverseprofile. It shall be also connected to a suitable tensile test machine. As general rule, half of thetest sample shall be positioned in a straight manner, while half of it is bent.

B-4.4 The axial load is then increased uniformly, from zero to 110% of the laying tension, at arate not exceeding 300 kN/min. This maximum tension shall be kept constant (maximum loadvariation of ± 2%), during a minimum period of 1 (one) hour.

B-4.5 After tensioning the sample, the following measurements shall be made directly on itsoutermost structural layer:

a) longitudinal deformation of a chosen sample region in the straight sample portion,with a minimum length of 4 (four) inside diameters (reference marks shall bepositioned at a minimum distance of 2 (two) diameters from any end termination);

b) outside diameters taken at two positions 90° apart (in a fixed transverse section,located in the curve sample portion);


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B-4.6 The acceptance criteria for the longitudinal deformation (ld) and for the mean diametricdeformation (mdd), for loaded and unloaded sample (residual values) are:

ld mddloaded ± 3,0% ± 3,0%

unloaded ± 1,0% ± 1,0%

B-4.7 Additionally, residual inside diameter deformation shall be checked. The maximumacceptable residual deformation is 1%.

B-4.8 If required, the test sample is replaced on the test device and tensioned until failure. Therupture tension shall not be lower than 200% of the operating tension or 140% of the layingtension, whichever is the greatest. The failure mechanism and location shall be recorded.

B-5 COMBINED TENSILE AND PRESSURE TEST

B-5.1 The purpose of this test is to evaluate the flexible pipe resistance to combined tensionand internal pressure. Is is applicable for pipes which are supposed to withstand tension anspressure simultaneously.

B-5.2 Test sample may be the same as the one used in tensile test. It shall be mounted, in astraight manner, full of water, in a suitable test device, with restrained torsion. Test pressure isset to the operating pressure and kept constant (maximum pressure variation of -0 and + 20%),during the whole test period.

B-5.3 The sample is loaded until failure, at a rate not exceeding 300 kN/min. The rupturetension, failure mechanism and location shall be recorded. Neither leakage nor sample failure isaccepted until tension reaches 2 (two) times the operating tension.

B-6 RADIAL MECHANICAL COMPRESSION TEST

B-6.1 The purpose of this test is to evaluate the flexible pipe resistance to compression load,when passing through the tension’s of the laying vessel.

B-6.2 The test sample shall have a minimum length of 10 (ten) times the inside diameter. Itshall be positioned, empty, without internal pressure, on a special compressive device thatsimulates the laying vessel tension’s, with the same geometry of shoes and the same number ofbelts.


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B-6.3 The compressive load is uniformily increased, from zero to 140% of the specifiedcrushing load, at a rate not exceeding 100 kN/m/min. This maximum compression load shall bekept constant (maximum load variation of ± 2%), during a minimum period of 1 (one) hour.

B-6.4 In the loaded condition, and after unloading completely the sample, its inside diametershall be measured in two positions 90° apart (in the middle transverse section of the sample)shall be measured.

B-6.5 If required, this test shall be performed with the sample under tension. In this case,before applying the compressive load, the sample is uniformly tensioned, at a rate notexceeding 300 kN/min., until the laying tension is reached. This value shall be kept constant(maximum tension variation of ± 4%), during the whole test period.

B-6.6 The accpetance criteria for the mean diametric deformation (mdd), for loaded andunloaded sample (residual values) are:

a) - 3,0% < mdd < + 3,0%(inside and mean diameter - loaded samples)

b) - 1,0% < mdd < + 1,0%(inside and mean diameter - unloaded sample)


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INDEX

AABBREVIATIONS AND SYMBOLS • 6ACCESSORIES DESIGN • 30Anti-wear Layer • 9

BBend Stiffner • 30Buoyancy Modules • 30

CCarcass • 7Coating • 32COMBINED TENSILE AND PRESSURE TEST • 44COMPLEMENTARY DOCUMENTS • 5Control of the Manufactured Pipe/Accessory • 36Crushing Loads • 14

DData Book • 37Design External Pressure • 13Design Loads, 18Design Pressure • 13DESIGN REQUIREMENTS • 15Design Tension • 13Design Verification • 29DETERMINATION OF DYNAMIC LOADS ON FLEXIBLE PIPES, 39Dynamic Flexible Riser • 7Dynamic Risers on other Floating Units • 22Dynamic Risers on Semisubmersible Units • 22

EEnd Fittings • 32EXTERNAL PRESSURE TEST • 42Extreme Condition • 13Extreme Loads • 14

FFailure Modes • 15

End Fitting, 17Pipe Clogging, 18Pressure Barrier, 16Structural Layers, 16

Far Position • 11Fibers and Composite Materials • 24Fishscaling • 8Flowline • 7Flowlines • 21

GGeometrical Configuration of Pipe • 10

HHandling Accessories for Installation • 31HANDLING, STORAGE, PACKAGE, INSTALLATION, SERVICING AND OPERATION • 37Holding Bandage • 9’


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IInstallation and Retrieval Loads • 14; 19Insulating Layer • 9INTERNAL PRESSURE TEST • 41

JJumper • 7

LLaying Tension • 14loads and conditions for Installed Pipe, 21loads on Flexible Pipe, 21

MMANUFACTURING AND CONTROL • 31Material Selection and Qualification • 23Materials for Use in Buoyancy Modules • 25Materials for Use in Sealing Systems • 25Maximum External Pressure Gradient • 14Maximum External Pressure Gradient, 18Mechanical Loads

Global Analysis, 20Minimum Internal Pressure • 14

NNear Position • 11Neutral Position • 11Non Destructive Examination • 32Non-bonded Flexible Pipe, 12Normal Operating Condition • 13

OOffset • 11Operating Loads • 13; 18Operating Pressure • 13Operating Tension • 14Outer Sheath • 9; 32Outerwrap • 10; 30

PPipe Layers • 7Pliant Wave • 10Polymers • 24Pressure Armor • 8Pressure Barrier • 8Process Control and Checking • 33Product Design Identification, 30PURPOSE • 5

QQUALIFICATION TESTS, 41Quality Terminology • 12

RRADIAL MECHANICAL COMPRESSION TEST, 45Repairs • 33Rough Bore Flexible Pipe • 12


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SSafety Factor for Failure Mode of Item 5.2.1.2 • 25Safety Factor for the Failure Mode of Item 5.2.1.3 • 26Safety Factor for the Failure Mode of Item 5.2.1.4 • 26Safety Factor for the Failure Mode of Item 5.2.1.5 • 26Safety Factors for Failure Mode of Item 5.2.1.1 • 25Safety Requirement for Pipe Clogging • 29Safety Requirement for the Failure Mode of Item 5.2.1.6 • 26Safety Requirement for the Failure Mode of Item 5.2.1.7 • 26Safety Requirement for the Failure Mode of Item 5.2.1.8 • 27Safety Requirement for the Failure Mode of Item 5.2.1.9 • 27Safety Requirement for the Failure Mode of Item 5.2.2.1 • 27Safety Requirement for the Failure Mode of Item 5.2.2.2 • 27Safety Requirement for the Failure Mode of Item 5.2.2.3 • 27Safety Requirement for the Failure Mode of Item 5.2.2.4 • 27Safety Requirement for the Failure Mode of Item 5.2.2.5 • 28Safety Requirement for the Failure Mode of Item 5.2.2.6 • 28Safety Requirement for the Failure Mode of Item 5.2.2.7 • 28Safety Requirement for the Failure Mode of Item 5.2.2.8 • 28Safety Requirements • 25Safety Requirements for End Fitting • 28Safety Requirements for Pressure Barrier • 27Shutdown Internal Pressure • 14Smooth Bore Flexible Pipe • 12Special Processes • 31Static Flexible Riser • 7Static Risers • 21Steels • 23Strength Determination of Structural Materials for Design Purpose • 24Structural Layer • 7

TTensile Armor • 7TENSILE TEST, 43

WWelding • 31Wires/Strips of Layers • 32