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CONTEC - SC-05
Maritime Installations and Operations

FLEXIBLE PIPE

2nd Amendment This is the 2nd Amendment to Standard PETROBRAS N-2409 REV. A, and it must be securely attached to the front page of the Standard. It is used to alter the text of the Standard in the parts indicated. Items are void and will be revised later: 3.1.11 Carcass Interlocked metallic construction that is used as the innermost layer to prevent total or partial collapse of the internal pressure sheath or pipe due to pipe decompression, external pressure, tensile armour pressure and mechanical crushing loads. Note: When used to protect the external surface of the pipe, it is called anti-abrasive protection.

3.1.77 Product Generic term, used to designate any element of the flexible pipe system (for example: pipe, ancillary component, or accessory, whichever is applicable).

PROPERTY OF PETROBRAS

7 pages

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TABLE 6 - FLEXIBLE PIPE LAYER DESIGN CRITERIA

Design Load Cases and Combinations Service Conditions Normal Operation Installation

Abnormal Operation Recurrent Extreme Operation Operation FAT Functional Functional, Functional, Functional, Functional and Flexible and Design Criteria environmental environmental environmental environmental Pipe Layer environme and accidental and accidental and accidental ntal The maximum allowable reduction in wall thickness below the minimum design Creep value, due to creep into gaps in the supporting structural layer, shall be 30 % under all load combinations. Internal Pressure The maximum allowable strain shall be 7.7 % for PE and PA, 7.0 % for PVDF in Sheath static applications, and 3.5 % for PVDF in dynamic applications. For other polymer Strain materials the allowable strain shall be as specified by the manufacturer, who shall document that the material meets the design requirements at that strain. Stresse Internal a Carcass Buckling Loadb,c 0.80

0.67 for Dmax 300 m {[(Dmax 300)/600] x 0.18 + 0.67} for 300 m < Dmax < 900 m 0.85 for Dmax 900 m

Stress Tensile Armours Buckling Load

d

0.67

0.85

0.85

0.80

0.85

0.91

0.67

Stressd,e Pressure Armours Buckling b,c Load for Smooth Bore Pipe Stressf

0.55

0.85

0.85

0.80

0.85

0.91

0.67 for Dmax 300 m {[(Dmax 300)/600] x 0.18 + 0.67} for 300 m < Dmax < 900 m 0.85 for Dmax 900 m 0.55

Holding Bandage
a) b) c) d) e) f) g)

The mechanical loads to which the internal carcass may be subjected shall be as specified for the tensile and pressure armours; Dmax is the maximum specified water depth including tidal and wave effects. Utilizations greater than 0.67 are only allowed for pipes designed under Revision A of this Standard and if design methodology against hydrostatic collapse has been validated and reviewed by IVA for the specified pipe; The design criterion for the pressure and tensile armours is permissible utilization as defined in item 5.3.1.4; for compressive stresses in the tensile armour that can cause armour buckling, see item 5.3.2.6; For installation loading, the stress can achieve the material yield strength in one of the following layers: either the carcass or the pressure armour provided that in the other one the utilization be respected; Utilization = stress/structural capacity, where the structural capacity is equal to 0.9 times the tensile strength of the bandage; Utilizations indicated in the TABLE 6 are applicable to those stresses, strain, loading and failure modes mentioned in this Standard; manufacturer shall submit to the purchaser the intended utilization necessary in order to avoid other failure modes not foreseen herein.

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2nd Amendment 5.2.3 The design methodology shall account for the effects of wear, corrosion, manufacturing processes, dimensional changes, creep and ageing (due to mechanical, chemical and thermal degradation) in all layers, unless the pipe design is documented to not suffer from such effects. In order to predict the pipe hydrostatic collapse resistance, such prediction shall be based on the minimum value obtained from the design methodology, by taken into account, through a statistical approach, the possible reductions in the pipe resistance coming from, for instance, (i) the variations of the manufacturing processes and (ii) the spreading of the qualification test results. If the manufacturer design methodology is not validated, the normal distribution and three standard deviations (at the safety side), shall be adopted, from test results, to estimate, the pipe hydrostatic collapse resistance to external pressure. 8.1.2 Unless otherwise mutually agreed, manufacturer shall submit the purchaser (and also IVA, in case of prototypes), at the specified times, the following documents: a) to e) remain unchanged; f) as-built documentation: before the delivery of the pipe and any time on request, for a period equivalent to the specified service life; g) operating manual: remains unchanged; h) qualification test procedures, if production tests are required: prior to test run; i) qualification test reports, if production tests are required: prior to commencement of manufacture or before the delivery of the pipe, as per contractual arrangement; j) if the supply of prototype is allowed by the contractual arrangements, additional documentation, required by item 5.2.6: as per schedule of the prototype developing and qualification program mutually agreed at the commencement of contract.

ANNEX C
C-1.1.2 This ANNEX C defines some standardized basic qualification test procedures applicable to conventional flexible pipes (Pipes which concept follows the configuration of layers and end fitting showed, respectively, in Figures 6 and 8 of API RP 17B). Also, these procedures are only valid for product concepts which have been already considered field proven by the purchaser. C-1.2.2 Identification and expression of the variables to be used for data gathering, reports or any test document shall use the following terms (for a given pipe cross section, horizontal and vertical diameters, mean diameters measured at 2 different positions, 90 apart one from the other): a) b) c) d) e) f) LI - initial length; LL, LR - loaded and residual lengths, respectively; DVI, DHI - initial vertical and horizontal diameters, respectively; DVL, DHL - loaded vertical and horizontal diameters, respectively; DVR, DHR - Residual vertical and horizontal diameters, respectively; DMI, L, R - mean diameter, initial (I), loaded (L) or residual (R) values:

DMI, L, R =

DVI, L, R + DHI, L, R 2
3

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g) OVI,L,R - sample ovalization (see definition, item 3.1.75), initial (I), loaded (L) or residual (R) values:
OVI,L,R = DVI,L,R DHI,L,R DVI,L,R + DHI,L,R

h) percent length deformation for loaded sample and residual, respectively: L L LI L R LI L L = L L 100 and L R = 100 I I i) percent diameter deformation for loaded sample: DVL DVI DHL DHI DVL = 100 and DHL = 100 DVI DHI j) percent residual diameter deformation:
DVR = DVR DVI DHR DHI and DHR = DVI DHI

C-2.2.1.1 The purpose of this test is to verify the pipe elongation, diametric deformation, and twist against the design predictions and pipe tensile capacity. This test shall check the consequences on pipe performance characteristics such as reduction of structural capacity to buckling and pull out or rupture of tensile armours from the end fittings. Also, this test shall check the axial stiffness informed by the manufacturer. If required, this test may also check the structural damping of the pipe, with the same purpose. Manufacturer shall previously inform the pipe maximum tensile capacity and the theoretical curve Tension x Axial Deformation for the test temperature. Test results shall be in accordance with these predictions. A second stage of this test shall be performed up to sample rupture. Failure mechanism and location shall be recorded. When internal diameter pig measuring is required, manufacturer shall previously inform the maximum allowed deformation for which the pipe hydrostatic collapse resistance criteria are not affected, for the specified maximum water depth. C-2.3.2.3 At the second stage, the external pressure is increased at a maximum rate of 10 MPa/min. Before the predicted collapse is reached, the pressure shall be stabilized during at least 15 minutes in 2 intermediate pressure steps (equally estimate in relation to the predicted collapse pressure). Sample is than led to the collapse. C-2.3.3.2 For the second stage, the measured collapse pressure shall be equal (see Note 1) or greater than the predicted pipe hydrostatic collapse resistance (see Note 2), estimated by the manufacturer, which shall comply with the requirements of clauses 5.2.3 and 5.3.1.1 of this Standard.

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1) For the purpose of this test criterion, the following applies: a) if the manufacturers design methodology is validated (reference item 5.2.2.2 of this Standard) and if a conservative design approach is adopted (reference item 5.2.3), it is improbable that the measured collapse test is equal or close to the predicted pipe hydrostatic collapse resistance; in case this coincidence occurs, the purchaser may require further collapse tests, in order to confirm if the predicted pipe hydrostatic collapse resistance is at the safety side; the need of new tests would be defined by also taking into account how close are the following values: - the predicted pipe hydrostatic collapse resistance; - the ratio between the design external pressure and the specified utilization; b) if the design methodology is not validated, manufacturer shall demonstrate the predicted pipe hydrostatic collapse resistance, by means of a statistic approach (reference item 5.2.3 of this Standard), based on additional test results carried out in the same pipe structure. 2) As per TABLE 6 of this Standard, the predicted pipe hydrostatic collapse resistance shall be equal or greater than the ratio between the design external pressure and the specified utilization.

C-2.4.3.2 In addition, the same sample shall be subjected to the hydrostatic collapse test. For criteria for collapse test, see item C-2.3.3.2 of this ANNEX. If the pipe is insulated, the sample shall be dissected up to the insulation layer in order to verify the integrity of this material, prior to the carrying out of the collapse test. The manufacturer shall previously inform in the test procedure the criteria for integrity of the insulation material.
C-2.5.3 Acceptance Criteria

The acceptance criteria for the external diameter deformation, sample ovalization, and longitudinal elongation, for loaded and unloaded conditions, are given in TABLE C-3.

TABLE C-3 - ACCEPTANCE CRITERIA FOR DEFORMATION / OVALIZATION

Parameter Loaded

THE

DIAMETRIC

Unloaded (residual)

External Deformation Ovalization

Diameter

-3.0 % DVL +3.0 % -3.0 % DHL +3.0 % -1.5 % OVL +1.5 % -1.5 % LL +1.5 %

-1.0 % DV R +1.0 % -1.0 % DH R +1.0 % -0.5 % OV R +0.5 % -0.5 % L R +0.5 %

Longitudinal Elongation

In addition to the criteria in the TABLE C-3 above, the following applies: a) for longitudinal elongation, axial stiffness of the pipe obtained from the test shall be in accordance with manufacturer predictions; b) for unloaded condition, criteria for pipe internal diameter deformations shall comply with the manufacturer carcass design tolerance; c) no structural damage of the end fitting itself (e.g. cracking or rupture of its structure) or of pipe layers (e.g. wire rupture) shall be observed; 5

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d) the result of the hydrostatic collapse of the sample segment subjected to this test shall comply with criteria found in item C-2.3.3.2 of this ANNEX. C-2.7.1.5 If specified, pipe annulus region may be filled with corrosive fluids, in order to simulate sour service conditions. The recommendations and requirements found in items 9.6.4.1.9 of API RP 17B shall be adopted. C-3.2.5.3 Samples shall be kept in the bath for a period of 1 month with a daily cycle of valve opening and close. Crack and reseat pressures, as per item C-3.2.6 are measured. Afterwards, valves are inspected against internal and external corrosion and internal abrasion.
C-4.4.1 General Criteria for All Tests and Pipe Handling Test

During Field Test, the following criteria shall be verified: a) tensile armours of the sample shall not present buckling in any direction; b) sample shall not present kink or corkscrew (corkscrew is defined as an increase of the pipe diameter due to the change of the lay angle of some few tensile armour wires); c) sample shall not have any damage in its outer sheath that allows the water ingress into the annulus space, nor any slippage of the outer sheath from the end fitting; d) sample shall not present visual localized twist; e) sample shall not present any visually identifiable structural or functional damage; f) caliper collars shall run throughout the sample from the top to the bottom. If not, further dissection results shall not indicate buckling evidences; After retrieval and during sample dissection, the following criteria shall be verified: g) tensile armours of the sample shall not present buckling in any direction; h) deviation of the nominal tensile armour lay angle shall be less than 5 deg or the corresponding pitch values; i) maximum allowable gap between 2 adjacent wires shall not be greater than 3 times the width of the tensile armour wires, at the same pitch region of these wires and in the interest region under analysis; j) tensile armour wires shall not be found excessively loose in such a way that they can be easily moved, e.g. by hand without effort; k) sample shall not have residual deformation greater than 1 % in any measurement of external diameter, at a certain pipe section (DH or DV); l) for verification of residual twist, sample successive axial marks shall be within 0,2 degree/meter along its lengthwise. Notes: 1) In case criteria of topics i) to l) are not achieved, manufacturer shall perform further investigations in order to demonstrate that pipe is keeping its resistance after field test. 2) Purchaser could consider optimization of test samples (e.g. one single sample for more than one test) if: (a) NDE, made available by manufacturer, is able to confirm the criteria listed hereafter, in such a way that dissection, at the end of all tests, is unnecessary (b) planned simulation covers all in service conditions.

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ANNEX D
(see page 80)
(CONCLUSION)

TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number C-3 C-3.1 C-3.2 C-3.2.1 C-3.2.2 C-3.2.3 C-3.2.4 C-3.2.5 C-3.2.6 C-3.2.7 C-4 C-4.1 C-4.2 C-4.3 C-4.3.1 C-4.3.2 C-4.3.3 C-4.4 C-4.4.1 C-4.4.2 N-2409 Chapter or Items Title Qualification tests of vent valves General Scope Immersion test at high temperature Cyclic test Seawater long term immersion test Test of simulated immersion in sea bottom External sealing pressure test Test of reproducibility of crack and reseat pressures Flow test Basic procedure for field test of a flexible pipe Objectives Introduction Test description First end subsea connection test Second end subsea connection test Dip Test Acceptance criteria General criteria for all tests and pipe handling test Additional criteria for the first and second connection tests N-2409 Page Number 63 63 63 63 64 64 64 65 65 66 66 66 66 67 67 68 69 70 70 70 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections

_____________

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FLEXIBLE PIPE
Specification
This Standard replaces and cancels the previous revision. The Responsible CONTEC Subcommittee provides guidance on the interpretation of this Standard when questions arise regarding its contents. The Department of PETROBRAS that uses this Standard is fully responsible for adopting and applying the clauses thereof. Technical Requirement: a provision established as being the most adequate and which shall be used strictly in accordance with this Standard. If a decision is taken not to follow the requirement (nonconformity to this Standard) it shall be based on well-founded economic and management reasons, and be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by the verb forms shall, it is necessary..., is required to..., it is required that..., is to..., has to..., only ... is permitted, and other equivalent expressions having an imperative nature. Recommended Practice: a provision that may be adopted under the conditions of this Standard, but which admits (and draws attention to) the possibility of there being a more adequate alternative (not written in this Standard) to the particular application. The alternative adopted shall be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by the verbal form should and equivalent expressions such as it is recommended that... and ought to... (verbs of a nonmandatory nature). It is indicated by the expression: [Recommended Practice]. Copies of the registered nonconformities to this Standard that may contribute to the improvement thereof shall be submitted to the Responsible CONTEC Subcommittee. Proposed revisions to this Standard shall be submitted to the Responsible CONTEC Subcommittee, indicating the alphanumeric identification and revision of the Standard, the clause(s) to be revised the proposed text, and technical/economic justification for revision. The proposals are evaluated during the work for alteration of this Standard. The present Standard is the exclusive property of PETRLEO BRASILEIRO S.A. - PETROBRAS, for internal use in the company, and any reproduction for external use or disclosure, without previous express authorization, shall imply an unlawful act pursuant to the relevant legislation through which the applicable responsibilities shall be imputed. External circulation shall be regulated by a specific clause of Secrecy and Confidentiality pursuant to the terms of intellectual and industrial property law.

CONTEC
Comisso de Normas Tcnicas

SC - 05
Maritime Installations and Operations

Foreword
PETROBRAS Technical Standards are prepared by Working Groups - GTs (consisting of PETROBRAS specialists and specialists from PETROBRAS Subsidiaries), are commented by PETROBRAS Units and PETROBRAS Subsidiaries, are approved by the Responsible Subcommittees - SCs (consisting of specialists belonging to the same specialty, representing the various PETROBRAS Units and PETROBRAS Subsidiaries), and ratified by the CONTEC Plenary Assembly (consisting of representatives of the PETROBRAS Units and PETROBRAS Subsidiaries). A PETROBRAS Technical Standard may be submitted to revision at any time by the responsible Subcommittee and shall be reviewed every 5 years to be revalidated, revised or cancelled. PETROBRAS Technical Standards are prepared in accordance with PETROBRAS Technical Standard N - 1. For complete information about PETROBRAS Technical Standards see PETROBRAS Technical Standards Catalog.

PROPERTY OF PETROBRAS

80 pages and Index of Revisions

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1 SCOPE

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1.1 This Standard is based on standard ISO 13628-2 and establishes additional requirements, exceptions and other modifications for supplying submarine high pressure unbonded flexible pipes. 1.2 This Standard should also be used by manufacturers when developing prototypes and when evaluating flexible pipes, for installation and operation phases, including damaged and repaired pipes. Note: Alternative design methods and criteria may be used for new developments, if previously agreed upon by the parties. Despite of section Introduction of standard ISO 13628-2, it is mandatory for the manufacturer to identify any variations from this Standard and provide details to purchaser.

1.3 This Standard does not provide specific design requirements for flexible pipe ancillary components and accessories, but contains some requirements regarding the following: a) the scope of validation and verification of their design methodologies by the Independent Verification Agent; b) coating protection. 1.4 Unless otherwise specified above, Section 1 - Scope of standard ISO 13628-2 applies to this Standard. 1.5 The current revision of this Standard shall be applied for supplies beginning from its issue date. 1.6 This Standard contains Technical Requirements and those regarding documentation to be submitted. 1.7 Sections and subsections of standard ISO 13628-2 which are not found herein are in force while new sections or subsections (i.e. which are not found in the ISO Standard) have been included hereafter. The numbering of ISO sections or subsections is unchanged while new sections or subsections are numbered in the sequence. See Contents, which indicates the changes, the inclusions, and the unchanged sections or subsections of standard ISO.

2 SUPPLEMENTARY DOCUMENTS
The documents listed in items 2.1 and 2.2 are mentioned in the text and contain valid requirements for the present Standard.

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2.1 Base Standard ISO 13628-2:2000

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- Petroleum and Natural Gas Industries - Design and Operation of Subsea Production Systems - Part 2: Flexible Pipe Systems for Subsea and Marine Applications.

2.2 Normative Reference API RP 17B API Std 1104 ASME Section IX ASTM B733 ASTM B571 BS EN 288-8 - Recommended Practice for Flexible Pipe; - Welding of Pipelines and Related Facilities; - Welding and Brazing Qualifications Non-Interfiled (Boiler and Pressure Vessel Codes); - Standard Specification for Autocatalytic (Electroless) Nickel-Phosphorus Coatings on Metal; - Standard Practice for Qualitative Adhesion Testing of Metallic Coatings; - Specification and Approval of Welding Procedures for Metallic Materials Part 8: Approval by a Pre-Production Welding Test.

Note:

For the purpose of this Standard, only the following editions are valid: a) ISO 13628-2 - First Edition - 2000; b) API RP 17B - Second Edition - 1998.

3 DEFINITIONS, SYMBOLS AND ABBREVIATIONS

3.1 For the purpose of this Standard, the definitions of the section 3 of standard ISO 13628-2 are applied, unless otherwise defined below. Additional items to standard ISO 13628-2 are also found hereafter (i.e. item 3.1.46 and others in the sequence). 3.1.11 Carcass Interlocked metallic construction that is used as the innermost layer to prevent total or partial collapse of the internal pressure sheath or pipe due to pipe decompression, external pressure, tensile armour pressure and mechanical crushing loads. Note: When used to protect the external surface of the pipe, it is called outerwrap.

3.1.19 Fishscaling Angle a) for a tensile armor wire, on a pipe cross section, the angle between the tangent of the pipe section and the orientation of the width, at the centroid of the wire section [see FIGURE 1 (a)]; b) for a pressure armor profile, on a longitudinal pipe section, the angle between the profile, in its width direction, and the pipe cylindrical generatrix, at the centroid of the profile section [see FIGURE 1(b)]. 3

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(a)

(b)

FIGURE 1 - FISHSCALING
3.1.20 Independent Verification Agent Independent party or group, selected by the manufacturer and accepted by the purchaser, that is responsible for the verification and review of (1) design methodologies and criteria, (2) manufacturing processes and tolerances, and (3) product, flexible pipe system and prototype performances in the light of the technical literature, analyses, test results, and other information provided by the manufacturer. 3.1.24 Jumper Short flexible pipe used in subsea and topside, for static or dynamic applications. Note: Unless otherwise specified by the purchaser, jumper shall have an interlocked pressure armour overlying the internal pressure sheath.

3.1.29 Quality Conformance to specified requirements, which shall include servicing and traceability of materials and products. 3.1.34 Smooth Bore Flexible pipe with an internal pressure sheath, as the inner most layer and with a leak proof intermediate sheath, applied outside the pressure armour, and sealed in the end fitting.

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An independent party, accepted by the purchaser and qualified to witness, confirm or approve the referenced data, result, procedure, test or qualification regarding a product (i.e. flexible pipe, ancillary component, or accessory). Notes: 1) Whenever the product is a prototype, the third party is the independent verification agent. It also applies if purchaser requires confirmation or approval of a specific product performance, characteristic or test procedures and results. 2) In case that a product has already been qualified by the purchaser, for a specified application, third party is defined as per standard ISO 13628-2, provided that it is previously accepted by the purchaser.

3.1.46 Abnormal Operation Condition Operation condition for which Pc (yearly combined probability of occurrence), for the functional, environmental, and accidental loads, is equal to 10-4. 3.1.47 Accessory Generic term used to designate every item that is not a constitutive part of the pipe (including end fittings) and of its ancillary components. Note: Examples of pipe accessory are bolts and nuts, sealing rings, bend stiffener stopper, and bend stiffener adapter for I-tube.

3.1.48 Anti-Abrasive Protection Accessory used to protect dynamic risers against abrasion in the TDP region. 3.1.49 Buckling of Tensile Armors Buckling of the tensile armors in the radial or any other direction caused by axial compression (true wall compression), associated or not with pipe bending, twist or torsion. Note: Birdcaging is a radial buckling of the tensile armors.

3.1.50 Buoyancy Module Ancillary component used to provide distributed flotation over discrete points of a section of the flexible pipe in order to make feasible the achievement of a particular pipe configuration. 3.1.51 Buoyancy Tank Ancillary component used to provide concentrated flotation of segments of a flexible pipe in order to make feasible the achievement of a particular pipe configuration. 5

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Carcass deviation of its ID roundness that the manufacturer must take into account when conservatively establishing the collapse and crushing capacities of the pipe, considering the effects from the manufacturing process, specified installation methods, equipment, and conditions. 3.1.53 Certifying Authority Third party chosen by the government authority or by the purchaser for certifying that the product is designed, manufactured, tested or installed in compliance with the specified documentation and laws and regulations issued by the country institutions where the above equipment will be installed. 3.1.54 Configuration of Flexible Pipe Geometrical shape of the pipe, during installation or operation, that varies according to the distribution of weight and buoyancy along the pipe, for instance. Common riser configurations are: Free-hanging, Lazy-S, Steep-S, Lazy-Wave, and Steep-Wave. 3.1.55 Crushing Loads Temporary compressive guidance-induced loads or localized radial loads imposed to the pipe, during its installation (laying or retrieval operations) by typical laying equipment such as tensioners, wheel, sheave, chute, gutter, and handling collars. Crushing loads are classified as the following (see FIGURE 2).
CRUSHING LOAD

DESIGN CRUSHING LOAD (UTILIZATION AS PER TABLE 6) PIPE MAXIMUM CRUSHING LOAD CRUSHING VARIATION CURVE

DOUBLE AMPLITUDE OF VARIATION FROM THE LAYING VESSEL

REQUIRED CRUSHING LOAD

LAYING EQUIPMENT

MINIMUM CRUSHING LOAD (HOLDING THE PIPE)

TIME

FIGURE 2 - CRUSHING LOADS

3.1.55.1 Design Crushing Load For a particular pipe application, it is the maximum crushing load that the pipe withstands considering an extra margin that corresponds to the utilization indicated by 5.1.3.3. This load includes the squeeze effect that is induced by the tensile armours.

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3.1.55.2 Loads Induced by the Laying Equipment: a) minimum crushing load: - for a particular laying condition and application, it is the load, induced by the laying equipment, which is necessary for holding all the suspended line of connected pipes during their installation; b) required crushing load: - load that refers to the minimum crushing load, increased by the amplitude of the variation of this load coming from the laying equipment; Note: Amplitude of the variation means that one caused by the control devices of the laying equipment resulting, e.g., from the characteristics of these devices and, also, the variations coming from the pipe external diameter. c) maximum crushing load: - load that refers to the minimum crushing load, increased by two times the amplitude of the variation of this load coming from the laying equipment; it corresponds to the maximum expected value to be applied to the pipe (by the laying equipment) during its installation. 3.1.56 Design External Pressure Maximum hydrostatic external pressure to which the pipe shall be subjected during its life, which varies according to the maximum water depth specified by the purchaser, including tidal and wave effects. 3.1.57 Design Tension Maximum tensile load to which the pipe shall be subjected during its life. Note: For flowlines, the design tension occurs during its installation. For risers, the design tension is obtained from the most critical between the operating or installation loadings.

3.1.58 Extreme Operation Condition Normal operation condition for which the yearly combined probability of occurrence - Pc - of the functional, environmental, and accidental loads is equal to 10-2. 3.1.59 Far Position Static position of the riser top connection, when the floating unit is displaced in the riser plane, in an orientation, which causes the maximum stretch of the riser for the specified offset. In such situation, the riser top region is far from riser bottom one (see FIGURE 3).

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OFFSET OFFSET SEA LEVEL

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SEAFLOOR

WHERE: 1 - FAR POSITION 2 - NEUTRAL POSITION 3 - NEAR POSITION

FIGURE 3 - POSITIONS OF THE RISER

3.1.60 Flexible Pipe System A fluid conveyance system, connected to field equipment in both extremities, in operation or ready to operate, for which the flexible pipe(s) is the primary component and includes ancillary components and accessories attached directly or indirectly to the pipe(s). 3.1.61 Flowline Flexible pipe, for static application, laid on the seafloor, buried or not, used to link 2 subsea equipment such as, rigid or flexible pipes, manifolds, X-tree or any combination of them. 3.1.62 Free-Hanging Catenary Riser configuration as per standard API RP 17B, item 7.4.1 and FIGURE 4. 3.1.63 Holding Bandage Bandage made of polymeric, fabric or fiber reinforced tape wound around the tensile armours, attaching and compressing their wires/strips against the pipe body to avoid buckling of these wires/strips. 3.1.64 In Service Inspection In-service periodic measuring or verification of the product characteristics (or other features of the system/surroundings and that can cause impact in the product integrity) in order to detect and prevent against defects or non-conformities in it and to determine if the product can safely comply with the intended performance, as specified (or with revised performance limits if they are properly established after documented downgrade analysis). 8

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In service means installation or operation phases, whichever is applicable.

3.1.65 In service monitoring In-service continuous or periodic measuring or verification of variables related to integrity with the followings purposes: a) to assess the product degradation or to predict its remaining service life; b) to detect, in service, abnormal behavior of the product/flexible pipe system or to give sufficient warning of imminent failures preventing accidents; c) to detect defects through continuous checking when periodic inspection cannot detect non-conformities that occur randomly, accidentally or due to operational error (e.g. outer sheath damage during installation, in locations of difficult access); d) to check the design premises and methodology predictions in order to verify uncertainties from the used models (i) to calculate loads, fatigue accumulated damage and wear, (ii) to predict responses of the product to the imposed loadings (e.g. displacements, strains, configuration lengthwise, and motions), and (iii) to check product capacity and utilization factors; it includes monitoring of external and internal environments, floating unit responses and operational practices (e.g. load-out and draft of a FPSO); e) to check behavior of prototype, specially its characteristics/capacity linked to unprecedented use of materials, design methodologies, product concepts or applications (loadings and exposure). Note: In service means installation or operation phases, whichever is applicable.

3.1.66 Laying Tension Maximum tensile load to which the pipe shall be subjected during installation (laying or retrieval operations). 3.1.67 Lazy-S Riser configuration as per standard API RP 17B, item 7.4.1 and FIGURE 4. 3.1.68 Lazy-Wave Riser configuration as per standard API RP 17B, item 7.4.1 and FIGURE 4. 3.1.69 Maintenance All activities related to the action of correction and preservation intended to avoid any kind of problem or non-conformity related to the flexible pipe system are defined as maintenance.

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3.1.70 Maximum Pressure Differential

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Maximum difference for a given pipe cross section, between the design external pressure and the minimum internal one experienced during its life (installation and operation conditions). 3.1.71 Minimum Internal Pressure Minimum internal specified pressure experienced by the pipe during its life (installation and operation conditions). 3.1.72 Near Position Static position of the riser top connection, when the floating unit is displaced in the riser plane, in an orientation which causes the minimum stretch of the riser for the specified offset. In such situation, the riser top region is near from riser bottom one (see FIGURE 2). 3.1.73 Neutral Position Static position of the riser top connection corresponding to the position of the floating units without the influence of winds, currents or waves (see FIGURE 2). 3.1.74 Offset For a given direction, it is the maximum vessel displacement due to environmental loading. Static offset (also called mean offset) is the vessel displacement due to combination of current, wave, drift and wind. Dynamic offset (also called extreme offset) is the static offset combined with wave frequency and low frequency motions. 3.1.75 Ovalization As per standard API RP 17B, item 3.1.17, but applied to pipe or pipe layer as referred in the specific clause (e.g. carcass ovalization). 3.1.76 Pliant-WaveTM Riser configuration based on the Lazy wave one, but in which the displacements of the TDP region of the riser are restricted by a dead weight attached to the pipe, at this region (see FIGURE 4).

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BUOYANCY MODULES

CLAMPS CABLES SEAFLOOR DEAD

FIGURE 4 - PLIANT WAVETM

3.1.77 Product Generic term, used to designate any element of the flexible pipe system (i.e. ancillary component, or accessory, whichever is applicable). 3.1.78 Production Tests Tests which purpose is to confirm the product performance and, indirectly, check the control of the manufacturing process. The purchaser can require them, even if a product design is considered already qualified (i.e. product is not a prototype). Procedures for carrying out production tests are generally those basic ones required for prototype qualification tests. 3.1.79 Prototype Product which concept, constituting materials, design methodologies, manufacturing processes, and prototype testing results have not been reviewed and accepted by an Independent Verification Agent and which performance (for a specific application) has not been approved by the purchaser through results, submitted by the manufacturer, of theoretical complementary analyses and of prototype qualification tests. 3.1.80 Prototype Tests Tests that are performed to verify the performance of prototypes. They may be full-scaled tests or may be carried out on samples (at benches or at the field). Prototype tests may be special ones not previously standardized, as they depend on the grade of innovation of the product concept, for example.

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3.1.81 Prototype Development Tests

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Those tests which objective is to verify if the design concept and if the manufacturing processes result in products that achieve the specified performance. They are tests planned, designed and carried out in the design growing phase in order to confirm the performance of the prototype and of its materials, for the intended application, and to confirm that the identifiable failure modes will not occur during the proposed product service life; their objectives are also to characterize materials (mainly alternative ones) and to optimize product design and manufacturing processes. 3.1.82 Prototype Qualification Tests Those tests which objective is to confirm that a representative product sample from the manufacturing process (see note), originated from an optimized design, complies with the specified performance, taking into account predicted failure modes, loading, and exposure and safety margins. They are carried out provided that the independent verification agent has approved the prototype development tests, if any. For industrial application in prototype construction (supply of extensive batches, lots), material characterization shall be included in this classification, if the development tests have not been performed in representative industrial scale sampling. Note: At this stage (i.e. prototype qualification), manufacturing process is carried out under controlled conditions for long running production, being the same of that to be used to produce the actual product intended for operation in the field.

3.1.83 Recurrent Operation Condition Normal operation condition which considers all functional loads (but pipe with maximum operating pressure) and 100 year environmental conditions. 3.1.84 Riser Pipe, for both static and dynamic applications, used to convey fluids between any of the following: a) floating vessels or fixed platforms and subsea equipment (including flowlines); b) an intermediate mid-water equipment (or buoy) to a subsea equipment (including flowlines); c) floating vessel of fixed platform to an intermediate mid-water equipment (or buoy); d) any combination of the following units: floating vessels or fixed platforms. Note: Unless otherwise specified by the purchaser, riser shall have an interlocked pressure armour overlying the internal pressure sheath.

3.1.85 Riser Hang-Off Structure for supporting riser at the connection to a production unit (jacket, semi-sub, tanker).

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Internal pressure (remaining in the pipe) after the system shutdown of the production unit caused, for example, when the limit environmental condition is exceeded. 3.1.87 Shut-in Pressure Highest value of the internal pressure considering, among others, the pressure necessary to start the plant operation, the breaking pressure of the valves of the gas lift compression system or the overpressure caused by the closing of safety valves. 3.1.88 Steep-S Riser configuration as per standard API RP 17B, item 7.4.1 and FIGURE 4. 3.1.89 Steep-Wave Riser configuration as per standard API RP 17B, item 7.4.1 and FIGURE 4. 3.1.90 Tensioner Mechanical device used to apply tension or support a pipe, during its installation, considering all suspended pipes connected to it. Also called caterpillar. 3.1.91 Thermal Exchange Coefficient - TEC Coefficient which provides the heat loss (expressed in Watts) of 1 m of pipe when subjected to 1 C difference between its internal and external surfaces. Its numerical value depends on the condition of the annulus: e.g. dry or wet. 3.2 Symbols and Abbreviated Terms In addition to those symbols and abbreviated terms found in item 3.2 of standard ISO 13628-2, the following are applicable: Dfat DFF PA-11 Pc TDP TEC ISO IVA - Accumulated Fatigue Damage Calculated by the Palmgreen-Miner Rule; - Design Fatigue Factors; - Polyamide 11; - Yearly Probability of Occurrence of Such a Combined Loading; - Touch Down Point; - Thermal Exchange Coefficient; - International Organization for Standardization; - Independent Verification Agent.

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4 FUNCTIONAL REQUIREMENTS AND RECOMMENDATIONS

For the purpose of this Standard, the original section and subsections of standard ISO 13628-2 are applied, unless otherwise modified below. Additional items to standard ISO 13628-2 are also found hereafter. 4.1 General 4.1.2 Functional requirements not specifically required by the purchaser and that may affect the design, materials, manufacturing, testing, performance, in service inspection and monitoring, and maintenance of the pipe (and of the flexible pipe system) shall be proposed by the manufacturer and submitted to the purchaser in the Design Premise. 4.2 Overall Requirements 4.2.1 Flexible Pipe The minimum overall functional requirements of the flexible pipe that shall be demonstrated by the manufacturer are as follows: a) to e) remain unchanged; f) by adopting the specified basic installation procedure, including the pull-in/ pullout methods, the pipe (and its ancillary components and accessories) shall be capable to be installed (lowered and recovered) and connected at both extremities in the field (e.g. at the specified subsea equipment and floating unit) by means of the specified vessel(s) and equipment (it includes, for instance, tensioners, pull-in/ pull-out machines, hydraulic collar, winches, and cables); g) the pipe and its ancillary components/ accessories shall be capable to be shipped, handled, transferred, stored, loaded to the installation vessel by means of the specified equipment and facilities. 4.6 System Requirements and Recommendations 4.6.1 Minimum System Requirements and Recommendations 4.6.1.2 Application Definition The flexible pipe system shall be specified as composed of either flowline, riser or jumper. The flexible pipe application shall be specified as either static or dynamic. For the dynamic application, manufacturer shall calculate the expected number of load cycles and their magnitudes and periods based on specifications provided by the purchaser such as environmental data and floating unit information (e.g. RAO and geometry). 4.6.1.12 Installation Requirements 4.6.1.12.1 The purchaser should specify performance requirements for the installation services to be provided, considering the following as a minimum: 14

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a) for installation by the purchaser, the purchaser should specify any load restrictions, clamping/ tensioner loads, overboarding chute requirements, installation tolerances, and port facilities limitations; based on the product characteristics and limitations, any intended modification or refurbishment of vessel/equipment proposed by the manufacturer shall be approved by the purchaser previous to contractual arrangement between these parties; b) remain unchanged. 4.6.1.12.2 The purchaser should specify requirements for the recoverability and reusability of the pipe throughout its service life. The pipe shall be designed to withstand, at least, 4 deployments and 4 recoveries similar to the installation conditions as per original specification. 4.6.1.14 Reuse Requirements a) for the recoverability and reusability of the flexible pipe throughout its service life, the manufacturer, based on information provided by the purchaser and agreed to be considered appropriated, shall assess (whichever applicable) the predicted remaining capacity and service life for the fatigue of metallic layers, aging of polymers, corrosion, wearing and for other kinds of degradations; b) for this purpose, purchaser shall allow the manufacturer to perform necessary inspections and tests in the entire pipe or in its samples in order to detect non-conformities, defects, and stage of degradation.

5 DESIGN REQUIREMENTS AND RECOMMENDATIONS

For the purpose of this Standard, the following sections and subsections of standard ISO 13628-2 have been modified as written hereafter. Additional items to standard ISO 13628-2 are also found hereafter. 5.1 Loads and Load Effects 5.1.2 Load Classes 5.1.2.1 As listed in TABLE 5 and TABLE 5A, loads are classified as functional, environmental (external) or accidental, as follows: a) functional loads are all loads on the pipe in service or during installation, including all loads which act on the pipe in still water except wind, wave or current loads; b) and c) remain unchanged. Note: Load classes and subclasses are listed in the left column of TABLE 5 and 5A.

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TABLE 5 - LOAD COMBINATIONS OF LOAD CLASSES, LOAD CONDITIONS

Normal Operation Abnormal Recurrent Extreme Operation Operation Operation Functional Loads a) loads due to mass and buoyancy of pipe, contents x x x and attachments, both temporary and permanent; Max. operating b) internal pressure as specified in 4.4.2; design pressure design pressure pressure c) pressure and thermal expansion and contraction x x x loads; d) external pressure; x x x e) external soil or rock reaction forces for trenched, x x x buried, or rock dumped pipes; f) static reaction and deformation loads from supports x x x and protection structures; g) temporary installation or recovery loads, including x x x applied tension and crushing loads, impact loads and guidance induced loads; h) residual installation loads, which remain as x x x permanent loads in the pipe structure during service; i) loads and displacement due to pressure and x x x tension induced rotation; j) testing pressures, including installation, x x x commissioning and maintenance pressures; k) interaction effects of bundled or clamped pipes; x x x l) loads due to rigid or flexible pipe crossings, or x x x spans; m) loads due to positioning tolerances during x x x installation; n) loads from inspection and maintenance tools. x x x Environmental loads 100 year conditions to Loads and motions caused directly or indirectly by all Survival conditions meet Pc = 10-2 environmental parameters as specified in TABLE 2 conditions (c) Accidental loads Loads and motions caused directly or indirectly by accidental occurrences, including the following: 1) dropped objects Not applicable (a) (b) 2) trawl board impact Not applicable (a) (b) 3) internal over-pressure Not applicable (a) (b) 4) compartment damage or unintended flooding Not applicable (a) (e) 5) failure of thrusters Not applicable (a) (e) 6) DP failure Not applicable (a) (e) 7) anchor line failure Not applicable (d) (b) 8) failure of turret drive system Not applicable (a) (e) Load Conditions a) Combinations of the above functional, environmental and accidental loads, as shown in TABLE 6, shall be analyzed if the yearly combined probability of occurrence Pc is equal to 10-2. b) Combinations, as shown in Table 6 of the above functional, environmental and accidental loads, shall be analyzed if Pc is equal to 10-4. c) Unless otherwise specified by the purchaser, 100-year conditions mean the combination of the following: (i) 100-year wave, 10-year current and the extreme offset and (ii) 10 year wave, 100 year current and the extreme offset. d) Combinations of the above functional, environmental and accidental loads, as shown in TABLE 6, shall be -2 analyzed if the yearly combined probability of occurrence Pc is equal to 10 . Unless otherwise specified by the purchaser, the following combination shall be considered, as loading condition with Pc = 10-2 for extreme normal operation condition: (i) 100 year wave, 10 year current and the offset of one line failed and (ii) 10 year wave, 100-year current and the offset of one line failed. e) Combinations, as shown in Table 6 of the above functional, environmental and accidental loads, shall be analyzed if Pc is equal to 10-4. Unless otherwise specified by the purchaser, the combination of annual wave and annual current with the accidental load shall be considered for survival conditions.

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TABLE 5A - ANNUAL PROBABILITIES FOR INSTALLATION

Type of Load Functional Loads Environmental Loads Installation Expected, specified, or extreme value. Probability of exceedance according to season and duration of installation period. If abandonment is possible, the maximum weather in a period 3 times the expected installation duration may be used. If abandonment is not feasible, a more conservative approach shall be used or the duration of the operation reduced to a period where reliable weather forecast is available (typically hours). Accidental Loads As appropriate to installation method

5.1.3 Load Combinations and Conditions 5.1.3.2 The design load conditions that shall be analyzed are installation, normal operation (recurrent and extreme), abnormal operation and factory acceptance testing. Load combinations shall be as defined in the notes for TABLE 5, in TABLE 5A, and column headings in TABLE 6. Load combinations with a yearly probability of occurrence less than 10-4 can be ignored. FAT load combinations shall be defined by the manufacturer based on the FAT procedures. 5.1.3.3 Design checks shall be carried out of any temporary conditions specified by the purchaser or the manufacturer. These shall be subjected to the same design criteria as the design load conditions, as specified in TABLE 6 and TABLE 6A.

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TABLE 6 - FLEXIBLE PIPE LAYER DESIGN CRITERIA

Design Load Cases and Combinations Service Conditions Normal operation Abnormal Operation Installation

Recurrent Extreme Operation Operation FAT Functional Functional, Functional, Functional, Flexible and Functional and Design Criteria environmental environmental environmental Pipe layer environmental environme and accidental and accidental and accidental ntal The maximum allowable reduction in wall thickness below the minimum design Creep value, due to creep into gaps in the supporting structural layer, shall be 30 % under all load combinations. Internal Pressure The maximum allowable strain shall be 7.7 % for PE and PA, 7.0 % for PVDF in Sheath static applications, and 3.5 % for PVDF in dynamic applications. For other polymer Strain materials the allowable strain shall be as specified by the manufacturer, who shall document that the material meets the design requirements at that strain. Stresse Internal a Carcass Buckling Loadb,c 0.80

0.67 for Dmax 300 m {[(Dmax 300)/600] x 0.18 + 0.67} for 300 < Dmax < 900 m 0.85 for Dmax 900 m

Stress Tensile Armours Buckling Load

d

0.67

0.85

0.85

0.80

0.85

0.91

0.67

Stressd,e Pressure Armours Buckling b,c Load for Smooth Bore Pipe Stressf

0.55

0.85

0.85

0.80

0.85

0.91

0.67 for Dmax 300 m {[(Dmax 300)/600] x 0.18 + 0.67} for 300 < Dmax < 900 m 0.85 for Dmax 900 m 0.55

Holding Bandage
a) b) c) d) e) f) g)

the mechanical loads to which the internal carcass may be subjected shall be as specified for the tensile and pressure armours; Dmax is the maximum specified water depth including tidal and wave effects. Utilizations greater than 0.67 are only allowed for pipes designed under Revision A of this Standard and if design methodology against hydrostatic collapse has been validated and reviewed by IVA for the specified pipe; The design criterion for the pressure and tensile armours is permissible utilization as defined in item 5.3.1.4; for compressive stresses in the tensile armour that can cause armour buckling, see item 5.3.2.6; For installation loading, the stress can achieve the material yield strength in one of the following layers: either the carcass or the pressure armour provided that in the other one the utilization be respected; Utilization = stress/structural capacity, where the structural capacity is equal to 0.9 times the tensile strength of the bandage; Utilizations indicated in the Table above are applicable to those stresses, strain, loading and failure modes mentioned in this Standard; manufacturer shall submit to the purchaser the intended utilization necessary in order to avoid other failure modes not foreseen herein.

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TABLE 6A - FLEXIBLE PIPE LAYER DESIGN CRITERIA - EXTENSIONS TO ISO

Pipe Layer Failure Mode Utilization, maximum elongation, or other design Consequences to Pipe criteria, for the service and Structural Capacity installation conditions, as indicated Design criteria to be Locally reduced pipe demonstrated and submitted in hydrostatic collapse the Design Report for all cases resistance and tension of the service and installation capacity conditions (reference is made to operating MBR item 5.3.1.7) Locally reduced pipe hydrostatic collapse resistance and tension capacity No increase of the utilization specified in TABLE 6 is allowed, for the service and installation conditions.

Causes/Origins

Loss of interlocking Carcass Excessive plastic deformation

Bending or Tension with bending Squeeze induced by the tensile armours and crushing loads (e.g. radial compression from the tensioners, launching wheel and hydraulic collars)

Loss of interlocking Pressure Armours

Excessive plastic deformation

Locally reduced pipe structural capacity against internal Bending, tension, and pressure, crushing crushing loads induced loads, tension and by the installation hydrostatic collapse equipment, or torsion (possibility of extrusion and leakage of the internal pressure sheath) Squeeze induced by Locally reduced pipe the tensile armours and hydrostatic collapse crushing loads induced resistance and tension by the installation capacity equipment Pipe presents excessive rotation under service and installation conditions (e.g. under maximum design pressure, laying or operating tension or combination of internal pressure and tension) as the tensile armours are not properly designed or manufactured.

Design criteria to be demonstrated and submitted in the Design Report for all cases of in service and installation conditions (reference is made to operating MBR item 5.3.1.7)

No increase of the utilization specified for the carcass in TABLE 6 is allowed. Criteria for pipe twist (1):

Tensile Excessive armours pipe twist

(i) Maximum allowed pipe rotation is 0.6/m under the Pipe twist, kinking or laying tension, maximum looping, locally reduced design pressure, and, in pipe structural capacity case of riser, under the against tension and operating tension, the later internal pressure, and associated or not to the rupture of tensile maximum design pressure. armour wires, squeeze (ii) In the unloaded condition of pressure armour or (i.e. residual condition, carcass. when tension and pressure are relaxed) the maximum allowed pipe rotation is 0.2/m.

Note:

Criteria for excessive pipe twist covers only margins against loop and kink. Therefore, these criteria (allowed pipe twist) shall not be applicable to other failure modes such as pipe crushing (due to the squeeze of the tensile armours) or buckling of the tensile armours, which can be associated (or be anticipated) to the pipe rotation.

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5.1.3.4 The simultaneous occurrence of different load combinations shall be defined in the design premise of the manufacturer which shall comply, with the purchaser specification (load combinations and cases requested by the purchaser), if any. 5.1.3.5 The design load cases to be analyzed shall be derived from the load conditions as specified in item 5.1.2.2, column headings in TABLE 6, including those specified by the purchaser, if any. 5.1.4 Design Load Effects 5.1.4.1 In the pipe design, the manufacturer may allow for the effects of differential pressures provided that it is specified and previously authorized by the purchaser and is clearly indicated in the design premise. Further, the effects of differential pressures shall not be used for the purpose of dimensioning the pipe against hydrostatic collapse, unless otherwise specified by the purchaser. 5.2 Product Design Methodology 5.2.1 Initially and whenever revisions occur, the design methodology and the manufacturing processes of the product and of the flexible pipe system shall be verified by IVA. The documentation submitted for verification of the design methodology and of the manufacturing processes shall include the following, as a minimum: a) to d), remain unchanged; e) manufacturing and design tolerances, manufacturing induced stresses, welds, and other effects which influence pipe structural capacity; it includes manufacturing records and analysis through which it can be confirmed that the manufacturing processes are controlled and that the tolerances can be achieved; documentation regarding qualification of special processes and the repair procedures shall be also included due to the possible influence of these processes in the pipe structural capacity; f) remain unchanged; g) documentation indicating the characterization and the properties of the materials, as well as their qualification as per Chapter 6. 5.2.1.1 IVA shall have previous complete knowledge of all packages of manufacturers methodologies and criteria. In addition to the above, its review of those packages shall cover, at least, the following items (applicable to any product and flexible pipe system to be delivered): a) product and flexible pipe system design (including material selection and characterization, global analysis of the flexible pipe system, and product service life analysis and structural dimensioning, for all predicted failure modes); b) pipe manufacturing and assembling methods (including control of processes and acquisition and treatment of the manufacturing data); c) prototype development and qualification (including evaluation of experimental data and assurance that samples and test procedures are representative); d) evidences of the qualification of manufacturers suppliers (i.e. sub-vendors) and qualification of their products. 20

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5.2.2 IVA shall review and evaluate the design methodology and the manufacturing processes to establish the range of applications for which they are suitable. IVA shall issue a certificate and a design verification report describing the limits and constraints of the design methodology and of the manufacturing processes. The certificate shall be included by the manufacturer in the design report (see item 8.4) and the design methodology verification report shall be available (in Brazil) for review by the purchaser. 5.2.2.1 The certificate and report above mentioned shall cover a validated envelope of product designs and of manufacturing processes (including end fittings, ancillary components and accessories). 5.2.2.2 Design methodologies are considered validated (for a validated envelope of product designs) if IVA has sufficient evidences, provided by the manufacturer, that their predictions are confirmed through a comprehensive set of prototype tests and complementary analysis, taking into account the design methodology uncertainties and the capability and variations of the manufacturing processes, which shall be properly identified by the manufacturer. A statistical approach must be included in the manufacturer documentation to be reviewed in order to confirm that the prototype testing is performed in a representative sampling. 5.2.2.3 IVA may verify (see item 5.2.1) a single product design, but, in this case, the used design methodology would not be considered validated. 5.2.3 The design methodology shall account for the effects of wear, corrosion, manufacturing processes, dimensional changes, creep and ageing (due to mechanical, chemical and thermal degradation) in all layers, unless the pipe design is documented to not suffer from such effects. In order to predict the pipe hydrostatic collapse resistance, the lower bound value, obtained from the design methodology shall take into account, through a statistical approach, (i) the variations of the manufacturing processes and (ii) the spreading of the qualification test results. If the manufacturer design methodology is not validated, a normal distribution and three standard deviations shall be adopted to estimate the pipe hydrostatic collapse resistance to external pressure. 5.2.6 If the product design is outside the validated envelope of product designs (see item 5.2.2) and if its performance, for a specific application1, has not been approved by the purchaser by taking into account the results2 of theoretical complementary analyses and prototype qualification tests, submitted by the manufacturer, then the product is a prototype3 and the manufacturer shall carry out a prototype developing and qualification program to verify the product design, with the following minimum content: a) detailed description of the pipe concept and of all layers and their functions (see Note 4); b) detailed description of the concepts of the end fitting, ancillary components and accessories; c) specification of constituting materials (materials to be used in construction of pipe, end fitting, ancillary components, and accessories) and the their characterization and qualification tests 4 (herein standardized or not, including short and long term testing) (see Note 4);

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d) for dimensioning purposes, description of all possible failure modes of the pipe (end fitting, ancillary components, and accessories) and of evidences that the corresponding design methodology covers them; e) detailed description of the manufacturing processes and documentation confirming that they are controlled for producing long pipe sections (> 300 m); f) carrying out a comprehensive set of development tests based on the identified failure modes; g) carrying out a comprehensive set of global, service life, and local analysis for the intended service and application range, including conditions for pipe installation, for the available installation equipment; h) carrying out calculations and dimensioning of ancillary components and accessories; i) carrying out VIV analysis, when applicable; j) carrying out the fatigue analysis for the intended application range, when applicable; k) carrying out a comprehensive set of qualification tests [it includes field test, as per ANNEX C of this Standard (see Note 5)] provided that the previous development tests are successful and the respective product design is optimized; l) verification by IVA of the design methodologies, the specified criteria, manufacturing processes, and issue of certificate of approval and reports, applicable to the specified product. Notes: 1) Specific application means functional requirements and recommendations as described in Chapter 4 of this Standard, including installation and operational information and data. 2) Exception is made to the results of development tests, as per paragraph f) above, which do not need to be approved by the purchaser. 3) Products intended to be manufactured through processes that use (i) machines or controls with any change (in relation to machines and processes of products already qualified) or (ii) that use machines, processes, and workmanship from new plants are also considered prototypes. 4) Utilization for new concept of layers and new materials must be more conservative, i.e. with extra safety margins, than the ones specified in TABLE 6 and TABLE 6A, unless otherwise mutually agreed. 5) Alternatively to the carrying out of field test mentioned in paragraph k) above, if made available by manufacturer, purchaser may accept detailed design and operational information regarding Field-Prototype. Field-Prototype means that the product design is field proven through a performance demonstration of a real complete pipe, of similar structure of the pipe under analysis, under operational conditions equal or more critical than those specified (Reference is made to Chapter 4 of this Standard), designed and manufactured by the same methodology and processes/controls of the pipe under analysis, being all these design and manufacturing packages certified by IVA.

5.2.6.1 The manufacturer shall submit to purchaser a report containing technical information and all the results of the prototype development and qualification program above mentioned, with exception of paragraph f) (development tests). Also, the manufacturer shall submit to purchaser a certificate and a design methodology and manufacturing processes verification report issued by IVA, for the prototype, including the IVA review on the results of all the activities listed in paragraphs a) to k) of item 5.2.6. The prototype qualification tests shall be witnessed by IVA and purchaser, at its discretion, while development test shall be witnessed by IVA.

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5.2.6.2 The prototype qualification tests shall verify fitness-for-purpose for those design parameters, which are outside the previously validated envelope, if any. See standard API RP 17B and ANNEX C for guidelines on test scope and recommendations, which shall be duly complemented in order to incorporate specific investigations on characteristic failure modes and defects of the pipe, not foreseen in the standardized qualification tests. 5.3 Pipe Structure Design 5.3.1 Design Criteria 5.3.1.1 The pipe layers shall be designed according to the criteria specified in TABLE 6 and TABLE 6A, subject to the requirements given in item 5.3.1. Pipe structure shall be designed against all potential failure mechanisms listed in Table 3 of standard API RP 17B and following the recommendations of item 5.4 of standard API RP 17B, unless otherwise herein specified. 5.3.1.3 For stress criterion, the utilization for the internal carcass shall be calculated as specified in item 5.3.1.4. For buckling, utilization is defined as the ratio between the maximum external pressure (the maximum between either the full external pressure due to the maximum water depth or the maximum annulus pressure) and the pipe capacity, taking into account the water depth ranges defined in TABLE 6. Calculated residual deformation due to crushing and squeeze loads shall not cause utilization factor to exceed the criteria found in TABLE 6 and TABLE 6A, for all load combinations. The manufacturer shall evaluate buckling failure modes in the carcass and pressure armours, and shall confirm by analysis that the layers meet the design requirements. Hydrostatic collapse calculations for the carcass may account for the support provided by the pressure armour layer. 5.3.1.8 Fatigue life calculations shall be performed in accordance with item 5.3.4. The predicted fatigue life shall be as per TABLE 6B. Corrosion analysis (in accordance with item 5.3.4) shall show that the material loss from corrosion does not cause utilization factors to exceed the criteria of this sub clause under all load combinations. The fatigue criterion that shall be satisfied is written as Dfat. DFF 1, where Dfat = Accumulated fatigue damage (Palmgreen-Miner rule) and DFF = Design Fatigue Factor.

TABLE 6B - PREDICTED FATIGUE LIFE

Design Fatigue Factors (DFF) Safety class Low Normal 3.0 6.0

High 10.0

5.3.1.8.1 Risers for oil and gas shall have a high safety class while individual water injection risers (i.e. risers for water injection in a single well) shall have a low safety class. For water injection risers in more than one well, normal safety class shall be adopted.

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5.3.1.8.2 The accumulated fatigue damage shall be calculated taking into account the progressive wear of structural layers. If the pipe does not have anti-wear layers, maximum allowable wear of any structural layer shall not exceed 25 % of its thickness. At the end of the specified service life, the utilization factors specified in Table 6 shall be preserved. 5.3.2 Design Requirements and Recommendations for Pipe Layers 5.3.2.1 Internal Pressure Sheath 5.3.2.1.1 As a minimum, the internal pressure sheath shall be analyzed for the following load cases: a) most critical combination of internal pressure, external pressure (it includes the possibility of outer sheath is damaged and the external pressure is in direct contact with the internal pressure sheath), temperature, operating MBR and polymer condition; b) as per ISO. 5.3.2.1.5 For dynamic applications, the manufacturer shall have documented test records to verify that crack initiation, due to notch sensitivity and stress raisers (e.g. in case of PVDF is used, protrusion due to the extrusion process over the carcass), does not occur in the material used for the internal pressure sheath. This does not apply to sacrificial layers used in multiple internal pressure sheath constructions. 5.3.2.3 Intermediate Sheath If an intermediate sheath is designed to prevent leakage of annulus fluid outside the layer or to prevent seawater ingress beyond this layer (required for smooth bore pipes), then the design of this sheath shall meet the requirements given in item 5.3.2.1. For dynamic applications, intermediate sheaths shall withstand wear due to relative motion between layers. Wrinkles and cracking due to bending should be avoided. 5.3.2.4 Internal Carcass The design of the internal carcass shall take into account the following: a) collapse with minimum specified internal pressure, maximum external pressure and carcass design tolerance; the external pressure shall be either the full external pressure acting on the outside of internal pressure sheath or maximum annulus pressure if this exceeds the external pressure; b) to e), remain unchanged; f) stresses caused by crushing loads, combined or not with tension (when the pipe is subjected to the squeeze loads from the tension armours), which may cause rupture or excessive permanent (or residual) or temporary deformation of this layer; g) the existence of a gap between the pressure armour and the internal pressure sheath, if any (in case of the design methodology foresees the back-up support of the carcass when pressure is acting directly in the internal pressure sheath).

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The pressure armours shall be designed to withstand the specified hoop stress; the design shall further ensure that gaps between wires are within the limits necessary to prevent excessive creep extrusion of the internal pressure sheath (reference is made to TABLE 6) and the loss of interlock. Pressure armour design shall take into account the collapse with minimum specified internal pressure, maximum external pressure and maximum layer ovalization. 5.3.2.5.1 Pressure armour shall be designed to withstand the crushing loads combined with tension (when the pipe is subjected to the squeeze loads from the tension armours), induced by the installation methods and equipment. 5.3.2.5.2 For safety reasons, unless otherwise specified, risers shall have an interlocked pressure armour overlying the internal pressure sheath. 5.3.2.5.3 For smooth bore pipes, the external pressure shall be the full external pressure acting on the outside of the leak proof intermediate sheath. Utilization factor against pressure armor buckling is indicated in TABLE 6. 5.3.2.6 Tensile Armours 5.3.2.6.2 The complete pipe structure shall be designed so that the torsional balance and compression strength characteristics of the pipe meet functional requirements. The torsional balance concept shall be in such a way that pipe does not rotate up to the limit of formation of loop, kink, or buckling of the tensile armours. 5.3.2.6.3 TABLE 6A brings a criteria for excessive pipe twist, but it includes only margins against loop and kink. However, the allowable pipe twist shall be reduced if its effects may induce other failure modes, such as the following: a) pipe crushing (due to the squeeze of the tensile armours); or b) buckling of the tensile armours, when the pipe is subjected to axial (true wall) compression taking into account the end cap effect, associated or not to bending and torsion loads. 5.3.2.6.4 Tensile armours shall be designed against buckling due to axial (true wall) compression (compression due to hydrostatic external pressure acting on the pipe, added to effective compression, induced by the riser catenary top motions), associated to bending and torsion loads. TABLE 6 defines permissible utilization against buckling which is referred to the limit stress that causes the buckling of the tensile armours, for both conditions of the pipe annulus, dry or flooded. This permissive utilization against buckling is applicable for buckling in any direction (radial and in the cylindrical surface of the layer).

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5.3.2.7 Additional Layers

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5.3.2.7.4 Holding bandage shall be designed in order to avoid the tensile armours radial expansion (and, eventually, the radial buckling of armours) caused by axial (true wall) compression, associated or not to bending and torsion loads. Maximum allowable bandage elongation is limited to that one which causes a gap, between the tensile armour wires and the underlying layer, corresponding to 1/2 of the thickness of the armour wire. Utilization factor for stress in the holding bandage is indicated in TABLE 6. It is related to the material tensile strength. This design criterion is applicable for both conditions of the pipe annulus, i.e. dry or flooded of seawater, and for all load conditions (installation and service). 5.3.2.7.5 If a smooth bore pipe is specified for water injection application, a leak proof intermediate sheath, sealed in the end fitting, shall be applied outside the pressure armour in order to prevent the collapse of the internal pressure sheath, even if the annulus is flooded (due to an external sheath damage). 5.3.3 End Fittings 5.3.3.1 The end fittings shall be designed for reliable termination of all pipe layers, so that leakage, structural deformation, or pull-out of wires or extruded layers do not occur throughout the service life of the pipe, taking into account all relevant factors including shrinkage, creep, ageing, and pressure effects. The design methodology for end fittings shall be documented and shall be verified by documented tests and analyses. The methodology shall account for manufacturing tolerances. The design shall allow for support loads from any ancillary components attached to the end fittings, including bend stiffeners and restrictors and accessories used for pipe installation. 5.3.3.2 The design of the end fittings shall ensure sealing of the internal pressure sheath, of the outer sheath, and of the intermediate sheath at the end fittings (when applicable). The latter is required if this sheath is designed to prevent annulus flooding beyond this layer (in case of protecting thermal insulation from seawater contact or in case of smooth bore pipes). The design of the end fittings crimping/sealing mechanism shall ensure that the combined strain induced by the in-service pull-out forces and installation of each end fitting seal ring does not result in failure of the sheath throughout the service life. 5.3.3.3 In the design of the end fittings, axial movements of the carcass relative to the end fittings shall be mechanically restrained. In case of smooth bore pipes, the same is applicable for axial movements of the pressure armours. 5.3.3.5 For dynamic applications, fatigue life calculations shall be performed in accordance with items 5.3.1.8, 5.3.1.8.1 and 5.3.4.

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5.3.4 Service Life Analysis 5.3.4.2 Service Life - Dynamic Applications

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5.3.4.2.1 For dynamic applications the service life analysis given in item 5.3.4.1.1 shall first apply. In addition, a fatigue analysis shall be performed for both the pressure and tensile armour layers, which shall take into account all mechanical and dynamic effects that may introduce failure modes into the pipe in the dynamic application. As a minimum, the effects of stress concentration due to bending and strain-hardening (as a result of the end fitting assembly process), wear, fatigue, fretting, material degradation including corrosion, and degradation and draining of lubricant shall be accounted for. 5.3.4.3 Fatigue Analysis For dynamic applications, the analysis of load conditions shall show that the extreme stresses in the pressure and tensile armour layers are below the endurance limit, otherwise fatigue-damage calculations should be performed. Fatigue-damage calculations shall be based on Miners method using design S-N curves, which have been validated for the used wire materials, under the applicable service environmental. Besides, for service life prediction, manufacturer fatigue methodology shall be assessed, by means of tests, in order to quantify the fatigue performance losses of the tensile armour wires inside the end fitting, due to the as built conditions. As built is herein understood when wires are pulled and subjected to local bending moment and shear load introduced by the geometry of the end fitting and by the embedded resin. Also, when wires are strain-hardened during the end fitting assembly process, and subjected to geometric changes. The fatigue life analysis shall also confirm that the internal pressure sheath and outer sheath maintain integrity under the calculated alternating strains. 5.3.4.4 Risers for Reduced Service Life 5.3.4.4.1 If duly designed by the manufacturer, for reduced pipe service life (typically 5 years) and when the purchaser classifications of the flexible pipe system and of the connected equipment are considered to have low risk on safety, environmental damage, and operability of the production system, riser might not have an interlocked pressure armour. In this case, special attention shall be taken regarding the combination of the following: a) creep extrusion of the pipe internal pressure sheath through the tensile armours gaps at low curvature regions of the riser (e.g. TDP); b) ageing of the pipe internal pressure sheath due to agents such as time in service, composition and features of the conveyed fluid, including, for instance, chemicals, H2S, CO2, O2, pH, TAN, temperature, and BSW throughout the pipe service life. 5.3.4.4.2 Also, the impact of the reduction of the weight of the riser on its stability during installation and operation, due to the eventual lack of an interlocked pressure armour, shall be taken into consideration by the manufacturer. When preparing the In Service Inspection, Monitoring, and Maintenance/Replacement Programme, manufacturer shall include checking of the riser outer sheath just after the pipe installation (as laid inspection) and during operation in order to minimize risk of failures due to tensile armouring corrosion. 27

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5.3.5 Global Analysis - Requirements and Recommendations Unless otherwise specified, Global and Local Analyses shall comply with section 8 of standard API RP 17B and with the additional requirements and recommendations presented hereafter. 5.3.5.1 Conventions for referencing meteocean data, vessel position coordinates (riser connection, point for motions) and RAO shall be properly translated to the riser analysis modeling tool in order to generate consistent results. When filling in TABLE A-1 of ANNEX A, purchaser shall inform the conventions of the provided data. 5.3.5.2 The structural damping as cited in standard API RP 17B, item 8.2.3.1.4, shall be assumed as no more than 5 % of critical value corresponding to the wave period. Purchaser may approve the use of higher values if properly justified by the manufacturer by means of analysis and tests results. The above mentioned damping value is associated to Rayleigh damping model used in softwares based on implicit integration scheme. If the manufacturer intends to use a different approach, the values adopted shall be validated against the above mentioned methodology through the comparison of their results. Also, this validation shall be justified and submitted to the purchaser. 5.3.5.3 The global analysis model shall include, for the critical loading cases, the bend stiffener. Results shall demonstrate that the bend stiffener can properly protect the pipe. 5.3.5.4 Motion and Wave Modeling Procedures The motion and wave modeling procedures described hereafter shall be applied, according to the indicated analysis purpose, riser configuration and vessel motion, as per TABLE 6C.

TABLE 6C - REQUIRED ANALYSIS PROCEDURE

Analysis Purpose Vessel Motion Maximum Top and Bottom Tension, Minimum Bending Radius, Minimum Riser Length EHMP & IWP or DWP & IWP DWP & IWP EHMP Bending Stiffener Verification and Dynamic Riser Top Region When Installing DWP & IWP DWP & IWP EHMP

I - Dynamic Riser Configuration

(a) Free hanging (b) Others

SS or F(P)SO SS or F(P)SO Installation vessel

II - Installation (Static and Dynamic Pipes)

Notes:

1) SS means semi-submersible vessel. 2) F(P)SO means a ship-like vessel.

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5.3.5.4.1 Equivalent Harmonic Motion Procedure (EHMP) The following steps shall be followed: a) transfer the RAOs from the vessel center of movements to the riser top connection coordinates; b) obtain the response spectrum for the movements of the connection by crossing the wave spectrum and RAOs for the riser connection; c) determine the Rayleigh most probable maxima of motion displacements, for the connection movements; d) determine the zero up-crossing period for the vertical movement response; e) assume, for the riser connection regular movements, the maxima amplitude values as per paragraph c) above and period according to paragraph d) above; f) assume, for the regular movements of the riser connection, the same phase values of the transferred RAOs in paragraph a), taken for the corresponding period of paragraph d). Note: The above approach does not consider the direct wave action on the riser.

5.3.5.4.2 Design Wave Procedure (DWP) The following steps shall be followed: a) transfer the RAOs from the vessel center of movements to the riser top connection coordinates; b) obtain the response spectrum for the movements of the top connection by crossing the wave spectrum and RAOs for the riser top connection; c) determine the Rayleigh most probable maxima of motion displacements and accelerations, for the connection movements; d) determine the wave height (Hdesign) as the Rayleigh most probable maxima from Hs (significant wave height) as used to describe wave spectrum in paragraph b); e) evaluate periods (Tdesign1 and Tdesign2), which associated with Hdesign, shall furnish, respectively, the maximum harmonic displacement and maximum harmonic acceleration, both calculated as per paragraph c); among the possible T design values, chose the closest value to the wave peak period (Tp); this procedure shall be carried out, at least, 2 times, depending on top connection motion: (1) the most critical between surge/sway and heave, (2) the most critical between roll and pitch. 5.3.5.4.3 Irregular Wave Procedure (IWP) This procedure is to be considered as a validation check of the results of the above-mentioned procedures. Therefore, only the most critical loading cases, shall be analyzed according to this method. For each pipe, a minimum number of 4 full irregular analyses shall be chosen by following criteria: a) b) c) d) worst loading case for compression value; worst loading case for top tension; worst loading case for bending radius; worst loading case for bending stiffener design.

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Notes:

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1) When considering the specification of the number of harmonic components to describe wave spectra, a minimum number of 100 shall be considered. 2) The results coming from random analyses shall be statically processed in a way to give consistent and reliable maximum values. When simulating the chosen loading cases, 3 options are considered valid: a) to perform, at least 5, 30 minute simulations varying random seed for the initial harmonic components phases; the significant wave height shall occur at least once in each simulation; b) from simulated long time history (minimum 60 hours) of critical pipe top movement, select a minimum of 10, 5 minute windows to be analyzed; c) to perform a 3 hour simulation.

If the manufacturer is supplying a set of risers of the same structure which are to be connected to the same floating unit, purchaser might accept, if duly justified by the manufacturer, irregular wave analysis carried out for the riser(s) subjected to the most critical load conditions. For this purpose, manufacturer shall submit analysis that includes the riser(s) worst conditions indicated in paragraphs a) to d) above. 5.4 System Design Requirements 5.4.1 General 5.4.1.1 The design of the flexible pipe shall satisfy all specified system requirements referred in item 4.6, as listed in TABLE 8, and account for additional requirements as specified in items 5.4.2 to 5.4.6. The design shall be documented to meet all interface requirements specified by the purchaser or by the manufacturer. 5.4.1.4 The polymer/steel friction coefficient of the outer sheath material shall be used to design the system to withstand the compression forces of installation tensioners and to design the devices to be clamped to the pipe. Manufacturer shall design the pipe to withstand the loading imposed by the installation equipment. 5.4.2 Corrosion Protection 5.4.2.2 Surface Treatment All steel surfaces exposed to the external environment shall be prepared and coated for corrosion protection against all environmental conditions specified in Chapter 4, unless the material is documented to be corrosion-resistant in the specified environment. In addition to Chapter 4, the anti-corrosion coating shall protect end fitting, ancillary components, and accessories against long term exposure to the weather at the quay side (non protected area). The anti-corrosion protection shall be designed for the specified service life.

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5.4.3 Thermal Insulation

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5.4.3.2 As a criterion for the selection of thermal insulation material, the deterioration of its physical and mechanical properties due to fluids in the pipe annulus shall be taken into account; these properties shall be supported by test results and documented by the manufacturer. Tests and investigations on degradation of insulation materials shall includes verification of interactions among different kinds of deterioration caused by phenomena acting simultaneously such as creep, plasticization, hydro-thermal degradation and ageing. 5.4.4 Gas Venting 5.4.4.2 The following design requirements shall apply to the gas-venting system: a) to c) remain unchanged; d) gas relief valves used as part of the subsea pipe venting system shall not allow ingress of seawater for the full range of external pressure, from low pressure to high pressure (pressure equivalent to the specified maximum water depth); e) and f) remain unchanged; g) gas relief valves shall be qualified as per Chapter C-3 of ANNEX C. 5.5 Prototype and Production Tests 5.5.1 Whenever the proposed product is a prototype, prototype qualification tests shall be carried out by the manufacturer after the product passed in the development testing phase, if any. Unless otherwise specified, manufacturer shall adopt at least the test scope and procedures outlined in ANNEX C. 5.5.2 Even if a product is not a prototype, the purchaser can require production tests, which purpose is to confirm the pipe performance and check the control of the manufacturing processes. Procedures for carrying out production tests are generally those basic procedures specified in ANNEX C for prototype qualification tests. 5.5.3 Manufacturer is in charged of carrying out all investigations, analyses, and complementary tests if some non-conformity is noted in prototype qualification tests or in production tests. In principle, results of re-tests will not be accepted by the purchaser, unless the eventual failure cause is easily identified by the manufacturer (and accepted by the purchaser) and also if it is not being linked to the product itself, but originated due to the test equipment, sample preparation or procedure. Purchaser can reject any result of re-testing not previously agreed. 5.5.4 Manufacturer shall submit to the purchaser and IVA the results of the prototype qualification tests and of the production tests, as soon as they are completed, in order to allow the review of the design methodology validation and of the manufacturing process control.

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5.5.5 Test Procedures and Reports

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5.5.5.1 Procedures for carrying out prototype developing tests are not standardized herein as the product concept, constituent materials, and manufacturing processes cannot be previously foreseen by the purchaser. Therefore, the use of the basic procedures for the purpose of qualifying new product concepts may not be considered adequate or sufficient. In this case, manufacturer shall identify other tests necessary to confirm the product performance as its concept, the analyses of its failure modes and weak points, and the manufacturing capabilities are manufacturers responsibilities. It is anticipated that the approach for carrying out developing tests, as their purpose involves the validation of design methodologies, shall be much more comprehensive (in the investigation of all identifiable failure modes) and precise (in the data gathering, during tests). Consequently, development test programs, in principle, shall include a great variety of test bench/equipment and more accurate instruments, not usually required for prototype qualification tests. 5.5.5.2 Some basic prototype qualification test procedures are standardized in ANNEX C of this Standard which also define the minimum content of the detailed procedure and test report. These procedures are valid for conventional pipes, i.e. pipes which concept follows the configuration of layers and end fitting showed, respectively, in Figures 6 and 8 of standard API RP 17B. 5.5.5.3 Manufacturer shall submit to IVA and purchaser the prototype qualification and production test procedures and reports, at specified times, as per item 8.1.2. 5.5.5.4 Qualification test procedures shall indicate the predicted test results, failure mode, and their sequences, if any. In case a discrepancy occurs (oversizing confirmed by calculations, in this case, is not considered a discrepancy), manufacturer shall submit to IVA a complete technical report. IVA shall review the manufacturer design tools and manufacturer processes in order to identify possible causes of discrepancies. As a consequence, manufacturer shall provide purchaser a new validation of the design methodologies and manufacturing processes, which shall be approved by IVA. 5.5.5.5 Development tests shall be witnessed by IVA. Qualification tests, including field test, shall be witnessed by IVA and by the purchaser, at its discretion. 5.6 As Laid and In Service Monitoring and Inspection 5.6.1 The manufacturer shall provide purchaser relevant information that allows purchaser to carry out the as laid and in service monitoring/inspection of products to be supplied in order to assure their integrity. For this purpose, manufacturer shall consider its knowledge on the product design criteria, product weak points, uncertainties of its design tools, the uncertainties from the specified data (e.g. those from the conveyed fluid composition, external environment), based on information provided by the purchaser, grade of innovation of prototypes, and its background of manufacturing processes and performance of formerly supplied products to third parties.

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5.6.2 In order to make feasible the above mentioned monitoring/inspection of products, manufacturer shall suggest a Preliminary In Service Inspection, Monitoring, and Maintenance/Replacement Programme, as per item 8.2, including the supply of the mentioned documentation. For inspection/monitoring of products manufacturer shall provide, as applicable, the criteria corresponding to each defect, consequence, and possible cause as the columns named as such in Tables 24 to 26 of standard API RP 17B and to each failure mode, cause/origin showed in TABLE 6A of this Standard, taking into consideration that these non conformities can occur either in normal installation/operational conditions, when the operation is within the envelope of the specified data/conditions (e.g. when internal and external environments), or even when the product operation is outside of this envelope.

6 MATERIALS
For the purpose of this Standard, the following section and subsection of standard ISO 13628-2 have been modified as written hereafter. Additional clauses to this standard ISO 13628-2 are also found hereafter. 6.1 Material Requirements 6.1.3 Metallic Materials 6.1.3.2 Carcass 6.1.3.2.3 If the conveyed fluid contains entrained solids, the manufacturer shall calculate the erosion and erosion/corrosion rates for the specified fluid velocities and content throughout the service life of the pipe, and shall document that the calculated wear rates do not cause failure of the carcass. 6.1.4 End Fittings 6.1.4.1 Metallic Materials 6.1.4.1.3 The end fittings shall be resistant to corrosion by way of material selection or the use of suitable coating protection. If a corrosion protection is not specified, the use of cathodic protection is allowed only with the previous agreement of the purchaser. The material for the end fitting internal surfaces shall have documented resistance to erosion caused by solids entrained in the conveyed fluid. 6.2 Qualification Requirements and Recommendations 6.2.1 General 6.2.1.1 Test Requirements and Recommendations

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6.2.1.1.1 The physical, mechanical, chemical and performance characteristics of all materials in flexible pipe shall be verified by the manufacturer through a documented qualification programme. The programme shall confirm the adequacy of each material, based on test results and analysis that shall demonstrate the documented fitness for purpose of the materials throughout the specified service life of the flexible pipe. As a minimum, the qualification programme shall include the tests as specified in this subclause. The qualification of materials by testing shall consider all processes and assembly procedures (and their variation) adopted to produce the pipe, which may impair the properties and characteristics required by the design. 6.2.1.2 Test Data Test data shall kept on file for 20 years after delivery to purchaser, or throughout the service life, whichever is the longer. Manufacturer shall allow, on request by the purchaser, the prompt access of this documentation. 6.2.1.4 Test Methods The test methods shall be as specified herein. If test methods are not specified, the manufacturer may use his own methods and/or criteria or other ones developed by the raw material supplier. In such cases, the methods and/or criteria shall be documented and the results correlated with the specific material application. The documented performance shall be verified by IVA. Note: Normative references list some standards/guidelines for material testing. However, manufacturer can propose materials, which are not covered by such references. In this case, manufacturer shall submit to purchaser alternative standards or procedures for characterization and qualification of materials.

6.2.3 Polymer Test Procedures 6.2.3.3 Fluid compatibility 6.2.3.3.1 The manufacturer shall document the evaluation of all components of the environment to which the polymer is exposed, and perform tests on those components which are considered to possibly have adverse effects on the polymer. The criteria for acceptance shall be verified by IVA. 6.2.4 Metallic Materials 6.2.4.2 SSC and HIC testing 6.2.4.2.1 For sour service static applications, the HIC and SSC threshold limits of the steel wires shall be determined in accordance with items 6.2.4.2.2 and 6.2.4.2.3 and the manufactures document criteria.

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6.2.4.5 Fatigue Resistance

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For dynamic applications, steel wires shall be subjected to the following testing and evaluation, or equipment documentation provided. See standard API RP 17B for recommendations on fatigue testing and interpretation. S-N data shall be documented or generated for the following conditions: a) to c) remain unchanged; d) exposed to seawater (minimum 3 % NaC), at atmospheric pressure, at temperature between 12 C to 23 C (53.6 F to 73.4 F), with wires degreased and under the as built condition (with local bending moment and shear load introduced by the geometry of the end fitting and strain-hardening, as a result of the end fitting assembly process), and tested in accordance with the manufacturer's specifications; alternatively, as per item 5.3.4.3, fatigue performance losses can be quantified through full scale dynamic testing of pipe samples.

7 MANUFACTURING REQUIREMENTS
For the purpose of this Standard, the following section and subsection of standard ISO 13628-2 have been modified as written hereafter. Additional clauses to standard ISO 13628-2 are also found hereafter. 7.1 Quality Assurance 7.1.3 Process Control All main steps in the manufacturing process shall be subject to inspection. manufacturers quality plan shall specify inspection points, inspection methods acceptance criteria. Results of all inspections shall be recorded. The manufacturer record every non-conformance verified during manufacture of the pipe. Process control be performed as a minimum for the following manufacturing processes as applicable: a) to d) remain unchanged. Note: When the process control is performed through the measurement of the layer characteristics in intervals, as per items 7.2.2.2 and 7.4.2.2, then they may be increased provided that manufacturer has statistics demonstrating that the process is controlled. The and shall shall

7.2 Carcass 7.2.2 Inspection and Acceptance Criteria 7.2.2.2 The external diameter and ovalization shall be measured and the interlock checked at the start of the production run. Subsequent of this, these parameters shall be controlled (measured and checked) at least each 10 m or as agreed with the purchaser. All results shall be recorded and shall be in accordance with the manufacturers specifications and agreed with the purchaser, which shall conform to the requirements given in item 7.8.

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7.3 Polymer Extrusions 7.3.2 Inspection and Acceptance Criteria

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7.3.2.2 Thickness and diameter of the internal pressure sheath and the outer sheath shall be continuously measured (i.e. at least 1 measurement per second). Manufacturer shall record process statistical data at intervals, agreed with purchaser, throughout the extrusion process. Thickness shall be measured at the bottom, at the top and at both sides of the layer cross section. For the other extruded layers thickness and diameter measurements shall be recorded every 10 m (32.8 ft) for the first 50 m (164 ft), at these cross section positions; subsequently, the thickness and diameter shall be measured and recorded at intervals verified by the manufacturer to be acceptable. Measurements shall be taken after the cooling process. 7.4 Pressure and Tensile Armour Layers 7.4.2 Inspection and Acceptance Criteria 7.4.2.2 The external diameter, ovalization (in case of pressure armour), and pitch (in case of tensile armours) shall be measured and recorded at least every 10 m (32.8 ft) or at intervals mutually agreed. As an additional verification of the pre-forming process, the fishscaling and clearances between 2 adjacent strips/wires shall also be checked. The interference or gap between 2 adjacent layers (pressure armour and internal pressure sheath), as foreseen in the pipe design conception, shall be controlled. The results shall be within the tolerances as specified in item 7.8. 7.4.2.2.1 For the purpose of compliance with item 5.3.2.7.4, no radial gap is allowed between the tensile armours or between the tensile armour and the adjacent layers (including the holding bandage). The absence of gap shall be indirectly controlled during the process running. 7.5 Anti-Wear, Holding Bandage, and Insulation Layers 7.5.1 General The manufacturer shall ensure that anti-wear layers, the holding bandage, taped layers used as manufacturing aids, and insulation layers are applied in accordance with documented procedures. The procedures shall include requirements for control and monitoring of the tape application, the applied tension (in case of the holding bandage), the pitch, and the overlap of the strip, and shall document acceptance criteria for flaws. The measurements of relevant parameters for process control shall be recorded.

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7.6 End Fittings 7.6.2 Assembly

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7.6.2.3 Control features shall be established and documented to ensure that any overheating of epoxy resin or polymer layers is prevented during welding and assembling operations. Also, if required, in the end fitting assembly procedure, that the tensile armour wires need to be bent back, this bending process shall be controlled and documented. The wire bending radius shall not be less than that one adopted for qualifying the wire or the pipe, including the fatigue criteria of the design methodology. 7.6.3 Inspection and Acceptance Criteria 7.6.3.3 The manufacturer shall use a qualified and documented procedure to verify that sufficient epoxy resin has been injected into the end fittings so that no voids are left in the end fittings which would affect their functional performance.The volume injected shall be checked by measuring the mass of injected epoxy. For the end fitting assembling on board, checking of the voids by means of x-ray or gamma-ray is not allowed, unless previous and mutually agreed and if authorized by laws and regulations and by the installation contractor. 7.6.6 Gas Relief Valves 7.6.6.1 Calibration 7.6.6.1.1 Each valve shall be calibrated and its crack and reseat pressures shall be checked in 6 readings (i.e. 6 cycles of valve opening/closing). Valve inlet is to be subjected to pressurized air. Cycles of valve opening/closing shall be performed at a pressurization/depressurization rate of 0.05 MPa/sec. The end of a cycle is defined as the time when no bubbles are noted (i.e. valve closing is assured). Crack and reseat pressures are measured at the end of each of the 6 cycles. Test criteria is the following: a) for the 6 cycles, the specified crack pressure (Pc) is kept in the range Pc 0.05 MPa; b) minimum allowable reseat pressure (Pr) = 2/3(Pc). 7.6.6.1.2 The manufacturer shall provide purchaser a certificate of calibration of each valve which content shall include the value of the measurements carried out, the series number and type of the valve, identify the instruments used in the measurements, their uncertainties, and their traceability with standard instruments.

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7.7 Special Processes
7.7.1 Welding

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7.7.1.1 Qualification 7.7.1.1.1 All welding operations shall be performed by qualified welders in accordance with the manufacturers approved procedures. WPSs, WPQRs and welder qualifications shall be documented and shall be available for review by the purchaser. Welding procedure qualification shall be witnessed and approved and records of welder qualification shall be reviewed by IVA agent who is qualified to witness and approve the standards and criteria (being) used. For welding performed with automated processes or for welds that serve only as manufacturing aids, IVA witness of welder qualifications may be substituted by an ASNT qualified Level II inspector. Welders and welding procedures shall be qualified according to standards API Std 1104, ASME Section IX, EN 288-3 or equivalent. Procedures shall include acceptance/rejection criteria. 7.7.3 Coating 7.7.3.1 Anti-corrosion properties of the coating shall be adequate to protect end fittings in severe marine corrosive environments, during storage (see item 5.4.2.2) and service, upper and below the seawater surface or in the sea bottom, for the specified maximum water depth (considering the product under mud at the bottom), without any extra cathodic protection. However, if mutually agreed, for ancillary components and accessories, cathodic protection can be used. Anti-corrosion coatings applied to end fitting parts, ancillary components, and accessories shall be resistant against severe abrasion and impacts that typically occur during pipe handling and installation. Coatings applied to these items, to limit corrosion due to internal, external, or annulus environments, shall comply with the purchaser specification, if any, and the manufacturers documented procedures which shall include acceptance criteria. Otherwise, the coatings shall comply with the manufacturers documented procedures. 7.7.3.2 The qualification procedure for application of the metallic coating onto the end fittings, ancillary components, and accessories, shall specify the following as a minimum: a) bath composition; b) control of temperature, time and atmosphere for heat treatments; c) hardness test of coating (if electroless nickel coating is specified, the hardness test is not required); d) adhesion test of coating (as per standards ASTM B733 and ASTM B571) after heat treatment, and subsequent verification of lamination through bending test of a coated specimen; e) optical microscopy or a similar method recommended to analyze the cross section of the coated surface, in order to check minimum thickness of the interdiffusion between the base material and the metallic coating, if applicable; f) coating thickness measurement; g) testing to check the coating against flaws and porosity when it is subjected to the following corrosion agents: SO2 (preferable), salt spray or CO2; h) procedures for checking the following: - demagnetization of pieces before coating, whenever necessary;

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- before coating, through dye penetrant test, 100 % of the surface of pieces against porosity, cracks, indentation, inclusion, and pits; - after coating, inspection for flaws and porosity [for cathodic coating, through the use of potassium ferro-cyanide K4Fe (CN6)]; i) chemical composition of the coating; j) verification of the adequacy of the geometrical complexity and dimensions of the specimen used for qualification purpose of the coating in comparison with the component/accessory. 7.7.3.3 For the supply of products with metallic coating, the manufacturers written procedure shall comply, at least, with the following requirements, unless otherwise mutually agreed: a) bath composition; b) control of temperature, time and atmosphere for heat treatments; c) hardness test of coating (if electroless nickel coating is specified, the hardness test is not required); d) adhesion test of coating (as per standards ASTM B733 and ASTM B571) after heat treatment, and subsequent verification of lamination through bending test of a coated specimen; e) optical microscopy or a similar method recommended to analyze the cross section of the coated surface, in order to check minimum thickness of the interdiffusion between the base material and the metallic coating, if applicable; f) coating thickness measurement; g) procedures for checking the following: - demagnetization of pieces before coating, whenever necessary; - before coating, through dye penetrant test, 100 % of the surface of pieces against porosity, cracks, indentation, inclusion, and pits; - after coating, inspection for flaws and porosity [for cathodic coating, through the use of potassium ferro-cyanide K4Fe (CN6)]; h) for each bath (coating process and heat treatment) manufacturer shall perform the control of the process through coupons, properly traceable to the history of the component/accessory to be delivered; i) coupons shall be used for checking coating chemical composition (after each immersion bath and before heat treatments), thickness (before heat treatment), porosity and flaws (after coating and heat treatment), bending characteristics (after heat treatment), residual stresses before heat treatment (stresses shall be compressive or neutral), and thickness of the interdiffusion of the coating, if specified, after heat treatment. 7.8 Manufacturing Tolerances 7.8.1 The manufacturer shall document the tolerances to be used for each layer of the flexible pipe. These tolerances shall be verified in the design process to be acceptable, in that the functional requirements of the individual layers and pipe are unaffected by variations within the specified tolerances. As a minimum, tolerances shall be specified for the following parameters: a) carcass: external diameter and ovalization; b) remain unchanged; c) pressure armour: external diameter, pitch (or lay angle), fishscaling, and gap between the pressure armour and the underlying layer, if any; d) tensile armours: external diameter, pitch (or lay angle), and fishscaling; 39

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e) holding bandage: external diameter, number of layers, direction of application over the pipe body, pitch (or lay angle), and overlap. 7.8.2 The tolerance for the length of the flexible pipe (with end fittings assembled) shall be the following: +(0.5 % of the pipe length + 10 m)/-0 m; 7.8.5 The tolerance for the pipe OD is 5 % of the nominal value submitted by the manufacturer to the purchaser in the design report.

8 DOCUMENTATION
For the purpose of this Standard, the following section and subsection of standard ISO 13628-2 have been modified as written hereafter. Additional items to standard ISO 13628-2 are also found hereafter. 8.1 General All the documentation mentioned in clause 8 shall be submitted to the purchaser. In addition, at any time, manufacturer shall promptly make it available to the purchaser on request. 8.1.2 Unless otherwise mutually agreed, manufacturer shall submit the purchaser (and also IVA, in case of prototypes), at the specified times, the following documents: a) f) g) h) i) to e) remain unchanged; as-built documentation: before the delivery of the pipe and any time on request; operating manual: remains unchanged; qualification test procedures, if production tests are required: prior to test run; qualification test reports, if production tests are required: prior to commencement of manufacture or before the delivery of the pipe, as per contractual arrangement; j) if the supply of prototype is allowed by the contractual arrangements, additional documentation, required by item 5.2.6: as per schedule of the prototype developing and qualification program mutually agreed at the commencement of contract. 8.1.3 Each pipe, ancillary component and accessory design shall have a specific identification number, generated by Manufacturer, associated to the its structure. The identification system of documents (data sheet, drawings) shall allow a quick recognition of its structural product design. New identification shall be attributed if any modification in the product design or manufacturing plant is carried out. 8.2 Design Premise The design premise shall contain the parameters as specified in TABLE 15. If the manufacturer has made assumptions on any of the parameters in TABLE 15, then it shall be specified in the design premise that the values are assumed. The design premise shall include all technical requirements and recommendations contained in the purchaser specification. 40

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TABLE 15 - DESIGN PREMISE

Parameter All other items remain unchanged In service inspection and monitoring (it covers installation and operating phases) Comments All other comments remain unchanged Preliminary In Service Inspection, Monitoring, and Maintenance/Replacement Programme, based on the failure modes already identified by the manufacturer as per its knowledge of product design criteria/weak points, and background of supplied products. For this, manufacturer shall estimate current uncertainties of its design tools and the uncertainties from the specified data (e.g. those from the conveyed fluid composition, external environment, based on the purchaser provided information). This programme shall include, at least, the following: - locations of the pipe/end fitting, ancillary components and accessories to be inspected/monitored; - specification of the inspection methods, equipment and criteria; - specification of criteria for inspection/monitoring (reference item 5.6 of this Standard); - recommended inspection/monitoring frequency; - description of the recommended maintenance actions, equipment, facilities, and logistic; - special access requirements for inspection, maintenance, and replacement; - loads imposed on product by the suggested inspection, monitoring and maintenance tools. All potential load cases for the flexible pipe system during manufacture, storage, transport, testing, installation, operation, and retrieval shall be addressed. A matrix showing the load cases to be checked for each component of the flexible pipe system shall be established and shall conform with the requirements given in clause 5 and in the purchaser specification. Required safety margins and structural capacities shall be specified for each layer of the pipe and components, and shall conform with the requirements given in clause 5 and in the purchaser specification. Manufacturer shall submit all safety margins which are not specified by the purchaser, including margins for fatigue prevention of ancillary components and accessories. S-N curves used in their design shall be made available, on request, at the manufacturer Brazilian office.

Design load case definition

Design criteria

8.4 Design report 8.4.1 The design report shall contain a detailed description, including drawings, of each pipe component. The description shall include a layer-by-layer description of the pipe, including specification and properties (original mechanical properties, as produced in the mill/subvendor plant, and those considered for dimensioning the pipe, e. g. after forming process in the pipe) of the materials, wire cross section and main dimensions, lay angle, diameter, thickness, number of wires, and so forth. 8.4.2 Unless separate material specification documentation is issued, material specification and data shall be included in the design report. Material data shall include yield or tensile strengths and fatigue parameters for dynamic service (S-N curve slope, intercept and endurance limit) and shall identify fluid components that may adversely affect material. S-N curves shall be according to items 5.3.4.2.4 (flooded annulus) and 6.2.4.5 (exposed to air, seawater and annulus environment). 8.4.3 Each component shall be documented to have sufficient structural capacity to sustain the design loads and stress listed in the design load report, with the safety margin specified in the design premise and agreed with the purchaser.

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8.4.5 The design report shall define, for the flexible pipe, the properties listed below. Wherever mentioned, permissible means a maximum load to which the pipe can be subjected without any damage or restrictions for future use, in relation to the requirements of this Standard and those from the original pipe specification, including its service life. The cause, origin, and location of the predicted damage or restriction shall be included in the report. a) remains unchanged; b) permissible axial compression for the following cases: pipe in straight line and bent at the operating MBR, both with the pipe annulus flooded; c) permissible crushing (radial), associated with the squeeze effect from the tensile armours, for the pipe section under the loading induced by the specified laying equipment, pipe empty and full of seawater; d) remains unchanged; e) axial and radial expansion or contraction induced by the maximum design pressure and design minimum and maximum temperatures; f) induced twist due to maximum design pressure and design tension; g) results of the global and local analyses for the specified installation and service conditions; h) pipe hydrostatic collapse resistance, as per item 5.2.3 of this Standard, considering, also, and the effects on this resistance of the crushing loads from the specified installation methods, equipment, and conditions; i) drawings (not including manufacturing drawings), specification and properties of materials, data used in calculations, accurate dimensions regarding interfaces, and design calculations of end fittings, ancillary components and accessories (fatigue included for items subjected to relevant dynamic loading); j) installation requirements and limitations: it shall be confirmed the critical parameters and requirements for the installation such as top installation angle, environmental conditions (pipe flood or empty), and maximum radial and axial loads, taking into account the installation equipment and basic procedure specified by the purchaser, if any. 8.7 As-Built Documentation The as-built documentation shall include, as a minimum, the following: a) to f) remain unchanged; g) all reports regarding non-conformities identified during manufacture, repairs and inspections performed after repairing, including the traceability of the affected region and its location with regards the pipe end fittings, position in the accessory; h) to l) remain unchanged; m) pipe maximum and minimum OD and length between end fittings; n) drawings of ancillary components and accessories, indicating dimensions, SWL (safe working load), weight, and summarized assembly instructions (specified torque of bolts). Note: Regarding paragraph g) above, non-conformity reports shall be included in a separated section of the as built data book.

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8.8.1 The operating manual shall be prepared for the system and shall address all maintenance tasks and restrictions, and emergency procedures, including repair procedures to be used on board the installation vessel, as specified by the manufacturer or purchaser. The manual shall include the following as a minimum: a) to c) remain unchanged; d) design minimum and maximum pressure, and test pressures (specify if design pressure is absolute value or differential); for safety reasons, for testing in air (external pressure is the atmosphere pressure), if the pipe is designed for differential pressure, the hydrostatic test pressure shall be highlighted; e) to i) remain unchanged; j) handling, storage, winding/unwinding procedures and limitations; k) and l) remain unchanged; m) restrictions on internal fluid components including, H2S, CO2, acids, bromides, amines, and inhibitors; n) remains unchanged; o) allowable maximum loads and top angle (risers); p) and q) remain unchanged; r) estimate service life (demonstration based on results of service life modeling) considering the more severe combination of the specified variables and their variations (along time) such as temperature, BSW, pH or TAN, CO2, SO2, O2 and chemicals content and characteristics of the internal fluid; s) detailed in service inspection, monitoring, and maintenance/replacement plan based on the requirements of TABLE 15. 8.8.3 In order to speed up solutions regarding pipe/ancillary components/accessories damage which may occur during their storage, handling, installation, and operation, manufacturer shall have procedures for repairing them in such situations, whenever possible. The scope of such procedures, which shall be proper for use in a non-protected area and on board of the installation vessel, shall cover, at least, the repair of the outer sheath and of the holding bandage layers. The execution of any repair in a pipe section shorter than 0.5 m should not take more than 8 h. The end fitting assembly should take around 24 h, under normal conditions. The requirements mentioned in item 7.9 are applicable for repairing pipe during handling, storage, installation, and operation. Procedures shall contain the list of required equipment, materials, qualified personnel, logistic and facilities. 8.9 Production Tests - Test Procedures and Reports As per 5.5.2, standard procedures and reports, when applicable, shall comply with ANNEX C of this Standard. 8.10 Documentation Regarding Prototypes When applicable, prototype developing and qualification program and its results, shall comply with item 5.2.6 and contractual arrangement.

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10 MARKING AND PACKAGING

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For the purpose of this Standard, the following section and subsection of standard ISO 13628-2 have been modified as written hereafter. Additional clauses to standard ISO 13628-2 standard are also found hereafter. 10.1 Marking The flexible pipe marking shall be applied to both end fittings and shall make the pipe permanently identifiable throughout the specified service life. As a minimum the following markings shall be applied: a) serial number of pipe; b) manufacturers name or mark; c) date of manufacture; Note: In addition the following markings shall be applied as specified by the purchaser: d) circular marking at regular intervals along the pipe length for reference during installation and surveys; e) longitudinal stripes on pipes (risers, flowlines, and jumper) to assess twist during installation and in service; f) for traceability purpose of each end fitting, ancillary component and accessory (exception to small size accessories such as bolts/nuts) their serial numbers shall be marked on them. 10.2 Packaging, Port, Road and Storage Facilities and Restrictions 10.2.4 For delivery purpose, manufacturer shall comply with the specified limitations of the purchaser equipment and facilities such as maximum allowed draft of a vessel in the port, barge crane limitations, equipment for handling and transportation (use of standard reels), support of the reel (cradle is available only for standard reels), maximum load in the storage floor, roads, and bridges.

11 SERVICING AND AFTER DELIVERY REQUIREMENTS

11.1 Manufacturer shall provide, at purchasers request, support for servicing at any time during the specified pipe service life. Irrespectively of which party is the responsible for an eventual non-conformity, all procedures and criteria necessary for evaluation of pipe capacity, and carrying out of eventual repair, maintenance, inspection, and test of supplied pipes shall be justified and provided to purchaser by the manufacturer. Manufacturer shall maintain qualified personnel for promptly carrying out of such activities, in order to give an opinion about the pipe integrity for the remaining service life, considering the original specification and the pipe history. In case that manufacturer suggests a pipe down grade or rejection, it shall be duly justified before the purchaser through a comprehensive technical documentation. If required, IVA shall approve the justification provided to the purchaser.

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11.2 For pipe reuse, manufacturer shall estimate the remaining life of the product for new projects, based on information provided by the purchaser. For this purpose, purchaser shall allow the manufacturer to perform necessary inspections and tests in the entire pipe or in its samples in order to detect non-conformities, defects, and stage of degradation. _______________

/ANNEX A

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ANNEX A - FLEXIBLE PIPE PURCHASING GUIDELINES

As per Annex A of standard ISO 13628-2. ______________

/ANNEX B

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ANNEX B - BEND STIFFENERS AND BEND RESTRICTORS

As per ANNEX B of standard ISO 13628-2. _____________

/ANNEX C

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ANNEX C - REQUIREMENTS AND RECOMMENDATIONS FOR PROTOTYPE QUALIFICATION TESTS C-1 PROTOTYPE QUALIFICATION TESTS
C-1.1 General C-1.1.1 This ANNEX C is based on standard API RP 17B. All items related to standard API RP 17B mentioned in this ANNEX, are mandatory. C-1.1.2 This ANNEX C defines some standardized basic qualification test procedures applicable to conventional flexible pipes (Pipes which concept follows the configuration of layers and end fitting showed, respectively, in Figures 6 and 8 of standard API RP 17B). Also, these procedures are only valid for products concepts which have been already considered field proven by the purchaser. C-1.1.3 Test samples shall represent the actual product to be supplied, considering both, the design methodology and the manufacturing processes. Training and manufacturing instructions for operators, processes and machines used to produce test samples and products to be delivered shall be the same. If previously and mutually agreed, the sample can include weak points (such as weld, repairs or process variations) and extreme manufacturing tolerances, in order to check the product performance against the established criteria. C-1.1.4 Before testing, manufacturer shall issue and submit to the purchaser a detailed test procedure including, at least, the following items: a) purpose of the test; b) description of the test bench, including dimensions, load capacity range, displacement range, sketches, photos and limitations, if any; c) description of test sample, including size, type and characteristics (data sheet and drawings of ancillary components and accessories); d) measuring, monitoring and recording equipment and instrumentation (including their accuracy, resolution, and sensitivity); e) description of the equipment and measures necessary in order to avoid hazard of personnel involved in the test; f) description of test preparation and sample conditioning; g) test description; h) description of the data acquisition system and treatment procedure; i) data forms to be recorded and filled in, during test; j) acceptance criteria, predicted results, and corresponding loading, deformation, strain, stresses, wear, and failure mode(s) and sequence of failures of pipe layers, ancillary components and accessories, when applicable; k) references, if any; l) schedule of tests and reference of the laboratory or company that will carry out the test.

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C-1.1.5 After testing, manufacturer shall present a detailed test report including, at least, the following items: a) gathered data and final results; b) uncertainties of instruments and calculated global uncertainties of measurements; c) comparisons between predicted and observed values, data, and sequence of failures, if applicable; d) conclusions; e) certificates of calibration of test equipment and instrumentation (including traceability reference with National standards); f) traceability of the test sample, including summary of raw material certificates, reference of the position where the sample was gathered from the pipe); g) findings of dissection, if required. C-1.1.6 Prototype dissection (including end fitting and ancillary components) shall be done whenever sample fails, irrespectively if dissection was previously required or not by the purchaser. Evaluation of failures and abnormalities shall be carried out and reported by the manufacturer. C-1.1.7 In order to verify prototype performance, the tests shall simulate typical and extreme loads and boundary conditions to which the product shall be subjected during its installation (including handling) or operation phases, for example. If the purpose of the test is to check pipe capacity, the test loading shall achieve: the loading corresponding to the extreme loading in service (utilization as per Chapter 5 of this Standard), the loading corresponding to the predicted damage (utilization = 1), and the loading corresponding to the pipe failure. Whenever ancillary components and accessories affect the test result, test sample shall include them. C-1.1.8 If pipe structure accommodation can affect the results, manufacturer shall evaluate the necessity of cycling the sample internal pressure, before testing. C-1.1.9 Manufacturer may suggest modifications on the test basic procedures described herein, in order to adjust available facilities and equipment ready to use, or to better investigate design predictions and failure modes, for a specific design concept. Manufacturer may also adjust test conditions to better represent the operational conditions. However, any suggested modification shall keep the test purpose, comprehensiveness, and the variables to be monitored, registered and recorded. Modifications of the basic procedures herein described, if any, shall be submitted to the purchaser and be clearly identified in the detailed test procedure. Note: It should be understood that test requirements found hereafter shall never be considered as a reason for over-dimensioning the product besides the specified functional requirements and recommendations (reference Chapter 4 and other contractual or performance specifications).

C-1.1.10 All tests instruments shall be adequate and compatible with the value of the variable to be measured. Manufacturer shall inform, for all test instruments, their accuracy, for the range of application, as well as their status of calibration. 49

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C-1.1.11 Qualification tests shall only be carried out after the approval, by the purchaser, of its procedure. C-1.1.12 Qualification tests shall be witnessed by IVA and a representative of the purchaser, at its discretion. C-1.1.13 Manufacturer shall assure the tests are carried out in accordance with safety, health, environmental requirements, and country regulations. Precautions shall be taken in order to avoid hazardous to personal and premises. C-1.2 Description of the Variables C-1.2.1 The variables are defined herein, based on the state in which they are measured, using the following terms: a) initial - dimensions before the beginning of the test (unloaded sample); b) loaded - dimensions obtained with the sample under loading; c) residual - dimensions obtained after load relief (unloading the sample, after each loading cycle included in the test procedure). C-1.2.2 Identification and expression of the variables to be used for data gathering, reports or any test document shall use the following terms (for a given pipe cross section, horizontal and vertical diameters, mean diameters measured at 2 different positions, 90 apart one from the other): a) b) c) d) e) f) g) LI - initial length; LL, LR - loaded and residual lengths, respectively; DVI, DHI - initial vertical and horizontal diameters, respectively; DVL, DHL - loaded vertical and horizontal diameters, respectively; DVR, DHR - Residual vertical and horizontal diameters, respectively; DMI, L, R - mean diameter, initial (I), loaded (L) or residual (R) values: OVI,L,R - sample ovalization (see definition, item 3.1.75), initial (I), loaded (L) or residual (R) values:

D M l; L; R =

DV l; L; R

h) percent length deformation for loaded sample and residual, respectively:

LL LI LR LI L L = L L 100 and L R = 100 I I

i) percent diameter deformation for loaded sample:

DVL DVI DHL DHI DVL = 100 and DHL = 100 DVI DHI

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j) percent residual diameter deformation:

DVR = DVR DVI DHR DHI and DHR = DVI DHI

C-2 BASIC QUALIFICATION TEST PROCEDURES

C-2.1 Burst Test C-2.1.1 Description

As per standard API RP 17B, item 9.5.1.1. C-2.1.2 Procedure As per standard API RP 17B, item 9.5.1.2.
C-2.1.3 Acceptance Criteria

The measured burst pressure shall be greater than 2 times the maximum design pressure. Further, the following shall not occur: a) b) c) d) e) yield or rupture of any structural part of the end fitting; leakage through the sealing system of the end fitting; failure of any tensile/pressure armour wire inside the end fitting body; loss of the anchoring system of the tensile armors; tensile armour wire pull-out from the end fitting.

C-2.2 Axial Tension Test C-2.2.1 Description

C-2.2.1.1 The purpose of this test is to verify the pipe elongation, diametric deformation, and twist against the design predictions and pipe tensile capacity. This test shall check the consequences on pipe performance characteristics such as reduction of structural capacity to buckling and pull out or rupture of tensile armours from the end fittings. Also, this test shall check the axial stiffness informed by the manufacturer. If required, this test may also check the structural damping of the pipe, with the same purpose. Manufacturer shall previously inform the pipe maximum tensile capacity and the theoretical curve Tension x Axial Deformation for the test temperature. Test results shall be in accordance with these predictions. A second stage of this test shall be performed up to sample rupture. Failure mechanism and location shall be recorded. When internal diameter pig measuring is required, manufacturer shall previously inform the maximum allowed deformation for which the pipe hydrostatic collapse resistance criteria is not affected, for the specified maximum water depth.

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C-2.2.1.2 Unless otherwise specified above, the test shall comply with item 9.5.2.1 of standard API RP 17B.
C-2.2.2 Procedure

C-2.2.2.1 As per standard API RP 17B item 9.5.2.2 (Procedure) with the following additions or modifications: C-2.2.2.2 The sample is axially loaded in steps until the Design Tension. During loading, and after unloading the following parameters shall be continuously registered and recorded: a) sample longitudinal elongation; b) sample twist; After removing the outer sheath at the middle of the sample: c) external diameter and perimeter (measured over the outermost tensile armour or hoding bandage). C-2.2.2.3 If required, one or more pigs shall be used to check the reduction of the internal diameter before and after the test. C-2.2.2.4 After measuring the above parameters, the sample is axially loaded until failure, at the rate not exceeding 300 kN/min. An intermediated visual inspection shall be performed after the tension load achieves 1.50 times the Design Tension, in order to check the sample against failures.
C-2.2.3 Acceptance Criteria

The acceptance criteria for sample longitudinal elongation, horizontal and vertical diametric deformations, and twist, for loaded (Design Tension) and unloaded conditions, are given in TABLE C-1.

TABLE C-1 - ACCEPTANCE CRITERIA FOR DEFORMATION AND TWIST

Parameter Loaded

ELONGATION,

DIAMETRIC

Unloaded (Residual)

Longitudinal Elongation External Diameter Deformation Twist

-1.5 % LL + 1.5 % -3.0 % DVL + 3.0 % -3.0 % DHL + 3.0 % 0.6 degree/m

-0.5 % LR + 0.5 % -1.0 % DVR + 1.0 % -1.0 % DHR + 1.0 % 0.2 degree/m

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In addition to the criteria in the TABLE C-1 above, the following applies: a) for longitudinal elongation, axial stiffness of the pipe obtained from the test shall be in accordance with manufacturer predictions; b) for unloaded condition criteria for pipe internal diameter deformations shall comply with the manufacturer carcass design tolerance; c) failure mechanism and location shall be as predicted by the manufacturer. The measured failure tension shall be greater than 1.50 times the Design Tension; d) no structural damage of the end fitting itself (e.g. cracking or rupture of its structure) or of pipe layers (e.g. wire rupture) shall be observed before the test maximum tension load is achieved (i.e. up to 1.50 times the Design Tension). Note: If mutually agreed and if the design predicted elongation is larger than the test criteria for longitudinal elongation (reference TABLE C-1), these criteria can be relaxed, provided that (i) the design predictions are confirmed during the test and (ii) the product complies with the specifications and functional requirements (reference Chapter 4 of this Standard).

C-2.2.4 Alternatives

As per standard API RP 17B, item 9.5.2.5, but keeping the same criteria specified above in item C-2.2.3.
C-2.3 Collapse Test C-2.3.1 Description

C-2.3.1.1 The purpose of this test is to evaluate the pipe resistance to external pressure and also to verify the adequacy of the end fitting inner sealing system(s), for the external pressure. If mutually agreed, before the contract execution, this test can be carried out with sealed simplified end caps that simulate the end fittings. C-2.3.1.2 The test description found in standard API RP 17B, item 9.5.3.1 applies, but adopting 10 times the internal diameter for the minimum length of the test sample. C-2.3.1.3 In addition, this test shall be carried out with a sample which has already been used in a test that simulates typical installation conditions (crush strength test). The purpose is to verify the pipe performance against hydrostatic collapse after being subjected to typical and representative installation loading.
C-2.3.2 Procedure

C-2.3.2.1 The test shall be performed in 2 stages: verification of the adequacy of the end fitting inner sealing system(s), for the design external pressure, and collapse the sample after increasing external pressure. During both stages, external pressure and ambient temperature shall be continuously monitored and registered. 53

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C-2.3.2.2 At the first stage, the external pressure is pressurized at a maximum rate of 10 MPa/min until a value between 1.0 times and 1.2 times the design external pressure. The pressure is kept within this range during a minimum 24-hour period, after stabilization is confirmed. C-2.3.2.3 At the second stage, the external pressure is increased at a maximum rate 10 MPa/min. Before the predicted collapse is reached, the pressure shall be stabilized during at least 15 minutes in 2 intermediate pressure steps (equally estimate in relation to the predicted collapse pressure). Sample is than led to the collapse.
C-2.3.3 Acceptance Criteria

C-2.3.3.1 For the first stage, acceptance criteria are: no external pressure drop, measured inside the hyperbaric chamber, to a value lower than the design external pressure and no leakage are accepted, during the whole test period. C-2.3.3.2 For the second stage, the measured collapse pressure shall be equal or greater than the predicted pipe hydrostatic collapse resistance estimated by the manufacturer [Ref. clause 5.2.3 of this Standard]. Also, the measured collapse pressure shall be equal or greater than the ratio between the design external pressure and the specified utilization, as per TABLE 6 of this Standard.
C-2.4 Crush Strength Test C-2.4.1 Description

C-2.4.1.1 The crush strength test is performed to determine the suitability of a particular design for installation with tensioners while the pipe is loaded to the laying tension. The number of tensioner belts shall be as specified for the installation vessels. C-2.4.1.2 The test set-up shall represent the tensioner system on the particular installation vessel, with the same number of belts and geometry of shoes. Shoes length shall have at least 0.40 m. The minimum length of the sample shall be 10 times the internal diameter.
C-2.4.2 Procedure

The pipe sample shall be positioned - empty without internal pressure - on the test device. Before apply the compressive load, the sample is uniformly axial and uniformly loaded, at a rate not exceeding 300 kN/min, until the laying tension is achieved. This load shall be kept constant, within +4 % maximum variation, during the whole test period. The radial compression load is increased from zero up to the Design Crushing Load, at a rate not greater than 1 % of the maximum load per second (1 %/sec). The radial compression load shall be kept constant (within 2 %), for a period of at least 1 hour. Loaded and residual maximum diametric deformations (DMax) and residual maximum ovalization (OVMax) of the pipe shall be obtained as the following:

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a) internal diameter deflection (or radial deflection) shall be measured in the sample cross section positions located underneath the shoes (and, if possible midway between adjacent shoes); b) DMax calculated as the ratio between the highest measured internal diameter deflection (or twice the highest radial deflection) and the initial diameter; c) OVMax calculated, for the deformed section, as per item 3.1.75 of this Standard. Note: In case of test bench load restrictions, if previously and mutually agreed, test crushing load can be reduced to the maximum crushing load for the specified application (reference item C-1.1.9).

C-2.4.3 Acceptance Criteria

The acceptance criteria for the maximum diameter deformation and maximum ovalization, for loaded and unloaded conditions are given in TABLE C-2.

TABLE C-2 - ACCEPTANCE CRITERIA FOR DEFORMATIONS/ OVALIZATION

Parameter Loaded Unloaded (Residual)

Diameter deformation Ovalization (rough bore pipes) Ovalization (smooth bore pipes)

-3.0 % DMax +3.0 % -1.5 % OVMax +1.5 % -1.5 % OVMax +1.5 %

-1.0 % DMax +1.0 % -0.2 % OVMax +0.2 % -0.5 % OVMax +0.5 %

C-2.4.3.1 If the maximum carcass design tolerance specified by the manufacturer for hydrostatic collapse, as per item 5.3.2.4 paragraph a) is greater than the one indicated in the TABLE C-2 for unloaded condition (i.e. 0.2 %), it shall prevail over the criterion defined herein. C-2.4.3.2 In addition, the same sample shall be subjected to the hydrostatic collapse test and the measured collapse pressure shall be equal or greater than the predicted pipe hydrostatic collapse resistance estimated by the manufacturer (reference item 5.2.3 of this Standard). Also, the measured collapse pressure shall be equal or greater than the ratio between the design external pressure and the specified utilization, as per TABLE 6 of this Standard. If the pipe is insulated, the sample shall be dissected up to the insulation layer in order to verify the integrity of this material, prior to the carrying out of the collapse test. The manufacturer shall previously inform in the test procedure the criteria for integrity of the insulation material.
C-2.5 Combined Bending and Tension Test C-2.5.1 Description

C-2.5.1.1 As per standard API RP 17B, item 9.6.3.1.1.

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C-2.5.1.2 As per standard API RP 17B, item 9.6.3.1.2, but test sample shall have a minimum length of 20 times the internal diameter excluding both end fittings. As a general rule, half of the test sample shall be positioned in a straight manner, while half of it is bent.
C-2.5.2 Procedure

C-2.5.2.2 The axial load is applied at a rate not greater than 1 % of the Laying Tension per second up to 110 % of its value. The allowable variation of this load shall be 2 %. This load is held for a minimum period of 1 hour. The axial load is released, and the diameter measurements retaken. C-2.5.2.3 If required, one or more pigs shall be used to check the reduction of the inside diameter before and after test. C-2.5.2.4 All measurements shall be made directly on the sample outermost tensile armour or holding bandage. C-2.5.2.5 During loading, the following parameters shall be registered and recorded: a) sample longitudinal elongation in the straight sample section, which shall have at least 4 times the pipe internal diameter (reference marks shall be positioned at a minimum distance of 2 diameters from the end termination); b) horizontal and vertical external diameter (DV and DH), in the curved section of the pipe, with one location being the contact face of the pipe. Note: If axial tension test is carried out for the pipe, paragraph a) above can be disregarded.

C-2.5.2.6 After carrying out the measurements, the sample region in contact with the dummy sheave shall be subjected to the collapse test.
C-2.5.3 Acceptance Criteria

The acceptance criteria for the external diameter deformation, sample ovalization, and longitudinal elongation, for loaded and unloaded conditions, are given in TABLE C-3.

TABLE C-3 - ACCEPTANCE CRITERIA FOR THE DIAMETRIC DEFORMATION/ OVALIZATION

Parameter External Diameter Deformation Loaded -3.0 % DVL +3.0 % -3.0 % DHL +3.0 % Unloaded (residual) -1.0 % DV R +1.0 % -1.0 % DH R +1.0 %

Ovalization Longitudinal Elongation

-1.5 % OVL +1.5 % -1.5 % LL +1.5 %

-0.5 % OV R +0.5 % -0.5 % L R +0.5 %

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In addition to the criteria in the TABLE C-3 above, the following applies: a) for longitudinal elongation, axial stiffness of the pipe obtained from the test shall be in accordance with manufacturer predictions; b) for unloaded condition, criteria for pipe internal diameter deformations shall comply with the manufacturer carcass design tolerance; c) no structural damage of the end fitting itself (e.g. cracking or rupture of its structure) or of pipe layers (e.g. wire rupture) shall be observed. d) the result of the hydrostatic collapse of the sample segment subjected to this test shall be equal or greater than the pipe hydrostatic collapse resistance estimated by the manufacturer (reference item 5.2.3 of this Standard); also, the measured collapse pressure shall be equal or greater than the ratio between the design external pressure and the specified utilization, as per TABLE 6 of this Standard.
C-2.6 Combined Tensile and Pressure Test (for Riser Applications Only) C-2.6.1 Description

C-2.6.1.1 The purpose of this test is to evaluate the riser resistance to the combination of internal pressure and axial load. Also, the test shall check the predicted failure tension load informed by the manufacturer. C-2.6.1.2 The test sample shall have a minimum length of 20 times the inside diameter, excluding both end fittings.
C-2.6.2 Procedure

C-2.6.2.1 One end of the sample is fixed and the other end is free for rotate. The sample shall be mounted in a straight manner, full of water (no internal pressure), in a suitable test device. Internal pressure is then set to the maximum operating pressure (pressurization rate not exceeding 10 MPa/min) and kept constant during the test within the range (-0/+20 %). Internal pressure shall be continuously monitored and registered, during the whole test period. C-2.6.2.2 The sample is axially loaded in steps, at a rate not exceeding 300 kN/min, until the Design Tension (calculated from the global analysis, for normal operation conditions) is achieved. During loading, and after unloading the following parameters shall be registered and recorded: a) sample longitudinal elongation; b) sample twist; After removing the outer sheath at the middle of the sample: c) external diameter and perimeter (measured over the outermost tensile armour or holding bandage).

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C-2.6.2.3 After measuring the above parameters, the sample is axially loaded until failure, at the same rate mentioned above. An intermediated visual inspection of the sample shall be performed after the tension load achieves 1.50 times the Design Tension, in order to check against failures.
C-2.6.3 Acceptance Criteria

The acceptance criteria for sample longitudinal elongation, horizontal and vertical diametric deformations, and twist, for loaded (design tension) and unloaded conditions, are given in TABLE C-4.

TABLE C-4 - ACCEPTANCE CRITERIA DEFORMATION AND TWIST

Parameter Loaded

FOR

ELONGATION,

DIAMETRIC

Unloaded (residual)

Longitudinal Elongation External Diameter Deformation Twist

-1.5 % LL +1.5 % -3.0 % DVL +3.0 % -3.0 % DHL +3.0 % 0.6 degree/m

-0.5 % L R +0.5 % -1.0 % DV R +1.0 % -1.0 % DH R +1.0 % 0.2 degree/m

In addition to the criteria in the TABLE C-4 above, the following applies: a) in addition to the criteria for longitudinal elongation, axial stiffness of the pipe obtained from the test shall be in accordance with manufacturer predictions; b) failure mechanism and location shall be as predicted by the manufacturer; the measured failure tension shall be greater than 1.50 times the Design Tension; c) no structural damage of the end fitting itself (e.g. cracking or rupture of its structure) or of pipe layers (e.g. wire rupture) shall be observed before the test maximum tension load is achieved (i.e. up to 1.50 times the Design Tension).
C-2.7 Dynamic Fatigue Test C-2.7.1 Description

C-2.7.1.1 For the purpose of dynamic test, test sample is defined as the assembly of the piece of pipe, end-fittings attached at both ends, bend stiffener, fasteners and all devices and components that simulate the riser top connection. It also includes all accessories and ancillary components of this assembly. C-2.7.1.2 A schematic showing the overall definition of the dynamic test program, including riser and bend limiter design, is shown in Figure 27 of standard API RP 17B. A typical test set-up is shown in Figure 28 of standard API RP 17B. Test sample is hung vertically from a rocker arm which can apply cyclic rotations. A tension load is applied to the lower end. The objective of this test is to determine the structural integrity and fatigue life design of the top connection, under simulated operational conditions, and to check the design methodology. If necessary, test loading shall be increased in order to lead the sample to the theoretical failure (theoretical accumulated damage equal to 100 %, as per manufacturer design methodology). The performance of the riser for the specified service life is verified by inspecting test sample in an intermediate stage of the dynamic test. Alternatively, test sample could be positioned horizontally or, even, vertically, but up side down. 58

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C-2.7.1.3 The minimum length of test sample shall be as per item 9.6.1.1.2 of standard API RP 17B. C-2.7.1.4 Test sample shall be subjected to maximum operating pressure and a conservative tensile load related to the dynamic environment. At purchaser discretion, test pressure can be changed to design pressure, if previously specified. C-2.7.1.5 If speficied, pipe annulus region may be filled with corrosive fluids, in order to simulate sour service conditions. The recommendations and requirements found in items 9.6.4.1.9 of standard API RP 17B shall be adopted.
C-2.7.2 Procedure

C-2.7.2.1 The cyclic loading of test sample should be divided into a minimum number of 5 (typically 7), each one with a different angle amplitude, frequency, and a number of cycles. The frequency shall not exceed 1.0 Hz, with a recommended value of 0.2 Hz. Higher frequencies may be used for smaller angle ranges. Note that a high frequency may reduce the total test period but may generate unacceptable temperature increase because of friction between the layers. Local test site conditions, including temperature, machinery, and cooling requirements, shall influence the cycling rate. An example of a typical cycling program is shown in Table 21 of standard API RP 17B. C-2.7.2.2 The total number of cycles in all blocks and the corresponding tensile cyclic loading shall be based on the environmental data and floater data specified by the purchaser. It shall be between 2 million and 4 million to achieve the specified service life. Extra cycling is necessary for achieving 100 % of accumulated theoretical fatigue damage. The bending radii shall achieve the minimum values obtained from the global dynamic analysis, performed by the manufacturer. Cyclic tensile and bending shall be applied in phase (maximum and minimum tension associated with respective maximum and minimum bending). C-2.7.2.3 The recommendations and requirements found in items 9.6.1.2.3 of standard API RP 17B shall be adopted. C-2.7.2.4 The following variables shall be continuously monitored and recorded during the test: a) b) c) d) e) f) g) h) number of cycles; internal temperature; external ambient temperature; internal pressure (sampling record of pressure during dynamic test and 24 hour pressure charts of hydrostatic tests); applied tension load; actual angles applied; phases for the applied tension and bending loads; if specified, pressure and temperature in the annulus region (filled with whichever specified, CO2 or SO2).

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C-2.7.2.5 The end of the dynamic fatigue test is defined when the theoretical predicted failure of test sample (accumulated damage equal to 100 %) is achieved. In order to achieve the accumulated damage = 100 %, purchaser can propose an increase of the tensile load for the last block of the test. NDE (preferable gamma ray for wire rupture detection) for internal inspection of test sample shall be carried out at intermediate steps of accumulated fatigue damage and also before cyclic testing (for the purpose of comparison of previously defined spots). These intermediate steps, unless otherwise specified, are the following: a) when the accumulated damage achieves the one corresponding to the specified service life is achieved; b) when the accumulated damage achieves 80 %. C-2.7.2.6 The purpose of these NDE is to check against eventual failures in any part of test sample (e.g. rupture of any individual tensile wire, outside or inside the end fitting body, failure of bend stiffener metallic parts, pull-out or displacement of tensile wires inside end fitting). Test sample shall be hydrostatically pressure tested at a minimum 1.25 times the maximum design pressure (hold period of 24-hour, after confirmed stabilization) when the specified service life is achieved. When 100 % accumulated damage is achieved, test sample shall be hydrostatic pressure tested at 1.00 times the maximum design pressure (hold period of 24 hour, after confirmed stabilization). Afterwards test sample shall be dissected. C-2.7.2.7 Dissection of the test sample shall comply with purchaser specification or procedure, when applicable. It shall be carried out to check for findings and eventual failures. Dissection shall be focused on the following: a) pipe structure over an area including the location of highest curvature variation and inside the end fitting body; b) end fitting parts and components inside its body. C-2.7.2.8 In addition, dissection shall be carried out to check for findings and eventual failures of the end fitting body/connector, bend stiffener, fasteners and all devices and components that simulate the riser top connection. It shall be conducted to record and report, through photos and sketches, for traceability of measurements and findings, evidence of non-conformities, defects, degradation, or wear of the dissected items.
C-2.7.3 Acceptance Criteria

C-2.7.3.1 Test sample shall have passed the test sequence without leakage, failure or defects up to the theoretical predicted accumulated fatigue damage equal to 100 % is achieved. The lists of defects are found in Tables 25 and 26 of standard API RP 17B and item B-3.3 of Annex B of standard ISO 13628-2. C-2.7.3.2 When criteria are not available for some defects found in these lists, test procedure, issued by the manufacturer, shall include these criteria for those defects. Manufacturer shall get from the IVA confirmation of the proposed criteria which shall be based on the manufacturer design methodology. The recorded degradation evidence shall be consistent with the predicted figures and characteristics mentioned in the test procedure and shall match with the performance requirements for the application. 60

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As per standard API RP 17B, item 9.6.1.4.

C-2.7.5 Alternatives

As per standard API RP 17B, item 9.6.1.5.

C-2.8 Outer Sheath Holding System Test C-2.8.1 Description

The purpose of this test is to verify the adequacy of the system designed to hold the outer sheath in the flexible pipe end fitting.
C-2.8.2 Procedure

C-2.8.2.1 The test sample with end fittings assembled in both extremities shall have its outer sheath pulled out in its longitudinal direction, by means of a traction system. This system shall not compress the outer sheath against the sample internal layers, allowing free sliding of this layer when it is under tension load. Note: Simplified end fittings can be used if they simulate the actual outer sheath anchoring system.

C-2.8.2.2 The load shall be increased gradually at a rate not exceeding 300 kN/min. up to the outer sheath tearing ultimate loading, defined as the load which causes the outer sheath rupture. Test procedure shall indicate the predicted tearing load. During test, the following parameters shall be monitored and recorded: a) curve showing outer sheath elongation x tension load; b) ambient temperature.
C-2.8.3 Acceptance Criteria

C-2.8.3.1 Outer sheath shall tear and no slippage from the end fitting is acceptable.
C-2.9 External Sealing System Test C-2.9.1 Description

The purpose of this test is to verify the adequacy of the external sealing system of the flexible pipe end fitting after the outer sheath is subjected to a tension representative of a typical pipe installation load. 61

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C-2.9.2.1 The test shall be performed in 2 stages as follows: a) apply a representative installation tension load on the sample outer sheath; b) verify the adequacy of the end fitting external sealing system, for the design external pressure, being the sample placed inside a hyperbaric chamber. C-2.9.2.2 At the first stage, the test sample with end fittings assembled in both extremities shall have its outer sheath pulled out in its longitudinal direction, by means of a traction system. This system shall not compress the outer sheath against the sample internal layers, allowing free sliding of this layer when it is under tension load. C-2.9.2.3 The outer sheath is tensioned gradually at a maximum rate 100 kN/min, step by step, until a representative installation tension load on the sample outer sheath is achieved. C-2.9.2.4 At the second stage, with the sample inside the hyberbaric chamber, the external pressure is increased at a maximum rate of 10 MPa/min until a value between 1.0 times and 1.2 times the design external pressure. The pressure is kept within this range during a minimum 24-hour period, after confirmed stabilization. C-2.9.2.5 During both stages, ambient temperature and loading shall be continuously monitored and registered.
C-2.9.3 Acceptance Criteria

The test shall be considered approved if no leakage is detected during the 24-hour period. Also, no water ingress shall be detected after sample dissection.
C-2.10 Internal Pressure Cycling Test (For Smooth Bore Pipes Only) C-2.10.1 Description

The purpose of this test is to verify the adequacy of the internal sealing system under cyclic pressure.
C-2.10.2 Procedure

C-2.10.2.1 The test shall be performed in 3 stages as follows: a) subject the sample to cyclic internal pressure; b) subject the sample to the hydrostatic pressure test; c) verify the adequacy of the end fitting sealing system of the intermediate sheath when it is subjected to design external pressure.

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C-2.10.2.2 At the first stage, the sample, with end fittings assembled in both extremities, shall be mounted in a straight manner, full of water (no internal pressure), in a suitable test device. The test sample shall be subjected to 500 cycles of internal pressure from the atmospheric pressure (plus 1 MPa) to the maximum design pressure (plus 1 MPa). Internal pressure cycling shall be performed at a rate not exceeding 10 MPa/min. C-2.10.2.3 At the second stage, the sample shall be subjected to a hydrostatic test (1.5 times the maximum design pressure, 24 hour hold period after stabilization). C-2.10.2.4 Finally, at the third stage, with the sample inside the hyberbaric chamber, the external pressure is increased at a maximum rate of 10 MPa/min until a value between 1.0 times and 1.2 times the design external pressure. The pressure is kept within this range during a minimum 24 hour period, after confirmed stabilization. For this stage, the outer sheath shall be previously removed or perforated so that water ingress into the annulus of the pipe occurs. C-2.10.2.5 During all stages, ambient temperature and internal and external pressures shall be continuously monitored and registered, as applicable.
C-2.10.3 Acceptance Criteria

The test shall be considered approved if no leakage from pipe bore to annulus is detected during the 2 first test stages. Also, during the third stage, no leakage shall be detected through the sealing system of the leak proof intermediate sheath.
C-3 QUALIFICATION TESTS OF VENT VALVES C-3.1 General

Representative samples of each type of vent valve used in the end fitting shall be subjected to a qualification test program. For tests specified below, manufacturer shall determine the sampling of each test in order to assure that test results are consistent. As a minimum, at least 3 samples of each type of valve shall be subjected to each test specified hereafter.
C-3.2 Scope

The qualification program of vent valves shall include at least the items C-3.2.1 to C-3.2.7.
C-3.2.1 Immersion Test at High Temperature

C-3.2.1.1 The purpose of this test is to verify the performance of the valve after long term exposition to high temperature.

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Submerge valve samples in a water bath with depth of 200 mm, during a 30 day period, and measure the crack and reseat pressures, as per item C-3.2.6. Water shall be kept at a temperature equal or superior than the maximum design temperature of the pipe (end fitting) in which the valve shall be installed.
C-3.2.2 Cyclic Test

C-3.2.2.1 The purpose of this test is to verify the reproducibility of the crack and reseat pressures of the valve after cycling the inlet pressure while keeping the external environment (valve outlet) at a pressure equal to the hydrostatic head of the specified water depth for the pipe. C-3.2.2.2 Procedure Samples of the valve shall be subjected to 5 000 cycles, being each cycle defined as 1 valve opening + 1 valve reseat. Pressurized air is used in the valve inlet while the valve outlet is pressurized to the hydrostatic head. By using water, valve outlet is constantly pressurized to the hydrostatic head equivalent to the specified water depth for the pipe (Pext). Inlet pressure (Pin) shall vary from a pressure 20 % below the valve reseat pressure to the one 20 % above the valve crack pressure. For this, valve shall be subjected to the maximum inlet pressure for a period of time of 0 seconds while, at the external stead pressure (i.e. Pin = Pext), the inlet pressure shall be kept for 2 seconds. Test is performed at the ambient temperature. Afterwards, samples are subjected to the test defined in item C-3.2.6.
C-3.2.3 Seawater Long Term Immersion Test

C-3.2.3.1 The purpose of this test is to verify the performance of the valve after long term exposition to seawater. C-3.2.3.2 Procedure Immerge valve samples into a 10 m deep seawater bath, keeping them for 6 months. After that, measure the crack and reseat pressures, as per item C-3.2.6.
C-3.2.4 Test of Simulated Immersion in Sea Bottom

C-3.2.4.1 The purpose of this test is to verify the reproducibility of the crack and reseat pressures of the valve samples after subjecting them to degradation caused by seawater and sand.

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Immerge valve samples into salt water bath (at the ambient temperature) and cover them with a layer of sand having thickness equal 50 mm. The sand grains shall have outside diameter between 0.074 mm and 0.250 mm, with the addition in weight of 30 % of silt with OD < 0.074 mm. Samples shall be kept in the bath for a period of 1 month with a daily cyclic of valve opening and close. Crack and reseat pressures, as per item C-3.2.6 are measured. Afterwards, valves are inspected against internal and external corrosion and internal abrasion.
C-3.2.5 External Sealing Pressure Test

C-3.2.5.1 The purpose of this test is to verify the valve external sealing system against seawater ingress. C-3.2.5.2 Procedure Samples coming from the tests described above in items C-3.2.2, C-3.2.3 and C-3.2.4 shall have their outlet hydrostatically pressurized, at the ambient temperature, in a range of pressures between 0.03 MPa up to the pressure equivalent to the hydrostatic pressure of the specified water depth. During test, valve inlet is under pressurized air. Test criteria is that valve shall avoid water ingress after 10 cycles of valve opening/closing. Additionally, valves shall be externally/internally inspected. No corrosion and abrasion is allowed, but, in case of the valves coming from the test defined in item C-3.2.4, some abrasion is allowed provided that the leakage criterion above is respected. C-3.2.5.3 Samples shall be kept in the bath for a period of 1 month with a daily cycle of valve opening and closer. Crack and reseat pressures, as per item C-3.2.6 are measured. Afterwards, valves are inspected against internal and external corrosion and internal abrasion.
C-3.2.6 Test of Reproducibility of Crack and Reseat Pressures

C-3.2.6.1 The purpose of this test is to verify if the valve crack and reseat pressures present values in a narrow range after 6 cycles of valve opening/closing. This test standardizes the method of measuring the valve crack and reseat pressures mentioned above in items C-3.2.1 to C-3.2.5 and establishes an additional criterion to tests described in these items. C-3.2.6.2 Procedure Valve outlet shall be connected to the bottom of a water column of 100 mm, open to the atmosphere. Inlet of valve samples are subjected to pressurized air. Cycles of valve opening/closing shall be performed at a pressurization/depressurization rate of 0.05 MPa/seg. The valve maximum opening pressure shall be kept constant during a period of 60 seconds. The end of a cycle is defined as the time when no bubbles are noted (i.e. valve closing is assured). Crack and reseat pressures are measured at the end of each of the 6 cycles. Test criteria is the following: a) for the 6 cycles, the specified crack pressure (Pc) is kept in the range Pc 0.05 MPa; 65

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b) minimum allowable reseat pressure (Pr) = 2/3(Pc).

C-3.2.7 Flow Test

C-3.2.7.1 The purpose of this test is to obtain the characteristic curve of the valve, Flow Rate x Inlet Pressure which shall match with the design premises. C-3.2.7.2 Procedure Valve outlet shall connected to the bottom of a water column of 100 mm, open to the atmosphere. Valve inlet pressure is varied in the full valve design range. For this, pressurized air is used in order to confirm that the flow rate specified in the valve design is fit for purpose, i.e. flow rate shall exhaust the gas trapped in the pipe annulus without permanent deformation of the pipe outer sheath. The flow rate measuring shall be within 5 m3/h. C-3.2.7.3 Acceptance Criteria The measured flow rate shall match the design premises.

C-4 BASIC PROCEDURE FOR THE FIELD TEST OF A FLEXIBLE PIPE

C-4.1 Objectives

This Section presents the Basic Procedure to be used in the field test of a flexible pipe as part of its qualification program. A Detailed Procedure shall be prepared by the manufacturer and it shall be based on this Basic Procedure. The objectives of the Field Test can be summarized as follows: a) verify the resistance of the pipe to the loads and conditions imposed during a first end connection, and verify if pipes characteristics allow the performance of first end connections; b) verify the resistance of the pipe to the loads and conditions imposed during a second end connection, and if pipes characteristics allow the performance of second end connections; c) verify the resistance of the pipe to the loads and conditions imposed on bottom when pipe is bent up to minimum curvature and is cycled at a specific water depth.
C-4.2 Introduction

C-4.2.1 The Field Test shall be performed in representative samples of the flexible pipe (minimum length of 90 times the pitch of the outermost tensile armour), at a specific water depth ( 1 %), according to the following sequence (different samples per test): a) DIP (Deep Immersion Performance) test; b) first-end connection test; c) second-end connection test; 66

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d) for the connection tests (paragraphs b) and c) above) a Vertical Connection Module (VCM) and a Dummy Manifold shall be used to simulate a subsea connection. C-4.2.2 The DIP test shall be performed in both dry and flooded annulus conditions. Unless otherwise specified, DIP test with dry and flooded annulus is performed in the same sample. To flood the sample annulus, the gas relief plugs shall be removed by ROV. These plugs shall be fitted on board to ROV interface. All the other tests shall be performed in the dry annulus condition. C-4.2.3 As a general directive, for first and second subsea end connection tests, manufacturer shall previously define the configuration of the pipe catenary and hunch, as well as their main dimension ranges due to the uncertainties of the pipe behaviour under the installation conditions. For this purpose, manufacturer shall predict the loads to be imposed to the VCM (momentum, twist and forces) by the pipe end fitting and vice-versa. During these tests, ROV checking of the interface pipe/VCM will be used to estimate the inclination and rotation of the VCM and, also, to verify the premises considered in the test procedure (such as pipe characteristics - for instance, axial and bend stiffness) and the compliance to the test acceptance criteria.
C-4.3 Test Description C-4.3.1 First End Subsea Connection Test

C-4.3.1.1 This test simulates a typical situation in which the pipe first extremity, with the VCM, is lowered, approaches the dummy manifold hub up to coupling, and then is laid on sea bottom. See FIGURE C-1 for details.

WINCH CABLE

PIPE ROV

VCM DUMMY MANIFOLD HUB

FIGURE C-1 - FIRST-END SUBSEA CONNECTION TEST

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C-4.3.1.2 The loads imposed to the pipe (curvature, compression and torsion) shall not cause any damage to them. Additionally, it shall be demonstrated that the pipes residual twist or bending stiffness does not make impossible the execution of the operation. Note: The measurements of pipe external diameter, as described in item C-4.3.3.2 paragraph a), shall also be used for the purpose of checking the pipe ovalization and performance during this test.

C-4.3.2 Second End Subsea Connection Test

C-4.3.2.1 This test simulates a typical situation in which the pipe is laid at the sea bottom while the second extremity, with the VCM, approaches the dummy manifold hub up to coupling. See FIGURE C-2 for details.

SHIP CRANE CABLE

WINCH CABLE ROV

VCM HUNCH BUNDLE

DUMMY MANIFOLD HUB

FIGURE C-2 - SECOND END SUBSEA CONNECTION TEST

C-4.3.2.2 The loads imposed to the pipe (curvature, compression and torsion) shall not cause any damage to it, including tensile armours buckling. Additionally, it shall be demonstrated that the pipes residual twist or bending stiffness does not make impossible the execution of the operation. This method has some key points that shall be taken into account: a) a hunch made by cable on a short region of the pipe (near the connection point) provides the flexibility required to make feasible the coupling; b) after coupling, the cable is released and the pipe lays down over the sea bottom without being controlled by the surface. Note: The measurements of pipe external diameter, as described in item C-4.3.3.2 paragraph a), shall also be used for the purpose of checking the pipe ovalization and performance during this test. 68

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C-4.3.3 Dip Test

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C-4.3.3.1 This test simulates a typical situation during the pipe laying, for which pipe catenary vertical top angle is less than 1 deg. The pipe is bent to the qualification radius and is kept in this position for 4 hours. The combination of loads acting on pipe in this situation (external pressure pipe end effect, cycled bending, torsion) shall not cause any damage to the pipe (e.g. buckling of the tensile armor wires). C-4.3.3.2 The sample shall have two regions of interest (for dry and flooded test conditions), both with the same length of at least 20 times the pitch of the outermost tensile armour and located at least, 15 pitches from the end fittings. Each region shall be at least 20 pitches apart from the other. Before beginning the test, each region is marked and measured as following: a) in its mid section, and from this point, each 0.5 m, to both sides, a ring mark shall be painted over the cross-section circumference; at these positions, measurements of pipe horizontal and vertical diameters (DH and DV) and pipe perimeter are done; both end fittings shall be identified (upper and lower ones) and all the measurements shall be done in such a way that the traceability of the recorded values and the comparison of gathered values, before and after testing, are assured; b) along its whole length, at least 3 marks are continuously painted in the axial direction, 120 apart each one from the other. C-4.3.3.3 The pipe is launched by the installation vessel. Thus, once the pipe section is in the touch down point (TDP) region, the catenary is adjusted to reach the qualification radius, i.e. the minimum radius through which the pipe shall not show any lateral displacement or loop formation (the qualification radius must be greater than the specified operating MBR). C-4.3.3.4 After all the necessary adjustments to reach qualification radius are done, this catenary configuration is kept for 4 hours, when vessel movements and environmental conditions are monitored and registered. ROV shall also inspect the pipe and record the images in video-tape. C-4.3.3.5 The bending radius at test section (in TDP) can be determined from a digital photo taken from the ROV monitor and calculated with the help of the ring marks over the sample. C-4.3.3.6 In order to verify ovalization, some caliper collars are installed in the test set. These calipers are hold in position by means of propylene ropes attached to the top end fitting. While laying the pipe, before starting with the actual test step, when the pipe test section is set in the vertical position, the ROV shall cut the rope of the first collar. By gravity, the caliper collar shall drop from the top end fitting towards the bottom one (or from the top holding collar to the stopper positioned in the bottom level). After each test step, the ROV shall cut the rope of other caliper collar that shall drop towards the bottom. So, a certain amount of caliper collars shall be provided for the DIP tests. Note: Calipers internal diameter shall be determined by considering the sample external diameter added to manufacturing tolerance (if necessary as built condition should be considered), maximum residual deformation from crushing loads and from hydrostatic pressure. 69

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C-4.3.3.7 After recovering the sample, an extra caliper collar should be run along the sample, in order to localize and verify residual deformation.
C-4.4 Acceptance Criteria C-4.4.1 General Criteria for All Tests and Pipe Handling Test

During Field Test, the following criteria shall be verified: a) tensile armours of the sample shall not present buckling in any direction; b) sample shall not present kink or corkscrew (corkscrew is defined as an increase of the pipe diameter due to the change of the lay angle of some few tensile armour wires); c) sample shall not have any damage in its outer sheath that allows the water ingress into the annulus space, nor any slippage of the outer sheath from the end fitting; d) sample shall not present visual localized twist; e) sample shall not present any visually identifiable structural or functional damage; f) caliper collars shall run throughout the sample from the top to the bottom. If not, further dissection results shall not indicate buckling evidences; After retrieval and during sample dissection, the following criteria shall be verified: Note: Purchaser could consider optimization of test samples (e.g. one single sample for more than one test) if: - NDE, made available by manufacturer, is able to confirm the criteria listed hereafter, in such a way that dissection, at the end of all tests, is unnecessary; - planned simulation covers all in service conditions. g) tensile armours of the sample shall not present buckling in any direction; h) deviation of the nominal tensile armour lay angle shall be less than 5 deg or the corresponding pitch values; i) maximum allowable gap between 2 adjacent wires shall not be greater than 3 times the width of the tensile armour wires, at the same pitch region of these wires and in the interest region under analysis; j) tensile armour wires shall not be found excessively loose in such a way that they can be easily moved, e.g. by hand without effort; k) sample shall not have residual deformation greater than 1 % in any measurement of external diameter, at a certain pipe section (DH or DV); l) for verification of residual twist, sample successive axial marks shall be within 0.2 degree/meter along its lengthwise. Notes: In case criteria of paragraphs i) to l) is not achieved, further investigation should be performed by manufacturer in order to demonstrate that pipe is keeping its resistance after field test.

C-4.4.2 Additional Criteria for the First and Second Connection Tests

During First and Second Connection Tests, the following criteria shall be verified: 70

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a) the loads imposed to the sample (curvature, compression and torsion) shall not cause any damage to them; additionally, it shall be demonstrated that the pipes residual twist or bending stiffness makes feasible the carrying out of the operation; b) after the cable connected to the sample is paid out from the vessel, sample shall be entirely laid on sea bottom. ______________

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ANNEX D - TABLE TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number 1 2 2.1 2.2 3 3.1 3.1.1 to 3.1.10 3.1.11 3.1.12 to 3.1.18 3.1.19 3.1.20 3.1.21 to 3.1.23 3.1.24 3.1.25 to 3.1.28 3.1.29 3.1.30 to 3.1.33 3.1.34 3.1.35 to 3.1.39 3.1.40 3.1.41 to 3.1.45 3.1.46 to 3.1.92 3.2 4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.3 4.4 4.5 4.6 4.6.1 4.6.1.1 N-2409 Chapter or Items Title Scope Supplementary Documents Base Standard Normative reference Definitions, Symbols and Abbreviations Terms and definitions As per ISO Carcass As per ISO Fishscaling Angle Independent Verification Agent As per ISO Jumper As per ISO Quality As per ISO Smooth bore As per ISO Third party As per ISO Titles of these subclause are available only in the N-2409 text Symbols and abbreviated terms Functional requirements and recommendations General NA NA NA Overall requirements Flexible pipe End fittings General design parameters Internal fluid parameters External environment System requirements and recommendations Minimum system requirements and recommendations General N-2409 Page Number 2 2 3 3 3 3 NA 3 NA 3 4 NA 4 NA 4 NA 4 NA 5 NA 5 to 13 13 14 NA NA 14 NA 14 14 NA NA NA NA 14 14 Changed as indicated below NA As per ISO Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections ISO fully revised. ISO scope is extended while new recommendations and requirements are included. New wording of Section and new normative reference documents to ISO are Included New subsection to ISO is included New normative reference documents to ISO are Included Changed as indicated below Some ISO definitions are modified while new ones are included As per ISO ISO definition is modified As per ISO ISO definition is modified ISO definition is modified As per ISO ISO definition is modified As per ISO ISO definition is modified As per ISO ISO definition is modified As per ISO ISO definition is modified As per ISO Additional definitions to ISO are included Additional abbreviated terms to ISO are included Changed as indicated below As per ISO As per ISO ISO requirement is changed As per ISO Changed as indicated below Additional paragraphs to ISO are included, specifically paragraphs f) to h) As per ISO As per ISO As per ISO As per ISO Changed as indicated below

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TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number 4.6.1.2 4.6.1.3 4.6.1.4 4.6.1.5 4.6.1.6 4.6.1.7 4.6.1.8 4.6.1.9 4.6.1.10 4.6.1.11 4.6.1.12 4.6.1.12.1 4.6.1.12.2 4.6.1.13 4.6.1.14 5 5.1 5.1.1 5.1.2 5.1.2.1 5.1.2.2 5.1.3 5.1.3.1 5.1.3.2 5.1.3.3 5.1.3.4 5.1.3.5 5.1.4 5.1.4.1 5.1.4.2 to 5.1.4.4 5.2 5.2.1 5.2.1.1 5.2.2 5.2.2.1 to 5.2.2.3 5.2.3 to 5.2.5 5.2.6 5.2.6.1 and 5.2.6.2 NA NA NA NA NA NA NA Load combinations and conditions NA NA NA NA NA Design load effects NA NA Pipe design methodology NA N-2409 Chapter or Items Title Application definition Corrosion protection Thermal insulation Gas venting Pigging and TFL requirements Fire resistance Piggyback lines Connectors Interface definitions Inspection and condition monitoring Installation requirements NA NA Exothermal chemical reaction cleaning Reuse requirements Design requirements and recommendations Loads and load effects General Load classes NA N-2409 Page Number 14 NA NA NA NA NA NA NA NA NA 14 14 15 NA 15 15 15 NA 15 15 NA 17 NA 17 17 20 20 20 20 NA 20 20 20 21 21 NA 21 22 to 23 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections ISO requirement is changed As per ISO As per ISO As per ISO As per ISO As per ISO As per ISO As per ISO As per ISO As per ISO Changed as indicated below Paragraph a) of ISO is changed while paragraph b) is kept as per ISO ISO recommendation is changed As per ISO This subsection is additional to ISO Changed as indicated below Subsections 5.1.2.1, 5.1.3.2, 5.1.3.3, 5.1.3.4, 5.1.3.5, and 5.1.4.1 and TABLES 5 and 6 are changed while TABLES 5A and 6A are included As per ISO Changed as indicated below Paragraph a) is changed while paragraphs b) and c) are kept as per ISO. Table 5 of ISO is changed while Table 5A is included As per ISO Changed as indicated below As per ISO ISO requirements are changed ISO requirements and Table 6 are changed. Additional to ISO, TABLE 6A is included ISO requirements are changed ISO requirements are changed Changed as indicated below ISO requirements and recommendations are changed As per ISO Changed as indicated below ISO subsection requirements are changed and extended. ISO paragraphs a) to d) and f) are unchanged, paragraph to e) is modified, and paragraph g) is included Additional subsection to ISO is included ISO subsection requirements are changed and extended Additional subsections to ISO are included As per ISO ISO subsection requirements are changed and extended. These are additional sub-clauses to ISO

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TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number 5.3 5.3.1 5.3.1.1 5.3.1.2 5.3.1.3 5.3.1.4 to 5.3.1.7 5.3.1.8 5.3.1.8.1 and 5.3.1.8.2 5.3.1.9 5.3.2 5.3.2.1 5.3.2.1.1 5.3.2.1.2 to 5.3.2.1.4 5.3.2.1.5 5.3.2.2 5.3.2.3 5.3.2.4 5.3.2.5 5.3.2.5.1 to 5.3.2.5.3 5.3.2.6 5.3.2.6.1 5.3.2.6.2 5.3.2.6.3 and 6.3.2.6.4 5.3.2.7 5.3.2.7.1 and 5.3.2.7.3 5.3.2.7.4 and 5.3.2.7.5 5.3.3 5.3.3.1 to 5.3.3.3 5.3.3.4 5.3.3.5 5.3.4 5.3.4.1 5.3.4.2 5.3.4.2.1 5.3.4.2.2 to 5.3.4.2.5 5.3.4.3 5.3.4.4 N-2409 Chapter or Items Title Pipe structure design Design criteria NA NA NA NA NA NA NA Design requirements and recommendations for pipe layers Internal pressure sheath NA NA NA Outer sheath Intermediate sheath Internal carcass Pressure armours NA Tensile armours NA NA NA Additional layers NA NA End fittings NA NA NA Service life analysis Service life - Static applications Service life - Dynamic applications NA NA Fatigue analysis Risers for reduced service life N-2409 Page Number 23 23 23 NA 23 NA 23 23 to 24 NA 24 24 24 NA 24 NA 24 24 25 25 25 NA 25 25 26 NA 26 26 26 NA 26 27 NA 27 27 NA 27 27 Changed as indicated below Paragraph (a) of ISO is changed while paragraph (b) is unchanged As per ISO ISO subsection is changed As per ISO ISO subsection requirements are changed and extended. ISO subsection requirements are changed. Paragraph a) of ISO is modified, paragraphs b) to e) remain unchanged, and paragraphs f) and g) are included ISO subsection requirements are changed and extended. These are additional sub-clauses to ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. These are additional sub-clauses to ISO Changed as indicated below As per ISO These are additional sub-clauses to ISO Changed as indicated below ISO subsection requirements are changed and extended. As per ISO ISO subsection requirements are changed and extended. Changed as indicated below As per ISO Changed as indicated below ISO subsection requirements are changed and extended. As per ISO ISO subsection requirements are changed and extended. This is an additional sub-clause to ISO Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections Changed as indicated below Changed as indicated below ISO subsection requirements are changed and extended. As per ISO ISO subsection requirements are changed and extended. As per ISO ISO subsection requirements are changed and extended while Table 6B is included. These are additional sub-clauses to ISO As per ISO Changed as indicated below

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N-2409 Chapter or Items Number 5.3.5 5.3.5.1 5.3.5.2 5.3.5.3 5.3.5.4 5.3.5.4.1 5.3.5.4.2 5.3.5.4.3 5.4 5.4.1 5.4.1.1 5.4.1.2 to 5.4.1.3 5.4.1.4 5.4.1.5 5.4.2 5.4.2.1 5.4.2.2 5.4.2.3 5.4.2.4 5.4.3 5.4.3.1 5.4.3.2 5.4.3.3 and 5.4.3.4 5.4.4 5.4.4.1 5.4.4.2 5.4.4.3 and 5.4.4.4 5.4.5 5.4.6 5.5 5.5.1 to 5.5.4 5.5.5 5.6 5.6.1 N-2409 Chapter or Items Title Global analysis requirements and recommendations NA NA NA Motion and wave modeling procedures Equivalent harmonic motion procedure (EHMP) Design wave procedure (DWP) Irregular wave procedure (IWP) System design requirements General NA NA NA NA Corrosion protection Galvanic corrosion Surface treatment Corrosion allowance Cathodic protection Thermal insulation NA NA NA Gas venting NA NA NA Pigging and TLP operations Fire resistance Prototype and production tests NA Test procedures and reports As laid and in service monitoring and inspection Product design and manufacturing deviation N-2409 Page Number 28 28 28 28 28 29 29 29 30 30 30 NA 30 NA 30 NA 30 NA NA 31 NA 31 NA 31 NA 31 NA NA NA 31 31 32 32 32 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO This is an additional sub-clause to ISO Changed as indicated below Changed as indicated below ISO recommendation is modified and changed to a requirement As per ISO ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. Paragraph d) of ISO is changed, paragraphs e) and f) are unchanged, and paragraph g) is included. As per ISO As per ISO As per ISO This is an additional subsection to ISO These are additional sub-clauses to ISO This is an additional subsection to ISO This is an additional subsection to ISO This is an additional subsection to ISO

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TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number 6 6.1 6.1.1 6.1.2 6.1.3 6.1.3.1 6.1.3.2 6.1.3.2.1 and 6.1.3.2.2 6.1.3.2.3 6.1.3.2.4 6.1.3.3 6.1.4 6.1.4.1 6.1.4.1.1 and 6.1.4.1.2 6.1.4.1.3 6.1.4.1.4 6.1.4.2 6.2 6.2.1 6.2.1.1 6.2.1.1.1 6.2.1.1.2 6.2.1.2 6.2.1.3 6.2.1.4 6.2.2 6.2.3 6.2.3.1 6.2.3.2 6.2.3.3 6.2.3.3.1 6.2.3.3.2 6.2.3.4 6.2.4 6.2.4.1 6.2.4.2 6.2.4.2.1 6.2.4.2.2 to 6.2.4.2.5 6.2.4.3 6.2.4.4 6.2.4.5 6.2.4.6 6.2.5 6.3 N-2409 Chapter or Items Title Materials Material requirements General Polymer materials Metallic materials General Carcass NA NA NA Pressure and tensilearmours End fittings Mettalic materials NA NA NA Epoxy material Qualification requirements and recommendations General Test requirements and recommendations NA NA Test data Applicability Test methods Polymer materials Polymer test procedures Fluid permeability Blistering resistance Fluid compatibility NA NA Ageing test Metallic materials General SSC and HIC testing NA NA Corrosion resistance Erosion resistance Fatigue resistance Hydrogen embritlement End fittings Quality assurance requirements N-2409 Page Number 33 33 NA NA 33 NA 33 NA 33 NA NA 33 33 NA 33 NA NA 33 33 33 33 NA 34 NA 34 NA 34 NA NA 34 34 NA NA 34 NA 34 34 NA NA NA 35 NA NA NA Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections Changed as indicated below Changed as indicated below As per ISO As per ISO Changed as indicated below As per ISO Changed as indicated below As per ISO ISO recommendations are changed to requirements As per ISO As per ISO Changed as indicated below Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO As per ISO Changed as indicated below Changed as indicated below Changed as indicated below ISO recommendation is changed to a requirement As per ISO ISO subsection requirements are changed and extended. As per ISO ISO subsection requirement is changed. As per ISO Changed as indicated below As per ISO As per ISO Changed as indicated below ISO subsection requirement is changed. As per ISO As per ISO Changed as indicated below As per ISO Changed as indicated below ISO subsection requirement is changed. As per ISO As per ISO As per ISO ISO subsection requirements are changed and extended. Paragraphs a) to c) of ISO are unchanged while paragraph d) is included As per ISO As per ISO As per ISO

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N-2409 Chapter or Items Number 7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.2.1 7.2.2 7.2.2.1 7.2.2.2 7.2.2.3 7.3 7.3.1 7.3.2 7.3.2.1 7.3.2.2 7.3.2.3 7.4 7.4.1 7.4.2 7.4.2.1 7.4.2.2 7.4.2.2.1 7.5 7.5.1 7.5.2 7.6 7.6.1 7.6.2 7.6.2.1 and 7.6.2.2 7.6.2.3 7.6.2.4 7.6.3 7.6.3.1 and 7.6.3.2 7.6.3.3 7.6.4 7.6.5 7.6.6 7.7 7.7.1 7.7.1.1 N-2409 Chapter or Items Title Manufacturing requirements Quality assurance General Documentation Process control Handling during manufacture Carcass General Inspection and acceptance criteria NA NA NA Polymer extrusions General Inspection and acceptance criteria Visual examination Dimensional measurements Test requirements Pressure and tensile armour layers General Inspection and acceptance criteria NA NA NA Anti-wear, Holding bandage, and insulation layers General Inspection and acceptance criteria End fittings General Assembly NA NA NA Inspection and acceptance criteria NA NA NDE and testing requirements Connectors Gas relief valves Special processes Welding Qualification N-2409 Page Number 35 35 NA NA 35 NA 35 NA 35 NA 35 NA 36 NA 36 NA 36 NA 36 NA 36 NA 36 36 36 36 NA 37 NA 37 NA 37 NA 37 NA 37 NA NA 37 38 38 38 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections Changed as indicated below Changed as indicated below As per ISO As per ISO A note is included is ISO subsection As per ISO Changed as indicated below As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. This is an additional subsection to ISO ISO subsection title changed. Changed requirements as indicated below. ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. As per ISO As per ISO This is an additional subsection to ISO Changed as indicated below Changed as indicated below Changed as indicated below

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N-2409 Chapter or Items Number 7.7.1.1.1 7.7.1.1.2 and 7.7.1.1.3 7.7.1.2 7.7.1.3 7.7.1.4 7.7.2 7.7.3 7.7.3.1 7.7.3.2 7.7.3.3 7.8 7.8.1 7.8.2 7.8.3 and 7.8.4 7.8.5 7.9 8 8.1 8.1.1 8.1.2 8.1.3 8.2 8.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.5 8.6 8.7 8.8 N-2409 Chapter or Items Title NA NA Metallic layers Polymer layers End fittings Heat treatment Coating NA NA NA Manufacturing tolerances NA NA NA NA Repairs Documentation General NA NA NA Design premise Design load report Design report NA NA NA NA NA NA Manufacturing quality plan Fabrication specification As-built documentation Operation manual N-2409 Page Number 38 NA NA NA NA NA 38 38 38 39 39 39 40 NA 40 NA 40 40 NA 40 40 40 NA 41 41 41 41 NA 42 NA NA NA 42 43 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections ISO subsection requirement is changed As per ISO As per ISO As per ISO As per ISO As per ISO Changed as indicated below ISO subsection requirements are changed and extended. ISO subsection requirements are changed and extended. Paragraphs a) and f) of ISO are unchanged, paragraphs b) to e), g) and h) are changed, and paragraphs i) and j) are included. This is an additional sub-clause to ISO Changed as indicated below ISO subsection requirements are extended. Paragraphs a) and c) of ISO are changed, paragraph b) is unchanged, and paragraphs d) and e) are included. ISO subsection requirements are changed and extended. As per ISO This is an additional sub-clause to ISO As per ISO Changed as indicated below ISO subsection requirement is changed. Other changes are indicated below. As per ISO ISO subsection requirements are changed and extended. Paragraphs a) to e) and g) of ISO are unchanged, paragraph f) is changed, and paragraphs h) to j) are included. This is an additional sub-clause to ISO. ISO subsection requirements are changed and extended. Other changes are indicated below. Table 15 of ISO is changed. As per ISO Changed as indicated below As per ISO ISO subsection requirements are changed and extended. ISO subsection requirements are changed and extended. As per ISO ISO subsection requirements are changed and extended. Paragraphs a) and d) of ISO are unchanged, paragraphs b), c), e), and f) are changed, and paragraphs g) to j) are included. As per ISO As per ISO As per ISO Paragraphs a) to f), and h) to l) of ISO are unchanged, paragraphs g) is changed, and paragraphs m) and n) are included. A note is also included in this subsection. Changed as indicated below

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N-2409 Chapter or Items Number 8.8.1 8.8.2 8.8.3 N-2409 Chapter or Items Title N-2409 Page Number 43 NA 43 43 43 NA 44 44 44 NA 44 44 NA NA 48 48 48 50 51 51 51 51 54 55 57 58 61 61 62 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections Paragraphs a) to c), e) to j), k), l), n), p) and q) of ISO are unchanged, paragraphs d), j), m), and o) are changed, and paragraphs r) and s) are included. A note is also included in this subsection. As per ISO This is an additional sub-clause to ISO This is an additional subsection to ISO This is an additional sub-clause to ISO As per ISO Changed as indicated below ISO subsection requirements are changed and extended. Changed as indicated below As per ISO This is an additional subsection to ISO This is an additional section to ISO As per ISO As per ISO

NA

NA NA Production tests - test procedures and 8.9 reports Documentation 8.10 regarding prototypes Factory acceptance 9 tests (FATs) Marking and 10 packaging 10.1 Marking Packaging, port, road 10.2 and storage facilities and restrictions 10.2.1 to 10.2.3 NA 10.2.4 NA Servicing and after 11 delivery requirements Flexible pipe Annex A purchasing guidelines Bend stiffeners and Annex B bend restrictors Requirements and recommendations for Annex C prototype qualification tests Prototype qualification C-1 tests C-1.1 General Description of the C-1.2 Variables Basic qualification test C-2 procedures C-2.1 Burst test C-2.2 Axial tension test C-2.3 Collapse test C-2.4 Crush strength test Combined bending C-2.5 and tension test Combined tensile and pressure test (for riser C-2.6 applications only) C-2.7 Dynamic fatigue test Outer sheath holding C-2.8 system test External sealing C-2.9 system test Internal pressure cycling test (for C-2.10 smooth bore pipes only)

This is an additional Annex to ISO

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TABLE D-1 - CONTENTS

N-2409 Chapter or Items Number C-3 C-3.1 C-3.2 C-3.2.1 C-3.2.2 C-3.2.3 C-3.2.4 C-3.2.5 C-3.2.6 C-3.2.7 C-4 C-4.1 C-4.2 C-4.3 C-4.3.1 C-4.3.2 C-4.3.3 C-4.4 C-4.4.1 C-4.4.2 N-2409 Chapter or Items Title Qualification tests of vent valves General Scope Immersion test at high temperature Cyclic test Seawater long term immersion test Test of simulated immersion in sea bottom External sealing pressure test Test of reproducibility of crack and resuat pressures Flow test Basic procedure for field test of a flexible pipe Objectives Introduction Test description First end subsea connection test Second end subsea connection test Dip Test Acceptance criteria General criteria for all tests and pipe handling test Additional criteria for the first and second connection tests N-2409 Page Number 63 63 63 63 64 64 64 65 65 66 66 66 66 67 67 68 69 70 70 70 Description of the Changes in Relation to the Same Standard ISO 13628-2 Numbering of Chapter and items, If Any, and Record ISO Unchanged Sections And Subsections

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INDEX OF REVISIONS

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Affected Parts Description of Alteration All standard revised

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IR 1/1