1.0 INTRODUCTION

1.1 General

The requirements contained within this document are strictly to define the technical requirements for the Additional Dry Gas Fields Development (ADGF) Subsea control umbilicals. In the event of any ambiguity, the requirements of this specification shall govern. Where there is any inconsistency between the referenced documents, the most onerous requirement shall apply. The VENDOR shall be responsible for bringing any ambiguity or inconsistency to the attention of BUYER.

1.2 Definitions

The following definitions are used for the purpose of this specification:

BUYER EPC Contractor or any agency, consultant or contractor acting on behalf of EPC Contractor.

VENDOR The Company responsible for the supply of the umbilicals in accordance with this specification.

Client CII, Conoco Indonesia Inc

Installation contractor The company installing the umbilical

Control system vendor The company designing and supplying the Subsea control system

must/ shall mandatory requirement

should preferred requirement

may one possible course of action

1.3 References

Title	Rev	Conoco Document No
Basis of Design	AFD	84506-60-00-2L-060
Overall Block B Field Layout	C	84506-3000-25-010
Hang Tuah Approach – Export Option B	D	84506-3000-23-200
Hang Tuah Approaches	C	84506-6030-23-210
Keong Field Layout at Manifold MK1	D	84506-6030-23-500
Kijing Field Layout at Manifold MJ1	C	84506-6030-23-700
Appurtenances General Arrangement Leg 4 Elevation	0	84502-50-00-60-853
Appurtenances Access Platforms General Arrangement Leg 4	0	84502-50-00-60-864
Top of Leg 4	0	84502-50-00-60-868
Appurtenances Access Platform Details	0	84502-50-00-60-869

1.4 Abbreviations

CIIL Conoco Indonesia Inc Ltd

CP Cathodic Protection

ESD Emergency Shut Down

FAT Factory Acceptance Test

FMECA Failure Mode, Effects and Criticality Assessment

HMI Human Machine Interface

HP High Pressure

IUT Infield Umbilical Termination

IR Insulation Resistance

IWOCS Installation and Workover Control System

LP Low Pressure

MCS Master Control Station

MODU Mobile Offshore Drilling Unit

MOgPU Hang Tuah Platform (formally known as Mobile Offshore Gas Production Unit)

MTBF Mean Time Between Failure

MWP Maximum Working Pressure

PCR Production Control Room

PCS Process Control System

PHPU Production Hydraulic Power Unit

PLEM Pipeline End Manifold

PSD Production Shutdown

ROV Remote Operated Vehicle

SCM Subsea Control Module

SCSSV Surface Controlled Subsurface Safety Valve

SPS Subsea Power Supply Unit

TUTU Topside Umbilical Termination Unit

UPS Uninterruptable Power Supply

UTA Umbilical Termination Assemblies

VDU Visual Display Unit

1.5 Project Overview

The Additional Dry Gas Fields Project (ADGF) is located in Block ‘B’ of the Indonesian sector of the West Natuna Sea, approximately 420 kilometers east of Malaysia. Conoco Indonesia Inc. Limited (CIIL), in conjunction with a partnering consortium (PSG Group), is currently completing the West Natuna Transportation System (WNTS) and the West Natuna Sea Gas Development (WNSGD).

CIIL plans to produce and supply sales quality gas from several fields in Block ‘B’ to the WNTS and to supply gas to the Duyong Central Processing Platform (CPP) which is operated by Petronas Carigali, Malaysia. These Block B fields include the Belida, Tembang and Buntal, which are currently being developed by CIIL, and the new fields associated with the ADGF Project. All gas gathering, processing and export will be carried out via a Movable Offshore (gas) Production Unit (MOgPU) facility.

CIIL’s ADGF Project comprises a gas gathering Infield Subsea System component and a gas Export Pipeline System for supply of gas to the Duyong CPP. The development of the Infield Subsea System includes collection and processing of gas from two satellite fields, Keong and Kijing, with the option to develop additional fields at a later date. These fields, and others, will be tied back to the MOgPU, which will process the gas before exporting to the Duyong facility. The new Infield Subsea System facilities will be controlled via a multiplexed electro-hydraulic umbilical from the MOgPU. The subsea control system will comprise a number of umbilicals, subsea distribution components, control modules, and other topsides and subsea control system components. Subsea trees, manifold structures, valves, piping and flowlines will be incorporated into the Infield System.

1.6 Field Overview

Block ‘B’ of the West Natuna Development contains several gas fields. The ADGF will produce gas from subsea wells at Keong and Kijing fields for processing at the MOgPU.

1.6.1 Infield System - Keong/Kijing Development

The Infield System shall include subsea flowlines, manifolds, tie-ins, umbilicals and subsea well control systems. The tie-back system utilises the following:

A new 14” flowline shall run from the Hang Tuah to Keong subsea manifold (MK1). One subsea gas well (K1) is an existing vertical TA exploration well and shall be tied back to the Keong subsea manifold (MK1) via a new 8” ~250m long flowline. Two new horizontal wells in the Keong locality (K2 and K3) will be drilled and completed in the third quarter of 2001. These wells (K2 and K3) will be located adjacent to the MK1 manifold and tied back using 8” ~20m rigid spool piece jumpers. A new 12” flowline shall then run from MK1 to the Kijing subsea manifold (MJ1) for tie-in of the Kijing wells.

The new subsea manifold MK1 shall have capability to tie-in the three Keong wells, as well as a 10” tie-in for tying in the Siput Field either initially, or at a later date. Connection for temporary pigging facilities is included on the Siput tie-in, the K1 step-out well flowline, as well as the tie-in for the flowline back to the Hang Tuah. Tie-in of the Kijing Field shall utilize the temporary pigging connection for the flowline back to the Hang Tuah.

The Keong and Kijing subsea wells shall be controlled from an existing electro-hydraulic (EH) control system centralized at the Hang Tuah via a new EH umbilical which shall be pulled in an existing J-tube located on leg 4 of the Hang Tuah. The pigtails shall then be connected to the topside systems at a new Topside Umbilical termination Unit (TUTU). The subsea end of the umbilical shall be terminated by an Umbilical Termination Unit (UTA) located near the MK1 manifold. Electric and hydraulic jumpers shall be installed between the UTA and the SCM mounted on each tree. The circuits shall be continued onward to the Kijing Field via jumpers through a weak link and an Umbilical Termination Unit (UTA) adjacent to the Kijing manifold. Electric, chemical and hydraulic jumpers shall connect the UTA and the SCM’s on the Xmas trees. Provision shall be made on the UTA for the future tie in of the Malong field.

A new three well subsea manifold shall be located at the Kijing Field. The MJ1 subsea manifold shall be located adjacent to the Kijing J3 well. The manifold shall include provision for later tie-in via a 3.0 km flowline for the second Kijing J2 well. Well 1 in the Kijing Field will not be tied in. Provision is also included on the MJ1 manifold for later tie-in of the Malong Field, and tie-in of a subsea well from an undefined field.

2.0 GENERAL REQUIREMENTS

2.1 General

The VENDOR shall be responsible for the design and supply of control and chemical umbilicals for the Keong Kijing control and chemical umbilicals for the Additional Dry Gas Field Development.

The following sections define the design conditions and equipment functional requirements to be met through design, assembly and testing.

2.2 Electrical

The control system vendor will define the minimum electrical cable requirements to allow direct monitoring of the well instruments and multiplex control of the subsea wells.

All aspects of the umbilical cable design shall comply with API 17E unless specified.

2.3 Hydraulic

All hydraulic fittings shall be of 316L stainless steel.

Hydraulic control fluid shall be Houghton Vaughan - Type Aqualink 300. All components of the hydraulic system shall be capable of operating reliably with these fluids as appropriate.

Hydraulic Power will be supplied to the subsea system at a cleanliness level of NAS Class 6, VENDOR shall ensure that this level of hydraulic cleanliness is maintained throughout the manufacturing and testing program.

VENDOR shall perform hydraulic analysis supported by testing to demonstrate the hydraulic characteristics of the umbilical hoses.

2.4 Mechanical

All equipment shall be designed with suitable lifting points to ensure safe handling both onshore and offshore during installation. All lifting points and equipment shall be subject to load testing in accordance with Section 4.0 and be supplied with valid third party certification. Consideration shall be given to the installation of equipment such that subsea items can be handled by diver deployed rigging. VENDOR shall consult with BUYER’S installation contractor throughout design phase.

The pull in bullnose assembly, Lifting slings and shackles or any special lifting frames for onshore handling shall be supplied by the VENDOR with the related equipment and all necessary certification. Det Norske Veritas "Rules for Certification of Lifting Appliances" or equivalent international standard shall apply.

Major subsea structures, ie umbilical terminations shall be manufactured from carbon steel painted to an approved subsea specification.

All equipment, associated interconnections and intervention aids shall be identified with a subsea marking system suitable for use throughout the system design life.

Unless specifically identified in Section 3.0, cathodic protection will be provided by the control system vendor’s sacrificial anodes on the UTAs. To allow correct design of the interfacing cathodic protection system, the VENDOR shall provide details of the minimum requirements for corrosion protection for 25 years service. The VENDOR shall be responsible for ensuring its equipment is adequately connected to the CP system and verify that all fixings, fasteners etc have adequate electrical continuity for effective cathodic protection.

As part of the load out and shipping activities the VENDOR will be responsible for packing the umbilical in accordance with the requirements defined by the installation contractor

2.5 System Analysis

As part of the overall umbilical design the VENDOR shall carry out the following system analyses and submit a technical report for each:

2.5.1 System Hydraulic Analysis

As a minimum, the analysis shall demonstrate flow rates with CLIENT defined fluids (appendix B) and umbilical expansion curves.

2.5.2 Electrical Power Analysis

The cable characteristics meet the minimum requirements defined by the control system vendor.

2.6 Interfaces

The following list highlights the areas of umbilical interface with equipment supplied by others. The VENDOR shall be responsible for specifying specific interface requirements from third parties and shall be responsible for defining the following interface data:

Umbilical J Tube: Umbilical hang-off arrangement

Umbilical Termination - topside: Hydraulic connection to TUTUs

Electrical connection to Topside Junction Box

Umbilical Termination - subsea: Mechanical connection to UTAs

Hydraulic connection to UTAs

Electrical connection to UTAs

Shipping & Installation guidelines Load-out / Shipping

Transportation

Installation handling

Seabed stability

Contingency Field splicing

All interface details shall be controlled by a database. The VENDOR will be responsible for giving notice of any interface data that may cause delay and offer design assumptions in the event that interface data is not available at the required time. All interfaces involving third parties shall be presented on drawings or specifications as appropriate.

2.7 Spares

VENDOR shall provide a list of recommended spares and quantities for installation and commissioning and a list of recommended spares and quantities for two-year operations.

2.8 Environmental Data

The field environmental data defined in Basis of Design, CII (Document No 84506-60-00-2L-060) shall be used, as appropriate, for all equipment design.

The VENDOR shall note that the above environmental conditions are relevant to the development location only. The VENDOR shall account for any environmental conditions imposed on the equipment as a result of location of manufacture and shipping.

2.9 Codes and Standards

All aspects of the Subsea Control System shall be in accordance with or exceed the following codes, standards and recommended practices. These aspects shall include design, fabrication, intended operational consideration, factory acceptable testing and operational manuals. Where conflict exists between the codes and standards, the most stringent shall apply. Where conflict exists between this specification and codes, this specification shall apply. Where conflict exists within this specification, the most stringent shall apply.

API 17D (API 17H)	Specification for Subsea Wellhead and Christmas Tree Equipment (& principles of 17H)
API 17E	Subsea Control Umbilicals
API 17F	Subsea Control System
API RP17A	Recommended Practice for the Design and Operation of Subsea Production Systems
API RP17I	Umbilical Installation Guidelines
AS 1000	The International System of Units (SI) and Its Application
ANSI/ISA-S5.1	Instrumentation Symbols and Identification
NAS 1638	Hydraulic Fluid Cleanliness
EN 10204	Material Certification Requirements
SAE J343	Test and Procedures for SAE 100R Series Hydraulic Hose
DnV RP B401	Cathodic Protection Design
BS 4109	Specification for Copper for Electrical Purposes. Wire for General Electrical Purposes and for Insulated and Flexible Cords.
ISO 9001; EN 29001/BS 5750	Part 1 Quality Systems - Specification for Design/Development, Production, Installation and Servicing

3.0 Umbilical Configuration

3.1 Hang Tuah / Keong Umbilical (U-MO/UTAK1)

One (1) static control umbilical is required to feed the Keong wells with hydraulic fluid, electrical power and communications and chemicals for the multiplex control of the subsea wells. The umbilical (U-MO/UTAK1) will be pulled through a J-Tube and run from the Hang Tuah to the manifold location MK1 (length to be defined by BUYER) where it terminates in a umbilical termination assembly (UTAK1). Final umbilical lengths will be defined during detail design and shall be manufactured to a tolerance of – zero to + 1% of overall length required for each umbilical.

The following functions are required from this umbilical:

Low pressure hydraulic - 1 x ½” x 207 bar MWP (operating 207 bar)

High pressure hydraulic - 1 x ½” x 345 bar MWP (operating 345 bar)

Corrosion Inhibitor - 4 x ³/₈” x 345 bar MWP (operating 207 bar)

Corrosion Inhibitor (Spare) - 1 x ¾” x 345 bar MWP (operating 207 bar)

TEG, MEG or Methanol - 1 x ¾” x 345 bar MWP (operating 310 bar)

Spare HP Line - 1 x ½” x 345 bar MWP

Communications lines - 2 x 4 mm² twisted pairs

Electrical Powers supply - 2 x 10 mm² pairs

The MOgPU interface umbilical (U-MO/UTAK1) shall be connected to an umbilical termination assembly UTAK1 (supplied by others) at the VENDOR’S facilities.

The umbilical shall include the following components:

The umbilical pull-in head

Topside umbilical hang off flange, armour termination, nuts, bolt and gasket..

Subsea umbilical armour termination and electrical penetrator assembly

Bend stiffener on UTAK1.

3.2 Keong Kijing Umbilical (U-UTAK1/UTAJ1)

One (1) static control umbilical is required to feed the Kijing well with hydraulic fluid, electrical power and communications and chemicals for the multiplex control of the subsea wells. The umbilical between MK1 and MJ1 (U-UTAK1/UTAJ1), length to be defined by BUYER, will be connected to UTAJ1 and Infield Umbilical Termination (IUT & UTAJ1 supplied by subsea control system vendor) at the VENDOR’S facilities. Final umbilical lengths will be defined during detail design and shall be manufactured to a tolerance of – zero to + 1% of overall length required for each umbilical.

The following functions are required from these umbilicals:

Low pressure hydraulic - 1 x ½” x 207 bar MWP (operating 207 bar)

High pressure hydraulic - 1 x ½” x 345 bar MWP (operating 345 bar)

Corrosion Inhibitor - 3 x ³/₈” x 345 bar MWP (operating 207 bar)

Corrosion Inhibitor (Spare) - 1 x ¾” x 345 bar MWP (operating 207 bar)

TEG, MEG or Methanol - 1 x ¾” x 345 bar MWP (operating 310 bar)

Spare HP Line - 1 x ½” x 345 bar MWP

Communications lines - 2 x 4 mm² twisted pairs

Electrical Powers supply - 2 x 10 mm² pairs

The umbilical shall include the following components:

Subsea umbilical armour termination and electrical penetrator assemblies (IUT)

Bend stiffeners one each for UTAJ1 & IUT.

3.3 Installation

The Hang Tuah / Keong umbilical (U-MO/UTAK1) will be pulled in and hung-off on the J-Tube and then laid away onto the seabed adjacent to the flowline. UTAK1 will be laid onto the seabed adjacent to the proposed tree location at MK1.

The Keong / Kijing umbilical (U-UTAK1/UTAJ1) shall be initiated from MJ1 location so that the umbilical is not exposed to undue stress during fitting of the UTAJ1.

The umbilical shall be installed in one completed and tested length. Final hook-up of the IUT and UTAK1 will be carried out by divers.

The umbilical cores will terminate to the Topside Umbilical Termination Unit (TUTU) via DIN fittings for all hoses/tubes and in an electrical junction box for the cables.

4.0 DETAILED REQUIREMENTS

4.1 General

The umbilical hoses/tubes should be capable of withstanding the hydraulic fluid design pressures specified with the required margin of safety.

All equipment within the umbilical in contact with, or potentially in contact with, the hydraulic fluid or with any of the chemicals, shall be compatible with those fluids for the full life of the umbilical. Chemical data sheets are included in Appendix B.

The suitability of the designs proposed for the electric cables, hydraulic lines and all associated equipment and fittings shall be documented. The suitability of the selected materials, insulation thicknesses, hydraulic lines, lay lengths etc., shall be demonstrated by testing and calculation or where possible by reference to previous testing and calculations, where identical components have been subjected to the same or similar service conditions.

The umbilical shall be supplied without joints for both the internal cores and the various sheathings.

The umbilicals shall consist of a number of thermoplastic hoses and/or metal tubes and electric cables laid up, if possible, in a symmetrical configuration. The interstices between the cores shall be filled with compatible plastic material or fillers to achieve a homogeneous construction; the materials selected shall be such as to achieve an umbilical construction able to withstand the crushing forces exercised on the bundle during its manufacture and deployment. The umbilical shall have an adequate strength member and some form of mechanical protection to meet the specified design loads.

The VENDOR shall supply all dimensions for each and every material and component that goes into making up the umbilical.

The ends of the umbilical shall be finished with mechanical, hydraulic and electrical terminations. The terminations shall mate to topside connectors, and subsea connectors supplied by Control System vendor. The VENDOR shall be responsible for ensuring the interfaces are correct.

4.2 Completed Umbilical

The umbilicals are to be fully armoured for mechanical protection, in place stability (without trenching), strength during installation and pull-in. The following parameters shall be considered or defined during detail design:

Design Load: 15 Tonnes minimum

Weight in Air (Filled): To be determined by the VENDOR

Weight in Water (Filled): To be determined by the VENDOR.

Materials:	All materials shall be compatible with the specified environment and the control fluid and chemicals specified.
Minimum Bend Radius:	Must be stated for the full range of tensions liable to be seen by the umbilicals.
Cross Section	A balanced symmetric construction is preferred
Strength Member	The umbilical shall be provided with reasonable and adequate strength to permit it to be self supporting during all stages of handling, installation and operation to suit the conditions specified.
Mechanical Protection	The umbilical shall be provided with reasonable and adequate protection during all stages of handling, installation and operation to suit the conditions specified.

The strength member/mechanical protection shall;

· Protect the umbilical during installation, laying, pulling up the J-Tubes and during any crossing operation.

· Provide support and termination at the top of the J-Tube and at the subsea end.

· Protect it during its life, including resistance to fishing snagging damage (VENDOR to define limitations of design).

· Provide adequate corrosion resistance over its operating life.

· Provide adequate weight for seabed stability.

· Although the base case is not to trench the umbilical, its design shall be suitable for trenching operations.

4.2 Outer Covering and Marking:

The umbilicals shall be marked as a minimum with characters, a minimum of 40 mm high at:

· The intervals specified below, indicating the umbilical’s true length.

· The first and last 200 metres of each end of each umbilical shall be marked showing actual length, every 10 metres.

· Thereafter it shall be marked, showing actual length, every 100 metres, zero shall be at the hang-off and IUT.

A continuous durable and permanent contrasting longitudinal lay line shall be included to allow measurement of any twisting. The outer sheath shall be yellow with a black lay line not less than 10 mm wide.

4.3 Umbilical Installation

In addition to any analysis required to establish the suitability of the proposed system, the VENDOR shall undertake analysis to address the following issues:

The VENDOR shall demonstrate analytically adequate service life of the umbilicals, accounting for installation conditions:

Armour Wire Wear

Armour Wire Fatigue

Copper Conductor Fatigue.

The VENDOR shall provide information regarding all limitations or constraints relevant to the installation including repair criteria for outer jacket damage during spooling and deployment. Advice shall also be given as to any effect that crossover protection, or possible crossings, may have on the umbilical.

The VENDOR shall review BUYER’S selected umbilical installation contractor procedures to ensure that the Installation Contractor's umbilical installation and handling procedures do not damage the umbilical. On completion of installation the VENDOR will be required to provide a written statement to the BUYER specifying that the VENDOR’S umbilical performance warranty has not been compromised during installation operations.

4.4 Fluid Compatibility

The VENDOR shall demonstrate to BUYER that all materials of construction are suitable for the intended use, particularly when in contact with the control fluid and all proposed chemicals. The design shall take into account the possibility of hose and electric cable materials coming into contact with such fluids. The VENDOR shall demonstrate compatibility.

The hoses/tubes and electrical conductors shall be of such a design that they will operate for the design life when completely immersed in seawater and are resistant to hydrolysis and micro-biological attack.

Details of control fluid and chemicals are given in the Appendix B.

4.5 Subassemblies

The following sections provide details of the umbilical component requirements, it should be noted that there is no requirement for J-Tube seals.

4.5.1 Hydraulic Hoses or Tubes

If a Subvendor is required for hose/tube manufacture, the Subvendor shall be proposed by the VENDOR for BUYER review and approval. The hoses/tubes shall be specially made for this contract after the placement of the order.

In the case of hoses, the hose reinforcement shall be applied in such a way as to minimise torsional forces generated during the hose pressurisation. No hose joints shall be permitted with the umbilical length.

During manufacture and testing of the hoses/tubes, the VENDOR shall take every precaution to ensure that no contamination enters the hoses. During all stages, including storage and transportation, the hoses /tubes shall be suitably capped-off. The umbilical lines shall be flushed to NAS 1638 Class 6 or as defined by the subsea controls vendor.

All hose couplings shall be manufactured from corrosion resistant materials compatible with the end terminations and connectors supplied by the Control System vendor, and be suitable for termination in the field using standard tools or specialised equipment provided by VENDOR. The couplings shall not reduce the hose bore by more than 30%.

Test Pressure:	1.6 x Working pressure
Proof Pressure:	2 2 x Working pressure
Burst Pressure:	4 x Working pressure (minimum)
Collapse Resistance:	As a gas production system there is the remote chance of pipeline pressures being vented to ambient, this could result in the chemical lines seeing a differential pressure of 80m of seawater. Hoses/tubes are to be suitable for operation in this upset condition.
Volumetric Expansion (hoses):	VENDOR to determine the volumetric expansion versus pressure in graphical form up to 1.5 x maximum working pressure. The VENDOR shall confirm this information by practical measurement on completion of umbilical manufacture.
Hose/tube marking:	Each hose/tube outer sheath/surface shall be uniquely numbered e.g. Line 1, 2, 3 ... etc. to aid termination and field repairs. Each hose/tube shall also be similarly marked with Manufacturers batch number, maximum working pressure, size and type. Marking shall be printed at not more than 1 metre intervals along the full length of the hose/tube. Marking can be applied at any stage up to, but preceding, the hydraulic testing.

4.5.2 Electric Cables

All the electric cables shall be supplied by the same manufacturer.

The electrical insulated conductors shall be designed to be capable of operating when completely flooded with seawater. The VENDOR shall demonstrate that the proposed electrical elements will meet this requirement over the operational life of the umbilical.

No conductor or cable joints shall be permitted within the umbilical length.

The manufacturer of the electric cable shall include some method or material to reduce the level of friction between each cable and between each core and the surrounding material. The object of incorporating some form or type of lubrication is to reduce the internal coefficient of friction and allow the individual cores to move or slide relative to each other.

The manufacturer of either the electric cables or of the umbilical shall provide all reasonable means of protecting the electric cables from any external compressive forces encountered during the manufacture, storage/loading, installation and operation of the umbilical. The VENDOR shall also provide all reasonable means of protecting the electric cables from any internal source of compressive force encountered during the same processes, including those caused by the expansion of any pressurised hoses.

The insulated conductors shall be laid up in such a manner as to give a circular cross section, to form a self-contained complete electric cable. The electric cable shall in turn be laid up with other electric cables, with or without hoses, to give an overall circular cross section.

Marking: The conductors shall each be identified by unique sequential number marking conforming to BS5467, or alternatively by unique colour coding. The marking shall be such as not to degrade the quality of the insulation, but shall be a permanent marking that can be read at any point along the total length of the cores.

Electrical characteristics @ 20°C
Power	DC loop resistance - 3.65 W/Km Max
	Inductance @ 50Hz - 0.78 mH/Km Max
	Capacitance @ 50 Hz - 65-95 nF/Km
	Crosstalk @ 50 Hz - ³ 60dB (between power pairs)
	- ³ 60dB ( pwr/comms)
	DC loop resistance - 9.5 W/Km Max
Electrical characteristics @ 20°C
Communications	Inductance @ 1.8 KHz - 0.8 mH/Km Max
	Capacitance @ 1.8 KHz - 95 nF/Km Max
	Crosstalk @ 1.8 KHz - ³ 60dB (Between comms)
	Crosstalk @ 1.8 KHz - ³ 60dB ( power/comms)
	Attenuation @ 1.8 Khz -0.6 dB/Km Max

Any conflict with the control system vendor requirements shall be highlighted to BUYER, but will require the VENDOR to rectify.

4.5.3 Pull-In Head

Access to the hydraulic lines and electrical conductors shall be gained by removal of the pull-in bullnose. The hydraulic lines and electric cores shall be sealed for the I-tube/J-Tube pull, in order to prevent water ingress and contamination of the control fluid. The termination shall be designed so that the delay between pull-in and being able to test the umbilical is minimised.

The design of the pull-in head shall be such that the umbilical does not exceed its minimum bend radius at the transition between the pull-in head and umbilical during the pull-in operation. Criteria and design to be agreed between VENDOR and BUYER.

4.5.4 Hang Off Assembly

Hang-off assemblies shall comprise a collar and split flange arrangement suitable for supporting the weight of the installed umbilicals in the J-Tube on the Hang Tuah. The split flange shall have a ½” NPT port and plug which can be used for J-Tube annulus access after umbilical pull-in.

VENDOR will supply all fittings and seals necessary to complete the assembly of the hang-off after pull-in of the umbilicals.

4.5.5 Umbilical Termination Assemblies

All subsea terminations shall comprise an armour termination flange that can maintain the full tensile strength of the umbilical, hose/tube tails with fittings and length agreed with the subsea controls vendor and electrical cable tail suitable for termination to a field installable electrical connector supplied by the subsea controls vendor.

Umbilical Termination Assemblies are required on the subsea ends of the Hang Tuah / Keong umbilical and both ends of the Keong / Kijing umbilical. Bend stiffeners shall be used on each armour termination to protect the umbilical against over bending during installation.

VENDOR will be responsible for coordinating the interface details with the control system vendor, ensuring that cable, hose and armour termination requirements are met and do not hold progress of the controls vendor design.

4.5.6 Umbilical Field Repair Joint

A set of field repair joints suitable for use on all static umbilical type shall be designed and supplied, these shall be capable of accommodating the full design load and shall not compromise the electrical or hydraulic characteristics of the associated umbilical. Field repair kits shall include bend stiffeners to protect the umbilical against over bending during re-deployment.

4.5.7 Provision of Samples

After completion of manufacture, the VENDOR shall supply 2 off 6” samples of the two subsea control & chemical umbilical types mounted on a plinth with the components sectionalised.

5.0 TESTING

All test equipment required to carry out the inspection and testing as described in the following sections shall be to the VENDOR’S cost.

5.1 Additions To API 17E Testing

5.1.1 Overall Umbilical Dimensional Checks

During all manufacturing processes after the laying up operation, the cross section of the umbilical shall be maintained as circular as possible. The ovality shall be as defined in the paragraph below.

The diameter shall be measured using a diameter tape over the armouring, if applicable, during the armouring operation at 100 metre intervals and it shall be within +/-8% of its average value. The difference between any two values of the overall diameter of the umbilical at the same cross section (ovality) shall not exceed 15%

5.1.2 Equipment Tests

The following equipment shall be subjected to a test to verify the design of the equipment with a sample length of umbilical:

J-Tube Pull-in Head

Hang-off Assembly

Subsea Termination

Field Repair Joint

5.1.3 Design Verification Test

The equipment shall be assembled to an umbilical sample of suitable length and subjected to a tensile load increasing in 1 Tonne steps until failure occurs.

5.1.4 Test Monitoring and Examination

During the test the electrical conductors shall be monitored as well as the hydraulic pressure in the hoses

On completion of the design verification tests, the umbilical sample shall be dissected, and inspected for damage to the conductors or hoses. The equipment assembly shall also be fully inspected and examined. A test report shall be completed for each equipment assembly and shall include test results and photographs of failed elements.

A proof load test certificate shall be issued for each equipment assembly clearly stating the load to which the assembly was subjected.

If the VENDOR can provide documented evidence that the previous hardware designs have been tested to the above conditions on similar umbilicals and furnish BUYER with copies of the reports which support these requirements then BUYER may at its discretion consider the designs to be verified.

5.1.5 Conductor Testing

Voltage of Spark testing during extrusion of the conductor insulation to be 12KV.

Conductor lengths to be subjected to a water soak test.

5.2 IR testing

All testing prior to the fitting of the subsea connectors to be conducted at 500 volts. All IR testing after fitting to the umbilical to be conducted at 240V.

5.3 Qualification Testing

All components used subsea shall have been subject to qualification testing for their intended use. The qualification tests shall include appropriate life testing (ie cycling), compatibility testing and strength testing in accordance with API 17E.

The VENDOR shall carry out qualification testing to agreed procedures or provide documented evidence that previous qualification tests have been performed successfully.

Compatibility qualification tests shall be performed on fluids if historical test results are not available.

5.4 Component/Assembly Testing

All padeyes, pull in and lifting equipment shall be subject to proof load testing to an applicable procedure for the service intended. Where dynamic loading through installation can be experienced, this shall be addressed in load testing criteria.

Hose and cables shall be tested in accordance with API 17E, Appendix A summarises the minimum testing for hoses & cables.

5.5 Factory Acceptance Testing

All deliverable subassemblies shall be subject to a Factory Acceptance Test (FAT) to fully demonstrate the functional requirements outlined in this specification. All FAT procedures shall be subject to BUYER approval prior to commencing tests.

5.6 Third Party Integration Testing

The VENDOR shall provide technical support and assistance during integration testing. Integration testing shall include, but not be limited to, the following:

· UTA Assembly and Testing

· IUT Assembly and Testing

5.7 Installation and Commissioning

The VENDOR shall provided installation and commissioning guidelines and outline procedures for all the umbilical and associated equipment.

The VENDOR shall provide technical support and assistance during installation and commissioning of the umbilicals.

6.0 SHIPPING/TRANSPORTATION

6.1 General

Method of shipping of the umbilicals shall be selected by BUYER

6.2 Lifting Equipment

Where applicable all deliverable equipment shall be supplied with dedicated riggings/slings etc or if necessary specifically designed lifting frames as part of the fixed scope of supply.

All rigging and lifting points shall be supplied with current certification with a minimum of 3 months before re-certification at the time of shipment.

All rigging and lifting points shall be tagged or hand stamped with appropriate details ie safe working load, equipment tag no and inspection date.

All equipment lifting points and associated rigging shall comply with offshore rigging/lifting standard and practices.

6.3 Packaging

All equipment shall be shipped in protective crates or pallets and, where appropriate with covers and environmentally sealed.

All crates and pallets etc shall be marked with the contract no, item no, equipment no and weight. Any handling instructions shall also be clearly marked on the outside of crate and covers. Packaging must be suitable for transporting of equipment by sea or air freight.

6.4 Umbilical Load-out

The VENDOR shall have suitable facilities for the load-out of the umbilical to shipping vessel or barge.

The VENDOR shall have the responsibility for packing the umbilical onto Reels or carousel, as defined by installation contractor, and ensuring the packing procedures are suitable for the correct installation of the umbilical.

Prior to transportation vessel sail-away VENDOR shall satisfy itself that the umbilical has been correctly packed for transportation and is free from defects.

7.0 DOCUMENTATION

Requirements for documentation shall be supplied as per COMPANY requirements.

Appendix A: Hose Testing Requirements

2 pages

COMPONENT TESTING DUCO

The following tables summarise the tests for each of the umbilicals covered by this specification and the tests are described in the subsequent sub-sections.

Note: 1) R = Required Testing

2) Electrical testing is in accordance with API 17E.

3) P = Previous Data

4) N = Not Applicable

Thermoplastic Hose Umbilicals

		Hydraulic Sample (verification)		Hydraulic Component (Acceptance)		Umbilical FAT
Change In Length	P
Proof Pressure 2 x WP	P		R
Pressure 1.5 x WP					R
Proof Pressure Decay	P		R		R
Burst	P		R
Cold Flexibility	P
Oil Resistance	P/R*
Impulse	P
Leakage	P
Ozone Resistance	P
Line Coupling	P
Volumetric Expansion	P		R		R
Visual	P		R		R
Dimensional	P		R		R
Bend					Note 1
Bend Fatigue
Flow Rate					R
Pressure Cycle					R
Material					Note 2
Cleanliness					R

Notes:

* If new material used.

1. Bend properties of umbilical to be verified by design calculations/previous data.

2. Sample of armour wire to be tested for specification compliance.

Electrical Testing

Electrical Test

Conductors

Electrical Component

Cable Sample (verification)

Umbilical Sample

Electrical Connector Installation

Umbilical FAT

Post Loadout Tests

Visual& Dimensional

Material

Water soak

Conductor Resistance

Resistivity of Screened layers

Insulation Resistance

@ 240 V

High Voltage DC

High Voltage AC

Complete Voltage Breakdown

Partial Discharge

Inductance Characteristics

Capacitance Characteristics

Attenuation Characteristics

Characteristic Impedance

Crosstalk

Spark Test (12 kV to be used)

Time Domain Reflectory

Appendix B: Fluid Data Sheets

Hydraulic Fluid

- Houghton Vaughan Aqualink 300

Corrosion Inhibitor - Champion IRN-290

- Petrolite KG-2277

- Nalcoexx EC1304A

FUNCTIONAL SPECIFICATION FOR SUBSEA CONTROL & CHEMICAL UMBILICALS

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