CHECK FOR LATEST REVISION PRIOR TO USE

UMBILICAL CRUSH TEST PROCEDURE IN ACCORDANCE WITH API 17E & ISO 13628-5

8/05/09

13145 12428 ECN/

N. Sime C.H. Edge BY

A. Carroll D. Graham CHECK

D. Graham J. Anderson OMUK

N/A N/A OMUS

N/A N/A MPS

K. Noble S. West INTRANET

Section 11.1 Update Orientation Definition REMARKS

8/10/08

DATE

used, copied or disclosed to any third party without the prior written authorization of Oceaneering International Services Limited.

PURPOSE To determine the capability of an umbilical to withstand deformation when subjected to lateral loading in accordance with the API 17E and ISO 13628-5 requirements.

REFERENCES API 17E ISO 13628-5:2002 HS0001 HS0018 S0179 Specification for Subsea Production Control Umbilicals Petroleum & Natural Gas Industries Design & Operation of Subsea Production Systems Part 5: Subsea Umbilicals Health & Safety Manual OMUK Job Safety & Environmental Analysis (JSEA) Procedure Test Procedure for Measuring the Conductor and Insulation Resistance of Electric Cables

3 3.1

RESPONSIBILITIES OMUK Production Department shall be responsible for preparing the Crush Test samples and in conjunction with any External Test facility used, conduct the tests in accordance with this specification. OMUK Quality Control Department shall be responsible for checking that the samples have been prepared in accordance with the specification. OMUK shall provide pressurisation and monitoring equipment as required by this procedure. Any External Test Facility (if used) shall be responsible for ensuring that the appropriate testing equipment is available at the agreed time and for the agreed period, and is fully functional with current calibration certification as required. Any External Test Facility (if used) shall make appropriate staff available for the duration of the setting up and testing of the samples. OMUK Engineering Department shall be responsible for interpretation of the results of the test and for issuing a report on the findings SAFETY A JSEA in accordance with OMUK procedure HS0018 shall have been completed prior to starting this test. The JSEA shall be available for and used by the operator to identify the hazards and the personal protective equipment to be used during the operation. The general safety requirements of Oceaneering Multiflex procedure HS0001 shall also be addressed. Safety requirements of the External Test Facility (if used) shall be observed at all times.

3.2 3.3 3.4

3.5 3.6

4 4.1

4.2 4.3

used, copied or disclosed to any third party without the prior written authorization of Oceaneering International Services Limited.

EQUIPMENT Crush Test Rig External Callipers Steel Rule 300mm Steel Plates 250mm x 150mm (or alternative designs where required by the contract) Permanent Marker Mechanical Hacksaw Camera

6 6.1

TESTS REQUIRED For Umbilicals with hoses and / or tubes:-

WARNING: TESTS (B) & (C) INVOLVES VERY HIGH PRESSURES WITH RISK OF SAMPLE FAILURE, AND DUE CARE AND ATTENTION MUST BE PAID TO PREVENT INJURY. 6.1.1 Test A (Dynamic and Static) This test shall be conducted with hoses and / or tubes unpressurised 6.1.2 Test B (Dynamic and Static) This test shall be conducted with hoses and / or tubes pressurised to a nominal value of 1000psi, equating to installation pressure (Unless another value is dictated as a contract specific requirement). 6.1.3 Test C (Dynamic Only) This test shall be conducted with hoses and / or tubes pressurised to their relevant nominal working pressure. 6.1.4 6.2 Water or water glycol shall be used as the test fluid. For umbilicals without hoses and / or tubes, only one test is required.

used, copied or disclosed to any third party without the prior written authorization of Oceaneering International Services Limited.

SAMPLE PREPARATION A separate representative umbilical sample is required for each test and should not have been subject to any previous testing that could impact test performance. Samples of umbilical shall be prepared with 1 metre outer jacket length, and sufficient pigtail length to enable termination of the hoses and / or tubes (Termination of hoses and / or tubes is not required for test A). Electric cables shall be prepared by stripping back insulation to allow access to the conductors and screen where applicable.

8 8.1

PREPARATION Where no predefined maximum load has been specified, the maximum deformation of the umbilical shall be 10% of the diameter. The Project Engineer shall specify up to 10 incremental diameter values based on this maximum deformation, and these values shall be input onto the Test Result table on page 6, prior to commencement of the test. Where a predefined maximum crush load is specified, the Project Engineer shall convert it into a load value based on the contact area of the test plate with the umbilical. The Project Engineer shall specify up to 10 incremental values from zero to the maximum converted crush load, which shall be input onto the Test Result table on page 6, prior to commencement of the test. Prior to commencing the test, electric cables where applicable, shall be tested in accordance with S0179 Test Procedure for Measuring the Conductor and Insulation Resistance of Electric Cables.

8.2

8.3

used, copied or disclosed to any third party without the prior written authorization of Oceaneering International Services Limited.

TEST REGIME Tests shall not commence without approval from the Project Manager as client witness may be required.

9.1

The Crush Test Rig shall be fitted with 2 flat steel plates, which shall be positioned directly opposite each other in accordance with API 17E & ISO 13628-5. The plates shall be nominally 250mm long with respect to the longitudinal axis of the umbilical and 150mm wide.

Note: The plate size or configuration may be changed in accordance with the requirements of the contract and / or by agreement with the client, to establish values e.g. pads of various designs, materials etc. Use of soft pads makes it difficult to determine the distorted diameter of the umbilical and Project Engineer should provide guidance for best practice. 9.2 Samples shall be placed, one at a time, centrally between the flat plates with long side parallel to the umbilical axis and where required shall be pressurised as detailed in section (6). The umbilical sample will be marked to give the centre point of the crush test sample when installed in the test rig. The centre line of the plates will be marked on the top of the umbilical on all four sides that will allow the lines to be projected after removal to find the TDC point on the sample. All markings will be made by permanent marker. (See sketch on Page 7) The plates shall be moved towards each other at a rate not to exceed 5mm / minute. Diameter or Load values shall be recorded against the Load / Diameter values previously written into the Test Result table on page 6 (Diameter measured by measuring distance between the flat loading plates). The appearance of the sample shall also be observed during the test and any visual changes recorded for inclusion in the test report. During the test, the hydraulic hose/tube pressures shall be monitored and recorded. On reaching 10% reduction in diameter, or the maximum applied load as specified in the Quality Plan or by the Project Engineer, the loading shall be stopped and then decreased at a rate not exceeding 5mm / minute. The electric cables where applicable, shall be re-tested in accordance with S0179, any hose and / or tube pressure shall be reduced to zero and the hose and / or tube ends plugged. The sample shall be removed from the Crush Test Rig. Measure the diameter of the samples across the pad contact area, to determine the amount of set in the umbilical following removal of the load, and enter it onto the record sheet.

9.3

9.4 9.5

9.6 9.7

9.8

9.9

used, copied or disclosed to any third party without the prior written authorization of Oceaneering International Services Limited.

9.10

If an external tests facility was used; following completion of all tests, the samples and equipment shall be returned to OMUK premises in Rosyth. After completion of test, the electrical cables within the sample shall be tested for insulation and DC conductor resistance.

9.11

10 10.1

TEST RESULTS The assigned OMUK Technician shall ensure that the table of results is completed for all samples under test. Production shall strip all samples for examination by Engineering Department. Photographs shall be taken as required, to record damage etc. for inclusion in the test report. Following completion of the examination, Engineering Department shall prepare a report detailing all test results, observations and conclusions.

10.2

10.3

11 11.1

ACCEPTANCE CRITERIA The umbilical shall be fully functional following the test regime as demonstrated by 9.6 and 9.11. Testing or strip down of the sample shall not reveal any defects, which have been caused by the test regime. The umbilical sample will be sectioned and a clear and unambiguous pictures taken of the end after it has been marked to show where the plates were situated. (See sketch on page 7) This information is for OMUK purposes only and will not have any bearing on the test results / report or the acceptance of the test itself. The information will be provided to the Engineering Department to be used for the validation of theoretical models defining / predicting the load paths through umbilicals.

11.2

11.3