FFS-SU-5274 Deepwater CALM Buoy Offloading System

FFS-SU-5274
DEEPWATER CALM BUOY OFFLOADING SYSTEM
APPLICATION: FLOATING/FIXED PLATFORMS
This document is the confidential property of Chevron U.S.A. Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system, or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording, or otherwise) without the prior
written consent of Chevron U.S.A. Inc.
Technology
Rev Date Description Author
Leader
11/12 Initial release W. Sonne T. Finnigan
November 2012 © 2012 Chevron U.S.A. Inc. All rights reserved. 1 of 50

Deepwater Calm Buoy Offloading System FFS-SU-5274
CONTENTS
1.0 Scope ..........................................................................................................................4

2.0 References ..................................................................................................................4
2.1 ......Classification and Rules ...................................................................................4
2.2 ......Purchaser Documents ......................................................................................5
2.3 ......Industry Codes and Standards .........................................................................5
2.4 ......Conflict Resolution ...........................................................................................6
3.0 Terminology ................................................................................................................6
3.1 ......Acronyms .........................................................................................................6
3.2 ......Definitions .........................................................................................................7
4.0 Functional Requirements and Description ..............................................................7
5.0 General Design ...........................................................................................................8
5.1 ......Design Life .......................................................................................................8
5.2 ......Load Cases ......................................................................................................8
5.3 ......Maintenance and Reliability .............................................................................9
5.4 ......Marine Growth ..................................................................................................9
6.0 Offloading System Requirements ............................................................................9
6.1 ......Offloading Buoy ................................................................................................9
6.2 ......Mooring System Components ........................................................................12
6.3 ......Mooring System Anchors ...............................................................................13
6.4 ......Marine Hoses (Floating) .................................................................................14
6.5 ......Surge Protection Systems ..............................................................................17
6.6 ......Mooring Hawsers ...........................................................................................17
6.7 ......Ancillary Equipment ........................................................................................18
6.8 ......Telemetry System ..........................................................................................20
6.9 ......Safety and Security ........................................................................................22
6.10 ....Spare Parts ....................................................................................................22
7.0 Positioning Requirements and Installation Tolerances .......................................23
7.1 ......General ...........................................................................................................23
7.2 ......Position Tolerance—Deeper Water ................................................................23
7.3 ......Position Tolerance—Shallower Water ............................................................24
8.0 Installation ................................................................................................................24
9.0 Materials and Workmanship ...................................................................................26
10.0 General Supplier Scope and Responsibilities .......................................................26
10.1 ....Design ............................................................................................................26
10.2 ....Interface Management ...................................................................................29
10.3 ....Fabrication and Manufacturing .......................................................................30
10.4 ....Testing and Quality Assurance ......................................................................30
10.5 ....Equipment Delivery ........................................................................................32
10.6 ....Loadout and Seafastening .............................................................................32

11.0 Mid-Water Offloading Lines ....................................................................................32

11.1 ....Offloading Line Design and Analysis ..............................................................33
11.2 ....Options ...........................................................................................................34
11.3 ....Flexible Offloading Lines ................................................................................34
11.4 ....Steel Offloading Lines ....................................................................................35
Appendix A Additional References .................................................................................49

1.0 SCOPE
1. This specification defines the minimum requirements for a deepwater catenary anchor leg
moored (CALM) buoy offloading system (i.e., offloading system) used to offload products
from a floating production, storage, and offloading (FPSO) vessel or a floating storage and
offloading (FSO) vessel, collectively referred to as F(P)SO vessel.
2. The offloading system could also be used to offload (or load) products from (or to) a
shore-based storage terminal.
Note The design aspects of mooring an export tanker and offloading operations at these
facilities are similar to the well-known shallow water CALM SPM buoy. However, these
facilities are typically in deeper water, not connected by flowlines to shore facilities. The
defining characteristic of this CALM buoy offloading system is the deep water depth for
which it is designed, which affects the type of mooring components used, the riser or
connecting flowline technology, and the distance they need to be separated from the
F(P)SO. In most other aspects these facilities are similar in design and function to a
typical shallow water CALM SPM buoy loading or offloading facility serving a
shore-based storage facility.
2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Unless otherwise specified in Section 2.2 or Section 2.3, use the latest edition of the
referenced documents.
3. Refer to Appendix A for additional references not cited in the text of this specification.
4. The offloading system shall be compatible with all the other parts that make up the offshore
development system. Common interfaces between the offloading system and the production or
storage facility (e.g., telemetry, electrical, instrumentation, ESD logic, etc.) shall be subject to
the same codes and standards for the corresponding parts.
2.1 Classification and Rules

1. The offloading system shall be provided in accordance with the rules of the American Bureau
of Shipping (ABS) or other Owner-accepted classification society in force on the effective
date of the contract.
2. Supplier shall be responsible for obtaining ABS approval and certification of the system,
including complete documentation, so that the system will be classified by the ABS.
3. As a minimum the following ABS rules and guidelines shall apply:
a. Rules for Building and Classing Single Point Moorings
b. Rules for Building and Classing Steel Vessels
c. Building and Classing Floating Production, Storage and Offloading Systems
d. Guide for the Certification of Offshore Mooring Chain
e. Rules for Building and Classing Offshore Installations
f. Guidelines and Classification notes as applicable

Oil Companies International Marine Forum (OCIMF)

OCIMF Buoy Mooring Forum SPM Hose Ancillary Equipment Guide
OCIMF Guide to Manufacturing and Purchasing Hoses for Offshore Moorings
OCIMF Guidelines for the Purchasing and Testing of SPM Hawsers
OCIMF Recommendations for Equipment Employed in the Bow Mooring of
Conventional Tankers at Single Point Moorings
2.2 Purchaser Documents

FFS-DU-5173 Global Performance and Stability Design for Floating Offshore Platforms
FFS-SU-5174 Analysis, Design, and Manufacture of Polyester Moorings
FFS-SU-5212 Design, Manufacture, and Installation of Permanent Moorings for Floating
Offshore Platforms
FFS-DU-5247 Model Testing for Floating Systems
FSO-SU-5260 FPSO Marine Cargo System
SID-SU-5106 Safety in Designs
2.3 Industry Codes and Standards

American Petroleum Institute (API)
RP 2A-WSD Recommended Practice for Planning, Designing and Constructing Fixed
Offshore Platforms—Working Stress Design
RP 2RD Design of Risers for Floating Production Systems (FPSs) and Tension-Leg
Platforms (TLPs)
Spec 5L Specification for Line Pipe
RP 17B Recommended Practice for Flexible Pipe
Spec 17J Specification for Unbonded Flexible Pipe
Spec 17K Specification for Bonded Flexible Pipe
RP 1111 Design, Construction, Operation, and Maintenance of Offshore
Hydrocarbon Pipelines (Limit State Design)
American Society of Mechanical Engineers (ASME)
B31.4 Pipeline Transportation Systems for Liquids and Slurries
B31.8 Gas Transmission and Distribution Piping Systems
Boiler and Pressure Vessel Code (BPVC)
Section V, Nondestructive Examination
ASTM International (ASTM)
A227/A227M Standard Specification for Steel Wire, Cold-Drawn for Mechanical Springs
E34 Standard Test Methods for Chemical Analysis of Aluminum and
Aluminum-Base Alloys

British Standards Institution (BSI)

BS 7910 Guide to methods for assessing the acceptability of flaws in metallic
structures
Det Norske Veritas (DNV)
RP B401 Cathodic Protection Design
OS F101 Submarine Pipeline Systems
RP F102 Pipeline Field Joint Coating and Field Repair of Linepipe Coating
RP F106 Factory Applied External Pipeline Coatings for Corrosion Control
OS F201 Dynamic Risers
Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS)
SP-75 Specification for High-Test, Wrought, Butt-Welding Fittings
NACE International (NACE)
SP0387 Metallurgical and Inspection Requirements for Cast Galvanic Anodes for
Offshore Applications
TM0190 Impressed Current Laboratory Testing of Aluminum Alloy Anodes
2.4 Conflict Resolution

Supplier shall submit any conflicts among the inquiry documents in writing to Owner for
resolution.
3.0 TERMINOLOGY
3.1 Acronyms
AUT—Automated Ultrasonic Testing
CALM—Catenary Anchor Leg Moored
CCR—Central Control Room
CP—Cathodic Protection
dwt—Dead Weight Tonnage
ECA—Engineering Critical Assessment
ESD—Emergency Shutdown
FPSO—Floating Production, Storage, and Offloading Vessel
FSO—Floating Storage and Offloading
HFE—Human Factors Engineering
HSS—Heat Shrink Sleeve
ICSS—Integrated Control and Safety System
ITP—Inspection and Testing Plan
IVA—Independent Verification Agency
LACT—Lease Acquisition Custody Transfer (Meter)

LF—Low Frequency
NDE—Nondestructive Examination
NDT—Nondestructive Testing
OOL—Oil Offloading Line
PTFE—Polytetrafluoroethylene (Teflon)
RAO—Response Amplitude Operator
ROV—Remote Operating Vehicle
RTU—Remote Telemetry Unit
SCF—Stress Concentration Factor
SMYS—Specified Minimum Yield Stress
SPM—Single Point Mooring
SWL—Safe Working Load
TER—Telecommunications Equipment Room
TQP— Technical Qualification Process
VIV—Vortex-Induced Vibration
3.2 Definitions
Class—Recognized marine classification society.
Class Rules—Rules and guidance published by a recognized marine classification society.
Work—All work and services required to be performed by Supplier to fully comply with the
requirements of this Contract.
4.0 FUNCTIONAL REQUIREMENTS AND DESCRIPTION

1. The catenary anchor leg moored (CALM) buoy offloading system shall be complete and fully
functional, meeting or exceeding applicable safety requirements and regulations.
2. The components of the offloading system shall be integrated and set up to ensure that the
entire system is ready to start operations after completion of installation, hook-up, inspection,
commissioning, and performance testing in the field.
3. Offloading system shall be a new, purpose-built facility designed to transfer the specified
products from a production or storage facility in accordance with the design basis. Unless
specified otherwise in the design basis, the minimum functional requirements shall be as
follows:
a. Designed to continuously transfer product at the design flowrate to (or from) the
production or storage facility to (or from) export tankers moored to the buoy.
b. Capable of mooring export tankers of the type and capacity (dead weight tonnage [dwt])
specified in the design basis, and compatible with the mooring and product transfer
interfaces. Export tankers shall be capable of freely weathervaning (360 degrees) around
the buoy while transferring products.

c. Designed to safely survive the 100 year return period storm without an export tanker
moored, and to safely survive the 10 year return period storm with export tankers moored
to it, unless specified otherwise in the design basis.
4. The buoy shall include a multi-anchor-leg mooring system of chain (or combination of chain
and steel wire or synthetic/polyester rope) and a central roller bearing rotation system to allow
continuous 360-degree weathervaning. The buoy shall also include, but not be limited to, the
following components:
a. Buoy hull with rotating turret or turntable assembly.
b. Product fluid swivel.
c. Floating hose product transfer system.
d. Mooring hawser assembly.
e. Anchors or anchor piles.
f. Anchor leg assemblies.
g. Navigation aids and ancillary equipment.
h. Tanker load monitoring and telemetry system.
i. Mooring system monitoring instrumentation.
j. Valve actuation and control equipment.
k. Navigation aids.
l. Flowlines (or pipelines) connecting the production or storage facility to the CALM buoy.
5.0 GENERAL DESIGN
5.1 Design Life

1. Offloading system shall meet the design life criteria specified in the project design basis.
2. Fatigue life for the following shall have a minimum safety factor of 10.
a. Buoy mooring system.
b. Mid-water offloading lines (F[P]SO offloading).
5.2 Load Cases

1. Supplier shall design the offloading system, without a moored export tanker, to withstand the
100-year return period metocean conditions. With the export tanker moored, the design
condition shall be the 1- or 10-year return period metocean conditions.
Note Operational design interval may be one or ten years, depending on the location and
typical metocean characteristics. For benign environments (such as West Africa),
ten years is typical. For locations with storms that may affect the specific site
(such as cyclones in the Gulf of Mexico or Asia), a one-year interval is used.
2. Load cases shall be developed for Purchaser review to maximize the mooring system and
offloading line responses and capacities.

3. Load cases shall be according to FFS-DU-5173 and shall take into consideration the following
conditions:
a. With export tanker moored (operational).
b. Without export tanker moored (survival).
c. With export tanker drafts fully loaded and at 20-percent loaded (ballasted).
d. Squalls (at squall-prone sites) shall be modeled based on time histories.
4. Supplier shall develop fatigue design conditions based on the metocean design basis and shall
submit for Purchaser review and comment.
5.3 Maintenance and Reliability

1. Buoy, mooring system, mid-water offloading lines, floating hoses, and all offloading system
components shall be designed for minimum maintenance intervention over the design life.
a. No routine maintenance task shall exceed 8 hours duration in order for the system to be
readily available for scheduled offloading operations.
b. System shall be designed with access for periodic inspection of components and spaces.
2. Hull shall be designed as follows:
a. To minimize the requirement for removal of any major component from the buoy for
maintenance or replacement.
b. To minimize wear and tear of normal operations and avoid major maintenance works.
5.4 Marine Growth

Supplier shall investigate the influence of marine growth on the mooring system and offloading
lines and determine whether to include the marine growth in the design to ensure the conservatism
of the system.
Note Type and accumulation rate of marine growth may affect weight, hydrodynamic
diameters, and drag coefficients of anchor legs and mid-water offloading lines.
6.0 OFFLOADING SYSTEM REQUIREMENTS
6.1 Offloading Buoy

1. Offloading buoy hull shall be divided into a minimum of six watertight compartments using
radial bulkheads extending from the cylindrical center-well to the outer buoy hull.
2. Watertight compartments shall be fitted with watertight inspection manholes.
Note The requirements described above do not preclude the use of buoy hulls of shapes
other than cylindrical.
3. Buoy shall be sized so it has adequate buoyancy to support the anchor legs, offloading lines,
and other equipment mounted on it, with a minimum of 6.56 feet (2 m) of freeboard.
4. Buoy body shall meet the following requirements:
a. Provide buoyancy and stability for the overall single point mooring (SPM) system.
b. Be constructed to remain stable in the sequential phases of the installation and hook-up
during operational conditions.

c. Be constructed to remain afloat and stable in the event that any combination of anchor legs
fail in an undamaged condition and two adjacent compartments are flooded or damaged.
1) In the damaged condition the resulting heeling angle during storm or operational
conditions shall not endanger the subsea offloading lines or exceed their bending
radius limit.
2) Draft marks on the buoy circumference shall enable monitoring of the floating
condition of the buoy.
3) Foam shall not be used in the compartments to ensure buoyancy in case of damage or
rupture to the buoy.
5. Buoy hull shall have a reinforced structural steel foundation, machined for mounting and
installing a central rotating roller bearing assembly.
6. Bearing foundation shall be designed to accommodate the bearing axial and radial thrust loads
and overturning moments.
7. Foundation shall provide the following:
a. A means for confirming dimensional tolerances.
b. A means for fastening, seating, and sealing the bearing assembly.
c. Access and means for inspecting the bearing assembly and/or components in-situ at the
offshore site without requiring hot work or external lifting devices.
8. The buoy hull and/or rotating assembly shall be equipped with the following items in order to
lift the complete buoy hull and rotating assembly as a single unit with any one buoy
compartment completely flooded.
a. Four or more lifting pad eyes
b. Shackles
c. Wire rope slings
d. Spreader bar, if required
9. The lifting equipment referenced in item 8 above shall be tested and certified by a
Purchaser-accepted inspector prior to use.
10. The provider shall supply the Purchaser its hull coating specification for review and comment.
Once accepted by Purchaser, the surface preparation and coating application of the internal
and external structure of the buoy shall be in accordance with that specification.
11. Submerged portions of the buoy hull shall be fitted with an external sacrificial anode cathodic
protection (CP) system with a design life of 10 years.
12. Buoy design shall minimize motions during expected operating conditions.
a. Supplier shall demonstrate how this shall be achieved.
b. This demonstration shall include buoy conditions with and without the export tanker
moored to the buoy.
c. Supplier shall also present calculated buoy motions in the form of response amplitude
operators (RAOs) and random sea significant and maximum responses to Purchaser for
review and comment.
13. Buoy shall be designed to protect the hull against accidental collision damage by moored
export tanker or service vessel.

14. Buoy product piping—located at an angle of 45 to 90 degrees from the tanker mooring
connection—shall be designed to incorporate the product line(s), including pipe spools,
valves, expansion joints, elbows, and flanges.
a. Buoy product piping structural area shall be fitted with permanent cable guides, fairleads,
reaction points, and necessary aids for alignment and connection of two floating hose
strings during installation or replacement.
b. The structural area shall have sufficient personnel access for inspection and maintenance
of the piping and associated piping components.
15. If dual offloading lines are used, the buoy shall be fitted with pigging loops/crossover
connections and flow line isolation valves to allow a return path.
16. Pigging loops shall have minimum 3D bends for circulating a scraper-type/cleaning pig
launched from the floating production, storage, and offloading (FPSO).
17. Buoy hull product inlet valves shall be located within the buoy center-well.
a. Product outlet valves shall be located on the rotating structure.
b. Buoy-mounted valves shall be ball-type and manually operated, unless otherwise
specified.
18. Buoy shall have a vent with valve and blank inboard of product line crossover at high point
and low point for venting and draining pipework. In addition, the product outlet lines shall be
fitted with a suitable diameter tee-connection and blanked valve situated before each outlet
valve, for use when line flushing by hose is required.
19. Buoy shall be fitted with a minimum of two personnel access ladders located on opposite sides
and a boat landing/fendering system extending to the buoy hull skirt to prevent contact
between mooring launches and service vessels. The boarding ladders shall be recessed and
protected on both sides by a steel framework having a D-type elastomer fender system
extending below the waterline to prevent entrapment of floating hoses or hawsers.
20. Buoy shall have a multi-seal swivel.
a. The design shall allow seals to be replaced on site without removal of the swivel from the
buoy.
b. Leak detection ports shall be provided for internal seals, connected to a leak detection and
collection reservoir.
21. Mooring buoy roller bearings shall be protected and sealed from sea water.
a. The sealing system shall provide a means for access to, and periodic inspection of, the
bearing housing area.
b. Roller bearing shall be grease-packed and shall be equipped with stainless steel lubrication
lines and grease fittings.
c. Grease fittings shall be protected from seawater corrosion by the use of grease-filled
stainless steel caps or covers, fitted securely over the grease fitting.
d. Grease lubrication system shall be as follows:
1) Automatic.
2) Replaceable in-place if it becomes unserviceable from corrosion or damage.

3) Able to be replaced by manual lubrication methods.

4) Capable of providing a way to confirm that the bearing is fully lubricated after
servicing.
22. Supplier shall provide a detailed description of the roller bearing and seals. Supplier shall also
deliver to Purchaser detailed procedures, tools, and any special materials or equipment to
maintain and replace the bearings and seals on location.
23. A means shall be provided for locking the buoy rotating turntable assembly in any selected
position during maintenance and repair operations.
24. Personnel guardrails and a tubular steel rope guard and swivel maintenance lift arrangement
shall be fitted on the buoy rotating structure.
25. Piping shall be configured so that flanged fittings can be easily removed or replaced without
forcing the flange faces apart.
26. A 316 stainless steel identification plate that complies with local regulations shall be provided
to identify such items as “Owner,” “Designer,” and “Fabrication facility.”
27. Electrical earthing points and cables between rotating assembly and fixed body shall be
provided to protect the bearings from damage if onboard welding is required.
28. In-place repair procedures shall be provided for the coating and painting systems.
6.2 Mooring System Components
6.2.1 General Requirements

1. Supplier shall provide all components necessary to moor the offloading buoy on
location for the design field life.
2. Design shall be according to FFS-SU-5212. For polyester mooring lines, design shall
be according to FFS-SU-5174.
3. Technical information on the components selected shall be reviewed by Purchaser.
certificates shall be available to Purchaser as hard copies or electronically before the
buoy is installed on location.
4. Maximum offset of the buoy shall be based on FFS-SU-5212. Alternatively, offset
may be based on design of the offloading lines and account for all intact and damaged
mooring conditions.
5. Fatigue calculations shall be based on FFS-SU-5212. For guidance, it is anticipated
that the buoy shall have an export tanker occupancy rate based on specific project
conditions.
6. The operational condition shall be based on maintaining a specific project sized tanker
safely moored to the buoy in a one- or ten-year return interval event. The survival
condition shall be based on the 100-year return interval event with no tanker attached
to the buoy.
Note The operational design interval can be one or ten years depending on the
location and typical metocean characteristics. For benign environments
(such as West Africa), ten years is typical. For locations with storms that may
affect the specific site (such as cyclones in the Gulf of Mexico or Asia), a one
year interval is used.

6.2.2 On Buoy Components of Moorings

1. Buoy shall be fitted with ratcheting, locking-type chain stoppers for securing each
mooring leg.
1. Chain stoppers shall be designed to permit chain pretension adjustment from the
rotating turntable deck and to cause minimal damage and wear on the chain links.
2. Chain stoppers shall be fitted with lifting lugs and each chain stopper housing or chain
connection shall be as follows:
a. Designed to avoid the out-plane and in-plane bending of the chain and to ensure
the fatigue life of the mooring system meets the design criteria.
b. Articulated to the vertical.
c. Numbered according to the number of chain legs per the mooring plan.
3. Design of the mooring system shall include the equipment or any plates or connection
points required to tension the anchor legs.
6.2.3 Anchor Leg Components

1. Anchor leg components shall be designed according to FFS-SU-5212 and
FFS-SU-5174 for polyester mooring lines.
2. For the lower (seabed) chain segment, sufficient chain length shall be allocated to
prevent the middle anchor leg section from coming in contact with the seafloor in the
slackest line at the maximum anticipated offset.
3. Supplier shall provide a means to monitor the anchor legs or to verify as-installed
tensions, to detect line failure, and to continuously monitor tensions throughout the
life of the field.
4. Mooring leg data shall be transmitted to the central control room (CCR) of the FPSO
and to a portable monitor to allow for constant monitoring.
Note Refer to Section 6.8, “Telemetry System”.
6.3 Mooring System Anchors

1. Supplier shall provide anchor points to withstand the long-term static and dynamic loading of
the anchor leg with the required safety factors, and shall consider the cyclic degradation of soil
strength and creep.
a. Suction or driven piles shall be acceptable.
b. Other anchor types such as the drag embedment, plate anchors, or suction embedded plate
anchors may be considered where they offer desirable characteristics including the
following:
1) Precise placement on the seabed.
2) Holding capacity that can be demonstrated through geotechnical calculations.
3) Ability to resist long-term static and dynamic loading.
4) Proven experience in previous offshore applications with comparable capacity.
5) Economically desirable considering purchase, handling, and installation costs.

2. Geotechnical and geophysical data as described in the design basis shall be used for anchor
design.
a. Supplier shall provide and design for CP for the anchor piles according to DNV RP B401.
b. Procedures for anchor design shall be developed by Supplier for Purchaser review and
comment.
3. Pile fabrication shall be in accordance with the requirements of API RP 2A and Purchaser
requirements.
4. Supplier shall conduct material and weld testing in accordance with API RP 2A minimum
requirements and Purchaser requirements. Testing shall be performed in accordance with
Supplier’s quality plan that has been reviewed and accepted by Purchaser.
5. Holes in lifting eyes shall be drilled or finished after assembly and welding of components,
e.g., check plates, shims, etc.
6. Design of the mooring padeye shall account for out-of-plane loading to accommodate the
installation tolerance.
6.4 Marine Hoses (Floating)
6.4.1 General Requirements for Loading Hoses

1. Offloading system shall be equipped with a floating hose system designed,
constructed, tested, marked, and packed in strict accordance with the requirements of
OCIMF “Guide to Manufacturing and Purchasing Hoses for Offshore Moorings.”
Floating hose system shall meet the following requirements:
a. Hoses shall be elastomeric, reinforced, and smooth bore, with a 285 psig
(19 barg) operating pressure rating.
b. Hose lengths shall be standardized as much as possible in order to minimize
spares.
c. Optimum hose configuration, length, and hose type shall be determined based on
the maximum size export tanker.
2. The floating hose system shall consist of strings of one or two off buoy, specially
reinforced, and buoyancy-distributed hose, mainline hose section.
a. Each string shall have reduced-diameter tail hoses and a tanker rail hose.
b. The total length of the floating hoses shall comply with OCIMF guidelines.
3. For multiple floating hose strings, the “outer” hose string shall have one additional
mainline section to prevent crossovers. Supplier may propose alternative
configurations.
4. Each floating hose string shall be fitted with a minimum of four solar powered winker
lights.
5. The export tanker end of each tail hose string shall be equipped with the following
required ancillary equipment as specified in the OCIMF “Buoy Mooring Forum SPM
Hose Ancillary Equipment Guide.”
a. Lever-operated butterfly valve with robust locking mechanism.
b. Camloc coupling fitted with Buna “O” ring and spool piece.
c. Lightweight blind flange.

d. Two hang off or snubbing chains.

e. Pelican hook arrangement for connection to tanker.
f. Pick-up chain.
g. Combined pick-up/marker buoy with through lifting capacity.
6. All ancillary hardware shall be hot dipped galvanized or stainless steel.
6.4.2 Other Hose System Requirements

1. Individual hose sections shall be joined together by Teflon (PTFE)-coated studs
and nuts.
2. Gaskets between hose sections shall be asbestos-free, fiber-raised face.
3. Gaskets at locations where the hoses join hard piping shall be spiral-wound
metallic-type raised face.
4. If double carcass hoses are required, a means of leak detection at the hose section ends
shall be included.
5. To prevent excessive damage due to wear and abrasion reducing the service life of the
hoses, tail and rail hoses shall be supplied with anti-chafe protection.
6. Hoses shall be inspected and tested during hose manufacturing in strict accordance
with OCIMF standard specifications.
a. Hoses shall be supplied with inspection/acceptance certificates from the
classification society.
b. If any hose fails to meet a test requirement, then all hoses of that type shall be
tested.
7. During all testing, hoses shall be supported on the horizontal axis on a sufficient
number of roller bearing dollies or low-friction devices to allow linear expansion
during pressure tests and to prevent excessive sagging between the support points.
Dollies shall be placed on a smooth, hard surface.
6.4.3 Marine Hose Breakaway Couplings (Optional)

1. Each hose string shall be fitted with a double-closure breakaway coupling in the tail
section to protect the hoses from excessive tension loading in the event an export
tanker breaks free from its mooring, and from pressure surge occurring in the loading
system.
a. Coupling separation shall occur under a predetermined axial load or surge
pressure level to protect the transfer system’s hoses and the buoy piping, swivel
seals, and instrumentation.
b. Upon parting, valve closure shall occur at a controlled rate to avoid creating a
pressure surge in the transfer system.
c. The design shall have an extensive list of supply references and documented
evidence of field service, including successful activation.

2. Breakaway couplings shall have the following characteristics:

a. Coupling shall be completely self contained, requiring no outside power source,
attachments, connections, or umbilicals.
b. The valve shall be mechanically locked in the open position and fail safe until the
unit parts.
c. To reduce wear and risk of damage in service, the device shall incorporate a
segmented valve design (sometimes known as a petal valve) so that the flow of
product does not impinge on or clog the mechanism.
d. If additional buoyancy is required, and flotation damage or loss does occur, the
residual weight of the device shall not cause auto submersion of the hose string.
e. To avoid external mechanical damage during hose string impact or crossover and
to negate the risk of hose string abrasion (in the case of multi-string systems), the
body diameter of the coupling shall not exceed the outside diameter of the hose
ends with which the unit shall be compatible.
f. The device shall be radially in balance to avoid imparting torsion in the hose
string.
g. The device shall be compact and short in overall length so that the total stiff length
of the coupling, adjacent hose flanges, and hose nipples is short enough to negate
the possibility of stress concentration resulting in premature hose fatigue.
h. To avoid wear, erosion, and clogging with crude oil when cooled and not flowing,
valve components and internal mechanisms shall be sealed from the product flow
until parting of the device occurs, thus ensuring a long, maintenance-free service
life.
i. Valve segments shall be controllable and it shall be possible to alter the closure
speed without dismantling the device.
1) Closure speed shall be infinitely variable.
2) Valve closure shall be augmented by the energy of the flowing product and
shall not be dependent solely upon spring power.
j. The coupling shall not be sensitive to bending, shear, torsional, or cyclic loads.
k. In order to effect adjustment of the instantaneous and controlled portions of
closure, it shall be possible to shut off a portion of the bore area instantaneously
while controlling the closure of the remaining bore area, thereby minimizing
outflow without jeopardizing a safe, surge-negating shut down.
l. The coupling shall be re-usable and maintenance free in service for a minimum
period of three years, requiring no attendance during that time.
m. The coupling shall be fabricated in materials suitable for use in salt water and
compatible with the cargo fluid specified. A full materials list shall be provided.
n. A full corrosion protection system shall be applied to suit the service required of
the device. A full specification shall be provided.

o. The couplings shall be subjected to the following tests to Purchaser satisfaction:

1) Dry valve closure test to ensure smooth unbinding operation.
2) Parting assembly proof test carried out by independent test house to ensure
reliability of break load.
3) Body hydrostatic test to ensure integrity of body forgings. Test pressure to suit
operational specification.
4) Systems pressure test in final assembled state. Test pressure to suit operational
specifications.
6.5 Surge Protection Systems

1. If the results of a hydrodynamic analysis indicate that pressure surges in the system will
exceed the design capacity of the loading system piping, swivel, or other flowline components,
an integral surge protection system may be considered.
Note Surge protection systems typically consist of fast-opening relief valves in the SPM
hull piping discharging the surge volume into tanks in the buoy hull. Upon activation,
pressure and level sensors initiate a shutdown of the F(P)SO loading pumps via a
telemetry link. Closed surge protection systems are appropriate to avoid any possible
product loss from the loading system to the sea.
2. Alternatively, an increase in the pressure rating of the piping and swivel to withstand the surge
may be appropriate.
6.6 Mooring Hawsers

1. SPM buoy shall be equipped with nylon mooring hawser assemblies supplied in accordance
with OCIMF “Recommendations for Equipment Employed in the Mooring of Ships at Single
Point Moorings,” OCIMF “Procedures for Quality Control and Inspection during the
Production of Hawsers,” and OCIMF “Guidelines for the Purchasing and Testing of SPM
Hawsers.”
2. The length and diameter of the mooring hawser shall be selected to provide the most favorable
loading distribution in the system as a whole.
a. The elongation length of the hawser and excursion of the buoy shall be compatible.
b. The allowable maximum force on hawser shall follow the OCIMF guidelines listed in
item 1 above.
3. Each mooring hawser assembly shall consist of the following components:
a. Buoy end stud link chain terminated at the buoy end with a heavy-duty shackle equipped
with a load pin to monitor hawser tensions. The stud link chain shall extend a sufficient
length to the hawser thimble shackle to ensure the hawser thimble assumes the correct
orientation and avoids contact with any structure and the buoy hull while hanging
overboard.
b. Circular-braided or double-braided mooring hawser(s) fitted with a galvanized steel
thimble. Twin hawsers shall be a matched pair, and their length shall be measured under
reference load with an allowable length of 0.5 percent between hawsers.

4. The hawser body, between the eyes, shall be coated with polyurethane.
a. Body coating shall be applied before any seizing or beckets are installed.
b. Polyurethane coating shall be applied evenly, without drips, sagging, or cracks.
5. Shackles and fittings shall be coated (galvanized or painted).
6. OCIMF chafe chain for the specified tanker size shall be connected to the tanker end of each
mooring hawser.
7. At the tanker end, a chafing chain support buoy shall be attached to the hawser end of each
chafing chain, with a minimum reserve buoyancy of 40 percent, and a heavy-duty impact and
abrasion-resistant polyurethane cover.
a. Inner foam material shall be resilient and non-crushable.
b. Buoy shall be a hawse type, allowing the chafing chain to pass through the buoy, and fitted
with a chain locking plate at one end of the steel hawse pipe.
c. Buoy end fittings shall include lifting points or padeyes for handling purposes.
8. Self-floating polypropylene pick-up line shall be 328 feet (100 m) long (minimum) ×
10 inches (25.4 cm) in diameter with a lightweight steel thimble at one end, soft eye on
the other. MBS shall be provided by Supplier.
9. Foam-filled pick-up marker buoy shall be attached to the tanker end of the pick-up line to
assist in the mooring hawser recovery and pick-up operation. The buoy shall be a tether type
equipped with end fittings, swivel, and attachment shackle for joining the marker buoy to the
pick-up line.
6.7 Ancillary Equipment

1. A winch shall be located on the rotating turntable assembly, primarily for assisting in
re-tensioning anchor chain legs.
a. The winch shall be designed for continuous service in an offshore marine environment,
including exposure to salt water spray.
b. A removable cover shall be provided to protect the winch against sea spray when not
in use.
2. The winch system shall include the following:
a. A pneumatic drive motor.
b. Brake gear.
c. Winch drum.
d. Frame.
e. Base.
f. Blocks, sheaves, reaction points, fairleads, and ancillary rigging necessary to perform
chain-tensioning functions.
3. A battery-powered marine signal light permanently mounted on the buoy shall have a clear
acrylic lens with a molded, top lens center-located bird spike.
a. The light shall be designed for 360-degree horizontal operation.
b. It shall emit a light visible at a range of 5 nautical miles (9 km), with an atmospheric
transmissivity factor of 0.85.

c. An automatic timer shall repeatedly flash a Morse code “U” signal at 15-second intervals.
d. The marine signal light shall have an automatic sun switch to operate the light only during
darkness hours.
e. An automatic lamp changer holding six lamps shall position a new lamp at the lens focal
center when a lamp fails.
f. Alternatively, an LED lamp system may be proposed.
4. Two battery banks located in two separate ventilated battery boxes designed for a salt water
marine environment shall be provided.
a. Batteries shall be sealed lead acid type.
b. Each battery bank shall provide for at least ten days without charging.
c. Battery bank size shall consider all loads except for the fog horn and shall allow for
offloading operations on the schedule specified in the design basis.
5. Two separate solar panel arrays shall be provided to charge batteries and to provide electrical
power to the buoy.
a. Each panel shall be sized to provide 75 percent of total system requirements, taking into
account variations in solar radiation, weather effects, and salt or bird deposit on panels.
b. Solar panels shall have a means to prevent birds from roosting on or over the panel.
6. Solar panels, battery banks, and electrical loads shall be arranged so that the following
requirements are met:
a. A failure of any solar panel or battery bank shall not remove power from the system.
b. Maintenance and removal of a solar panel and/or battery bank shall be possible without
removing power from the system.
7. Product ball valves located in the buoy hull shall be hydraulically operated and powered via an
accumulator storage system.
a. The accumulator shall have the capacity to operate each of the valves through a minimum
of 4 open/close cycles.
b. Accumulators shall be charged by remote air supply.
c. The pressure in the accumulator shall be reported via the telemetry system.
d. Operation of the valves shall be via telemetry and locally.
e. Valve closure speed shall be adjusted locally.
f. Air supply line connection shall be accessible on the buoy deck without opening hatches
to the buoy chambers.
8. Fog horn shall be activated via the buoy telemetry system and shall also have a local manual
switch.
a. Fog horn shall be designed for marine operating conditions with an acoustic range of
2 nautical miles (3.7 km), based on an audio level of 55 phons at the observer’s ear under
still air conditions.
b. An automatic timer shall provide a repeating Morse code “U” signal at 30 second
intervals.

c. Fog horn shall be directly accessible for maintenance and shall be separately powered with
a battery bank and a solar panel for recharging batteries.
9. Radar reflector shall be a 20-inch (0.5-m) diameter ANSI 316L stainless steel octahedral,
equipped with a bird spike. The radar reflector shall be mounted on the buoy in an
unobstructed location, visible from all approach directions.
10. Two 30-inch (762-mm) diameter ring-type life buoys with water lights and 100 feet (30 m) of
self-floating polypropylene line shall be mounted on the buoy in accessible locations. Life
buoy mountings shall prevent the life buoy from being washed away during storm conditions.
11. Two 22-lb (10-kg) dry ABC chemical fire extinguishers shall be furnished in readily
accessible watertight storage containers located on the buoy assembly, as appropriate.
12. Two “NO SMOKING” signs shall be clearly displayed on the buoy.
13. Buoy shall have a suitably sized, lockable tool/storage box for stowage of maintenance tools
and equipment.
6.8 Telemetry System

1. The telemetry system shall comprise equipment to be located on the buoy, at a base station
ashore in the CCR or in the F(P)SO telecommunications equipment room (TER), and two
portable units for use onboard the export tanker or service vessel.
2. Two redundant remote telemetry unit (RTU) systems shall be located on the buoy.
a. Each RTU shall be self-contained, with the exception of power supply and antenna, to
enable ease of removal for repair, and shall meet the requirements of all applicable local
and international standards.
b. Data measured by sensors on the buoy shall be collected and transmitted from the RTU
systems by dual redundant radio links to the FPSO base station and portable units.
c. The dual redundant radio links shall operate on a unique transmit/receive frequency pair
and on a non-interfering basis with the other systems.
d. Interrogation interval or scan time for this data transfer shall be continuous real time.
3. Design and location of the base station and RTU antennas shall consider the potential for
shielding problems, which may occur as the export tanker weather-vanes around the mooring
buoy.
a. Radio links shall have a combined availability of 99 percent.
b. In the case of potential transmittal path blocking by the export vessel, system layout may
include transmission paths of two directions separated sufficiently to avoid tanker
blocking.
c. Supplier shall propose alternative methods of communication if this level of performance
is not achievable.
4. Systems located on the buoy shall be powered by batteries connected to a solar charging
system.
a. Charging system and battery supply shall have 150 percent capacity to power the system
in normal site weather conditions and global location, and to power the system for 15 days
without input from the solar panels.
b. Supplier shall propose alternative methods of power supply if this level of performance is
not achievable.

5. Base station shall comprise dual redundant radio transceivers, RTUs, IBM-compatible
computer with color monitor, keyboard, and printers.
a. Computer shall be connected to the integrated control and safety system (ICSS).
b. Base station shall provide real-time displays, log reports of export tanker loadings, alarm,
and diagnostic facilities including remote calibration checks of load cells.
c. Base station shall be connected to an uninterruptible power supply to prevent short-term
power outages from affecting the monitoring system.
6. Portable units shall meet the following requirements:
a. Be enclosed in lightweight carrying cases designed for use in a marine salt spray
environment, NEMA 4X or IP 66 and corrosion resistant.
b. Be powered by batteries and be capable of connection into an external 110/250 VAC
power supply.
c. Incorporate a digital display of parameters being monitored, and audible and visible
alarms.
d. [Optional] Have emergency shutdown (ESD) capability of the loading system via the
connection to the ICSS.
e. Radio range shall allow portable unit operation of up to 1.25 miles (2 km) from the buoy.
7. Parameters shall have access-protected, user-adjustable alarm set points to allow for
modification by operators in the field. Alarm set point information shall be stored in a
non-volatile memory to ensure this information is not lost during a system or power failure.
8. Alarms shall be supplied for the following:
a. Visible—Battery charger/power voltage malfunction.
b. Visible—Radio link malfunction.
c. Audible/Visible—High hawser load warning and maximum hawser load alarm (2-stage).
9. Parameters from the buoy to be monitored at the base station and portable units shall include
the following:
a. Hawser load tension.
b. Maximum hawser load tension previous 10 minutes.
c. Internal piping pressure.
d. Buoy valve status (open/closed).
e. Valve operation accumulator status.
f. Buoy battery voltage.
g. Portable unit transmission status.
h. Surge system activation/tank status (optional).
10. The following telemetry system operations shall be performed remotely from base station:
a. Remote activation of the buoy foghorn.
b. Operation (open/close) of the buoy hull or PLEM product valves.
11. Telemetry system shall include 20 percent spare I/O capacity.
12. Operations and Maintenance manual specific to the telemetry system shall be provided.

6.9 Safety and Security

1. Supplier shall comply with all aspects of SID-SU-5106, which provides minimum
requirements. Where other parts of the technical requirements are more stringent, those shall
apply.
2. The design of the buoy shall consider the safety of personnel boarding and working on the hull
and rotating structure. Hazards such as foot holes, pinch points, and sharp projections shall be
eliminated.
3. The buoy, access hatches, instrumentation, hawsers, and floating hoses shall be designed to
minimize theft of equipment (e.g., protected/locked buoy equipment, access to valves, access
to panels) and to restrict access of unauthorized personnel.
6.10 Spare Parts

1. Supplier shall provide initial spare parts quantities as detailed below, together with a two-year
spares supply for ancillary and telemetry/instrumentation equipment.
2. Purchaser shall advise Supplier of locations where spares are to be delivered for storage.
3. In addition to the spares in Table 1 below, Supplier shall provide the start-up spares required
for hook-up and commissioning activities.
Table 1: Spare Parts (1 of 2)

Component Spares
Floating hose • One complete floating hose string, including fittings and ancillaries
system (e.g., bolting and gaskets, tanker end gear, valve, Camloc, lifting chains,
lights, and brackets).
• Tanker rail hoses—100% spare
• Tanker tail hoses—100% spare
• First-off-the-buoy hoses—100% spare
• Tanker end gear (butterfly valves, Camloc couplings, and blind flanges)—100%
• Camloc “O” rings—500%
• Lifting chains, shackles, etc.—100%
• Pick-up buoys—200%
• Hose winker lights, battery packs, etc.—200%
• Mainline bolting and gaskets—100%
• Gaskets for buoy/PLEM connection—500%
• Bolting for buoy/PLEM connection—200%
Offloading lines • Terminal end fasteners—100%
• Mid-line fasteners—5% (flexible option)
• Tension relief mechanism spares—one set
• Buoyancy modules—5%
Mooring • Mooring hawsers—200%
assemblies • Chain support buoys—200%
• Buoy shackles, pins, thimbles, links, triangular plate—100%
• Chafing chain—200%
• Hawser floats—100%
• Messenger lines—200%
• Marker buoys—200%

Table 1: Spare Parts (2 of 2)

Component Spares
Buoy body, • Chain stoppers—two complete units
turntable, and • Main bearing seals and splashguards—100%
swivel • Fluid swivel product and bearing seals—100%
• Main bearing bolts—100%
• Expansion joints—100%
• Manway and hatch seals—100%
• Navigational lights—200%
• Lamps—400%
• Batteries—100%
• Solar panels—200%
• Anodes—100%
• Valves—50% (one of each type and size minimum)
Machinery Manufacturer’s recommended spares kit for the following:
• Winch
• Hydraulic power unit
• Telemetry unit
Breakaway A spares list shall be provided. List shall include all seals, bushings and other
coupling (if used) parts subject to wear in service, as well as parts excessively stressed during a
normal parting event. The following initial spares shall be provided:
• Two (2) flushing spools
• Four (4) resetting kits
Special tools Supplier shall furnish special tools required by manufacturer’s recommendations.
7.0 POSITIONING REQUIREMENTS AND INSTALLATION TOLERANCES
7.1 General
1. Installation tolerances shall refer to the maximum distance from the intended design Easting
and Northing grid coordinate.
2. Supplier shall provide a primary and secondary positioning and position measuring system
capable of measuring to the accuracies indicated in Section 7.2.
7.2 Position Tolerance—Deeper Water

1. The position tolerance for anchors, buoys, and mooring line pretension shall be according to
FFS-SU-5212 except as noted in this section. The mooring design and hose/riser design shall
account for the tolerances in buoy position and mooring line tensions.
2. Anchor piles shall be installed within the following installation tolerances:
Horizontal position of the pile center: ± 2.6 feet (2 m) for < 164 feet (50 m) WD or
5 percent of WD
Heading of mooring padeye: ± 5°
Vertical misalignment: ± 5°
Penetration: ± 1 foot (0.3 m)
3. Mooring design loads shall incorporate the loads imposed due to the maximum misalignment
and pad eye heading tolerance.

4. For deepwater (328 feet [100 m]+), the buoy and mooring lines shall be installed within the
following tolerances:
Buoy position: ± 49 feet (15 m) or 5 percent of WD, whichever is less

Mooring line pretension: ± 2.5 percent of pretension
5. Mooring design and hose/riser design shall account for the tolerances in buoy position and
mooring line tensions.
7.3 Position Tolerance—Shallower Water

1. The position tolerance for anchors, buoys, and mooring line pretension shall be according to
FFS-SU-5212 except as noted in this section. The mooring design and hose/riser design shall
account for the tolerances in buoy position and mooring line tensions.
2. Anchor piles shall be installed within the following installation tolerances:
Lateral and radial position of the pile center: ± 9.8 feet (3 m)

Heading of mooring padeye: ± 5°
Vertical misalignment: ± 5°
Pile penetration: ± 1 foot (0.3 m)
3. For shallower water marine terminals (< 328197 feet [< 10060 m] water depth), the
mooring lines shall be installed with a catenary angle tolerance of ± 2.5 degrees. For terminals
in less than 197 feet (60 m) of water, the tolerance shall be ±2.0 degrees.
4. Mooring design loads shall incorporate the loads imposed due to the maximum misalignment
and pad eye heading tolerance.
5. Buoy and mooring lines shall be installed within the following tolerances:
Buoy position: 3.3 feet (1 m) radius of target

Mooring line pretension: ± 2 degrees of design catenary angle
6. Mooring design and hose/riser design shall account for the tolerances in buoy position and
mooring line tensions.
8.0 INSTALLATION
1. Supplier shall provide installation procedures for the buoy, mooring system, and offloading
lines for Purchaser review and comment 90 days prior to start of the installation. The
procedures shall define requirements and tolerances for the following parameters:
a. Pre-installation survey.
b. Anchor point location, positioning, and installation method.
c. Anchor point pre-load.
d. Temporary abandonment configuration/marking.
e. Buoy transportation and positioning.
f. Hook-up sequence.
g. Final tensioning/positioning.
h. Floating/underbuoy hose assembly and installation plan.

i. F(P)SO offloading lines configuration, buoyancy requirements.

j. F(P)SO offloading line pull-in to FPSO.
k. F(P)SO offloading line connection to buoy.
l. F(P)SO hydrotest of offloading lines.
m. Final system tests (hydraulic, telemetry, buoy systems).
n. Commissioning procedure.
o. Post-installation survey and as-built information.
2. Supplier shall provide installation spares and permanent and temporary installation aids.
3. Supplier shall prepare and submit for Purchaser review and acceptance complete installation
drawings showing the make-up of subassemblies and assembly and installation tolerances.
a. Drawings shall be supplemented by detailed installation specifications, procedures, or
special instructions as required to complete the offshore field installation.
b. Procedures shall also detail pre- and post-installation testing of the offloading system.
4. Drawings and detailed procedures shall meet the following requirements:
a. Include the weights and centers of gravity of subassemblies.
b. Show the location and capacity of lifting pad eyes.
c. Show installation aids for the following:
1) Anchor legs.
2) Marine anchors.
3) Floating hose system.
4) Mooring hawsers.
5) Offloading flowlines.
5. Installation equipment shall meet the component requirements, such as allowable bending
radii of hoses, risers, or spiral strand wire ropes.
6. Installation equipment shall comply with standard industry practices for acceptable handling
of mooring components and special handling of sensitive components.
7. A final remote operating vehicle (ROV) inspection of the installed system shall be made to
ensure the following:
a. No damage occurred during handling.
b. All components are in the proper orientation.
c. No kinks exist in the chain or wire.
8. Before installation equipment is demobilized from the field, the final position of the buoy,
mooring line tensions, mooring line angles, and anchor point locations shall be verified to be
as designed and within specified tolerances.
9. Supplier shall submit results of the installed system inspection in a report to Purchaser within
14 days after completion.
10. Supplier shall be responsible for the design and fabrication of installation aids required for
offshore installation of the complete offloading system.

9.0 MATERIALS AND WORKMANSHIP

1. Equipment and material shall be new, sound, proven in its performance, and suitable for use in
the marine environment.
a. Material shall be of proven reliability and quality that meets recognized marine and
offshore standards such as JIS, ASTM, and API, or equivalent.
b. Equipment shall comply with Purchaser-accepted standards and the technical
requirements.
2. Materials shall meet purchase specifications, and shall be free from imperfections of
manufacture and from defects that adversely affect one or more of the following:
a. Service life
b. Operations
c. Appearance
d. Serviceability
3. Temporary bracing, erection aids, scaffolding, testing materials, and tools and equipment used
in the construction, testing, and commissioning shall be furnished by Supplier in serviceable
and adequate form, but need not be new. Instruments shall have current test certificates.
4. Purchaser shall have access to all test reports, certified statements, and certificates required by
the regulatory bodies, classification societies, and Purchaser at all times during construction of
the offloading system components.
5. Components of this system shall be from established Suppliers in the industry so that spare
parts and service shall be readily obtainable during the design life of the system.
6. During transportation, storage, handling, and fabrication and before delivery, Supplier shall
protect material, equipment, and instruments. Equipment shall be stored as appropriate for the
specific type.
7. Supplier shall make repairs of defects in materials such as pipe, plates, or structural shapes
only if they can be repaired effectively to as-new condition, as defined in the appropriate
ASTM, JIS, or API designation and as specifically authorized by Purchaser, the classification
society, and regulatory bodies.
10.0 GENERAL SUPPLIER SCOPE AND RESPONSIBILITIES
10.1 Design
1. Supplier shall comply with the following requirements:
a. The design process shall be fully documented and supported by comprehensive
calculations in which assumptions, results, and conclusions are fully justified.
1) A design report shall be prepared in which data analyses, calculations, and
recommendations are clearly presented.
2) Document control procedures shall ensure the traceability and immediate availability
of documentation, drawings, correspondence, certification, and so on.

b. Supplier and Purchaser shall hold design review meetings to clarify key aspects of the
design.
1) Each design review meeting shall be held as early as possible in each design stage so
that Purchaser comments can be easily incorporated.
2) Design review meetings shall be in addition to regular project meetings.
c. In addition to initial and periodic quality audits, Supplier shall arrange for a verification of
the design process by a qualified independent third party if requested by Purchaser.
d. As part of the overall field layout optimization, exact final location, orientation, and
heading of the offloading terminal and pipeline shall be proposed by Supplier for
Purchaser review and comment.
e. Design drawings shall be supplemented by specifications necessary to convey the intent of
the design. Standard specifications for material and fabrication shall be referenced on the
appropriate drawings.
f. Scale model tests of the offloading system shall be performed to verify the system design,
response, and performance. Model tests shall include the effect on the offloading system
of the FPSO, offloading lines, buoy and mooring, and a Purchaser-agreed representative
export tanker.
g. For the F(P)SO, a detailed design of the offloading system shall be performed.
1) Design shall include offloading lines and their connections at the FPSO, offloading
buoy, buoy mooring system, and Purchaser-agreed representative export tanker.
2) Design shall consider the coupled effect among the various components (including the
FPSO) with flowlines and moorings.
3) Swell and local seas shall be properly accounted for in the fatigue and extreme
dynamic analyses.
h. For the F(P)SO, Supplier shall design the offloading lines for normal operating condition
and damaged offloading line condition.
1) Under normal operating condition, offloading lines are filled with oil or water.
2) Under damaged offloading line condition, one offloading line is filled with water
while the other(s) are filled with oil, or one line is out of service for repair or
maintenance.
3) Supplier may propose a single offloading line option for bonded or un-bonded,
short-segment flexible line technologies that meet the flow rate requirements.
i. An Operations, Maintenance, and Training manual shall be provided 6 months prior to
installation for Purchaser review and comment. Information provided shall include, but
not be limited to, the following:
1) A complete description of the offloading system components.
2) Safety advisories.
3) Terminal operating procedures.
4) A table of scheduled inspection and maintenance intervals.
5) Diagrams, drawings, and detailed procedures for maintenance activities.

6) Change-out procedures for major components (hoses, hawsers, bearings, navigation

aids).
7) In the case of polyester mooring, tension maintenance procedures.
8) In the case of segmented mooring lines, mooring line replacement procedure.
2. Supplier shall provide similar information for incorporation into a field-wide Operations,
Maintenance, and Training manual to be developed by Purchaser.
3. All maintenance activities shall be documented for use in the computerized maintenance
management system.
a. Maintenance and equipment information shall be provided by Supplier 60 days before
installation.
b. Maintenance activities shall be in accordance with the most recent OCIMF requirements
and shall include the following, as a minimum:
1) Hawser change-out.
2) Floating hose change out.
3) Mooring tensioning.
4) Fluid swivel seal and bearing inspection.
5) Fluid swivel seal and bearing replacement.
6) Main bearing lubrication.
7) Main bearing replacement.
8) For F(P)SO, flex-joint or gimbal joint maintenance on OOL.
9) For F(P)SO, offloading flow lines inspection and maintenance.
10) Navigational aids, instrumentation, and telemetry system.
4. Work areas accessible for people to perform normal operations, maintenance, and inspection
tasks shall comply with the relevant Purchaser general specifications on safety and human
factors engineering (HFE) requirements and human factors engineering (HFE) requirements
as specified in SID-SU-5106.
10.1.1 Mooring Design and Analysis

1. Mooring design and analysis shall be according to FFS-SU-5212, FFS-DU-5173, and
FFS-SU-5174.
2. Because the mooring system responses are greatly influenced by the buoy motions,
offloading line responses, and export tanker motions, the mooring analysis shall be
conducted in conjunction with these effects.
a. The analysis shall include the conditions of offloading lines both water filled and
oil filled.
b. For mooring fatigue analysis of paired or clustered lines, the most critical line in
each of the mooring clusters shall be included as a minimum.
3. A coupled analysis approach using an integrated offloading lines/buoy/mooring/
export tanker model shall be used. Supplier shall provide details of the proposed
methodology to Purchaser prior to the design of the mooring system.

4. Mooring system design shall be completed in accordance with the results of the
geotechnical and geophysical data given in the design basis. If these data reveal the
presence of geohazards or obstructions to the mooring system, or both, then Supplier
and Purchaser shall determine the most appropriate solution to the hazard identified.
10.1.2 Model Tests

1. Model testing shall be done as specified in FFS-DU-5173 and FFS-DU-5247. Supplier
shall submit for Purchaser review and comment a model scale and a detailed test
program that conform to the requirements of the codes and standards identified in
Section 2.0.
2. The scope of the model tests shall provide sufficient detail to ensure the systems
integrity in all situations, including the following:
a. Spread mooring system—demonstrate the performance of the mooring system,
under the specified environmental conditions, and in consideration of the
connection to the offloading lines and the export tanker.
b. Buoy motions—verify buoy motions used for detailed response, structure, and
fatigue analyses. Proper hull form and freeboard dimensions shall be modeled to
ensure accurate wave hydrodynamic loading.
c. Offloading line responses—model the offloading lines together with the anchor
legs.
1) The offloading lines shall be sized to reflect proper hydrodynamic loading
considering scale effects, and shall be constructed of material to ensure proper
stiffness and dynamic behavior.
2) The responses at the most critical offloading line attachment shall be
measured to verify loads used for offloading line design.
3. Supplier shall determine what loading conditions will be tested based on the
following:
a. Extreme and fatigue analyses that resulted in the maximum and/or critical motions
on the buoy.
b. Maximum and/or critical loads for the mooring system.
c. Maximum and/or critical loads for the offloading lines.
4. After completion of the model test program, the buoy model shall be retained for a
period of five years. Purchaser shall decide whether retention for a further period is
necessary.
10.2 Interface Management

1. Supplier shall implement and maintain an interface management system for all interfaces
related to Supplier’s scope of work.
2. Supplier shall clearly identify an internal interface coordinator for Supplier’s work scope.
3. The objective of interface management shall be to ensure that Supplier and its Sub-Suppliers
have a clearly defined process that identifies all the interfaces.
4. Interfaces shall have technical equivalence and compatibility at all interface locations and
shall meet Purchaser technical requirements.

10.3 Fabrication and Manufacturing

1. Materials and equipment shall be new and unused.
2. Material specifications, procured materials, manufacturing, equipment, fabrication and
construction, systems, assembling, and testing procedures shall be in strict accordance with
the codes, standards, and Purchaser requirements referenced in Section 2.0.
3. Preparation and procurement of manufactured items shall include the following:
a. Preparation of specifications.
b. Purchase orders.
c. Agreements.
d. Quality control/plant inspection.
e. Expediting.
f. Material/equipment documentation.
4. Project-specific specifications, quality control procedures, and material control procedures
shall be submitted to Purchaser for review and comment prior to issuing purchase orders or
agreements for materials or equipment.
10.4 Testing and Quality Assurance

1. Tests shall be carried out in accordance with authorized inspection and testing plans (ITP).
a. Inspection and quality assurance plans shall include all tests required by the classification
society, regulatory bodies, governing codes, and the technical requirements.
b. Supplier shall demonstrate that the quality assurance plan conforms to its ISO series
procedures.
2. Supplier shall be responsible for inspection and testing of equipment. Any involvement by
Purchaser and regulatory bodies shall neither relieve Supplier of complying with any and all
expressed specifications, nor affect Supplier’s warranty providing for satisfactory performance
under conditions of service.
3. At each stage, sufficient notice shall be provided to allow Purchaser representative to attend
the test.
4. After fabrication work is complete and before offloading system components are deployed for
installation, equipment and systems shall be tested as far as is practical to prove the following:
a. Equipment
b. Materials
c. System
d. Instruments
e. Piping
5. Official, signed test records shall be provided to Purchaser in a bound booklet systematically
indexed and arranged.

6. The following list, without limitations, shall define the minimum testing requirements:
a. Prior to blasting and coating, buoy hull compartments shall be leak-tested and structurally
strength-tested in accordance with the requirements of the classification society.
b. Plate thickness shall be re-checked for verification and conformance to the required
standards at a minimum of eight spots for each plate, at the following locations:
1) Chain hawse/stoppers structural support area.
2) Each compartment.
c. The chain hawse assemblies shall be trial-fitted with a chain sample of at least three links.
The chain stoppers shall be tested to determine their fit and operational function by fitting
a chain sample.
d. Bearing lubrication lines and fittings shall be verified clean and tight. Protection of
lubricating pipes against impacts shall be carefully inspected.
e. Winches and other lifting equipment located on the buoy shall be load tested to
125 percent of design capacity (safe working load [SWL]). A load cell or tension meter
shall be used to measure the applied loads.
f. Offloading system equipment, including all valves, shall be functionally tested in
accordance with manufacturer’s recommended procedures.
g. Product piping shall be hydrostatically tested to 1.25 times rated pressure prior to
assembly.
h. Prior to shipping the completed buoy, the entire piping system shall be leak tested in
accordance with ABS Rules for Building and Classing Single Point Moorings or
equivalent upon final assembly of the following:
1) Buoy hull and rotating turntable assembly.
2) Piping system and product swivel.
i. The completed buoy assembly shall be placed in the water at the fabrication site.
1) Final horizontal trimming shall be carried out using the trim ballast spaces.
2) Draft, inclination, final ballast composition, and final center of gravity shall be
recorded in a ballast protocol before and after trimming.
3) If the final displacement calculated from the final draft varies from the design
displacement by more than 5 percent, the final vertical center of gravity shall be
measured.
j. The following shall be tested at the fabrication site to determine operational function and
acceptance:
1) Navigation aids
2) Ancillary equipment
3) Hydraulic power unit
4) Telemetry monitoring and control system
5) Instrumentation
k. Where feasible, umbilical connections shall be trial fitted before buoy launch.

10.5 Equipment Delivery

1. Supplier shall be responsible for all components and materials until final acceptance of the
installation at site.
a. Supplier shall procure materials, equipment, and services required to execute the work.
b. System components shall be protected and maintained until final delivery.
c. A method of material control and material control reports shall be developed to coordinate
procurement, packing, preservation, expediting, transportation, and receiving of materials
and manufactured items that shall be incorporated in the offloading system.
d. Supplier shall ensure that all of its Sub-Suppliers and manufacturers are in compliance
with these requirements.
2. Material control report for stock material and manufactured items shall include copies of all
Supplier purchase orders, along with scheduled delivery dates and specifications of purchased
material or components.
3. Material control report shall include delivery schedules for materials and components and
shall be correlated to Supplier’s fabrication schedule to indicate the impact of material
deliveries on fabrication and installation.
4. Material control report for subassemblies and ancillaries shall include a detailed description of
each subassembly and ancillary, and a schedule showing dates for loadout and delivery to the
final destination. The name and type of carrier shall also be included.
10.6 Loadout and Seafastening

1. Supplier shall be responsible for the following:
a. Moving the buoy from the fabrication site.
b. Preparing the buoy for towing/transportation to the installation site, including any required
ballasting and towing bridle.
c. Maintaining the prepared buoy in the water for handover and access by the towing vessel.
d. Any lifting, loadout, and seafastening of the buoy and other components onboard the
marine barges or vessels.
2. Seafastening design shall be approved by a 3rd-party marine warranty surveyor acceptable to
the transport insurance carrier. Acceptance may be required from Owner Marine department
for critical transport items.
3. The fabrication and seafastening works shall be witnessed and approved by the 3rd-party
warranty surveyor.
11.0 MID-WATER OFFLOADING LINES

1. The mid-water offloading lines may use steel pipe or flexible bonded conduit technologies.
2. The proposed technology shall be thoroughly analyzed with regards to the following:
a. Technical merit
b. Life expectancy
c. Operational and installation risk

d. Serviceability
e. Life cycle cost
11.1 Offloading Line Design and Analysis

1. The offloading line design and analysis methodology shall be developed in conjunction with
the mooring system design and analysis.
a. Detailed design and analysis of offloading lines shall also include specific supports at each
termination, piping spools, and installation equipment and aids specific to the export lines.
b. Steel lines up to 20-inch (508-mm) diameter may be considered.
c. Flexible lines of larger diameters meeting fatigue requirements may be considered.
2. Flexible offloading lines shall be designed in accordance with the following codes:
a. API Spec 17J
b. API RP 17B
3. Steel offloading lines shall be designed in accordance with the following codes:
a. API RP 1111
b. ASME B31.4
c. DNV OS F101
d. API RP 2RD
e. DNV OS F201 as alternative to item d above
f. API Spec 5L
4. Supplier shall provide an analytical report of the offloading lines. The report shall summarize
the following:
a. Methodology
b. Programs used
c. Program features used
d. Program limitations
e. Specification followed
f. Input data
g. Load cases analyzed
h. Results for minimum and maximum line tensions
i. Fatigue life
j. Vortex-induced vibration (VIV) fatigue
k. Flex joint angles
l. Plan
m. Elevation drawings of the offloading lines

11.2 Options
Acceptable options for offloading lines shall be as shown in Table 2. The provider shall supply
documentation requested by Purchaser for review and acceptance.
Table 2: Options for Offloading Lines

Option Description
Flexible • Field-proven bonded flexible products designed to API Spec 17K, in segmented or
continuous sections.
• Supplier and specific design of the flexible flowline product shall be formally
pre-qualified in Owner’s technical qualification process (TQP).
Steel Pipe • Steel offloading lines shall be designed to a specified minimum yield stress (SMYS) of
60,000 psi (413 Mpa), equivalent to a steel grade of API 5L-X60.
• Line pipe and welding and nondestructive testing (NDT) shall comply with Purchaser
requirements in Section 4.0.
• Flex joints shall comply with Purchaser requirements for flexible joints.
11.3 Flexible Offloading Lines
11.3.1 Design
1. Detailed design of the flexible oil offloading lines system shall be performed.
2. The design shall include and consider the following:
a. Hydraulic analysis
b. Static analysis
c. Dynamic analysis
d. Interference analysis
e. Corrosion assessment
f. Installation analysis
g. Fatigue analysis
h. Engineering critical assessment (ECA)
11.3.2 Construction
1. Fully bonded flexible lines shall be constructed of elastomer and reinforcing layers.
Layers of reinforcing may be of textile or wire and may include heavier spiral or ring
reinforcement for hoop strength.
2. End flanges may be of nipple or nippleless design.
a. Flanges shall be fully tested in fatigue and for separation from the hose carcass.
b. The flange gasket and bolting design shall be proven for fatigue in tension and
bending to provide a service life compatible with the design life of the offloading
system.
c. Surfaces shall be coated and protected from corrosion.
d. Bolting shall be sealed from seawater when installed.

11.3.3 Pressure Rating

Flexible lines shall be rated to 25 bar differential internal operating pressure and rated to
10 bar differential external pressure without collapse at the full range of operating
temperature and conditions.
11.3.4 Configuration
1. The midwater shape of the offloading line(s) shall be in a single or double “W” design
to minimize the loads on the FPSO and buoy connections.
2. Offloading line shall be designed to be stable when filled with the full range of
product-specific gravities, seawater, or combination thereof.
3. Buoyancy modules connected to the offloading lines to maintain this shape shall be
connected by means that will remain for the service life of the installation.
4. Offloading lines shall be required to remain at a depth well below the draft of any
vessels foreseen in the field.
11.3.5 Offloading Line Terminal End Connections

1. The terminal connection arrangement to the FPSO and buoy shall include a means to
relieve the tension from the offloading line connection flange.
2. The arrangement shall be designed for the service life of the installation.
3. The arrangement shall be replaceable in its parts in the event of damage or wear and
shall be inspectable by divers or ROV at the critical locations of wear and connection.
4. Means to replace components shall be included in the design and supply.
11.4 Steel Offloading Lines
11.4.1 Design
1. Detailed design of the steel pipe oil offloading lines system shall be performed.
2. The design shall include the following:
a. Hydraulic analysis
b. Static analysis
c. Dynamic analysis
d. Interference analysis
e. Corrosion assessment
f. Wall Thickness calculation (steel)
g. Installation analysis
h. Fatigue analysis
i. ECA
3. Detailed design shall also include design of the offloading line supports at each
termination, piping spools, and installation equipment and aids specific to the
export lines.

4. With regards to line integrity and the interfacing requirements (such as surface layout,
vessel structure, and mooring system), the design shall define the optimized
combination of the following:
a. Length
b. Wall thickness
c. Top angle
d. Buoyancy requirements
e. Other key parameters.
5. The FPSO and buoy on which the offloading lines are supported shall be subject to
excursions caused by environmental loads and influenced by the mooring system and
export tankers.
a. Horizontal movement of the FPSO and buoy causes changes in the line catenary
configuration, and the analyses shall consider these excursions in the direction
and magnitude for the different environmental loading conditions.
b. Therefore, the FPSO and buoy excursions shall be incorporated in the static,
dynamic, and fatigue offloading lines analyses.
6. The proper added mass and drag coefficients shall be used to account for the existence
of buoyancy modules and VIV suppression device.
7. The design shall assess, by sensitivity analysis, the influence of key parameters and
assumptions such as the following:
a. Natural frequencies
b. Wave period
c. Fluid density
d. Top angle
e. Soil stiffness
f. Hydrodynamic coefficients
g. Element size
h. Spectrum
i. Directionality
j. Hang-off location
k. Units offset
l. Draft
8. The sensitivity analysis shall evaluate and define the top angle installation tolerance,
which shall be practical and achievable during offshore installation operations.
9. Pipe in the corroded condition shall also be considered.

11.4.2 Hydraulic Analysis

1. Hydraulic throughput analyses shall be performed to determine the optimum sizes and
configuration for the mid-water offloading lines between the FPSO and the buoy and
floating hoses.
2. Analyses shall include all system pressure losses including frictional losses through
the buoy.
3. The design flow rate of the system shall be as defined in the design basis.
4. The minimum delivery pressure to the export tanker manifold shall be one (1) barg.
5. Transient surge analyses shall be performed to identify the performance requirements
for a pressure relief system to be located downstream of the export pumps and lease
acquisition custody transfer (LACT) unit onboard the FPSO. Supplier shall interface
with FEC for this analysis.
6. Surge relief system equipment located on the FPSO shall be part of FEC scope of
supply.
11.4.3 Wall Thickness and Internal and External Pressure

1. Offloading line wall thickness shall be determined in accordance with ASME B31.4.
2. The minimum wall thickness for flow lines shall be calculated based on the following:
a. Design pressure (to be determined and confirmed by hydraulic analysis)
b. Hydrostatic test pressure
c. Pipe diameter
d. Material grade
e. Corrosion and erosion allowance
f. Water depth
3. Wall thickness shall be defined by the following:
a. Code formulae
b. Allowable pipe stresses
c. Resistance to buckle propagation
d. Pipe collapse
4. A buckle analysis shall be performed to determine the wall thickness of the flowline
required to resist collapse.
a. The analysis shall determine the collapse and buckle propagation pressures in
accordance with DNV-OS-F101.
b. If collapse is the adopted criteria, Supplier shall apply buckle arrestor with
maximum spacing of 984 feet (300 m).
5. The buckle analysis shall consider the following key parameters:
a. Dimensional tolerances
b. Diameter
c. Wall thickness

d. Line pipe ovality

e. Residual ovality after installation
f. Material grade and yield strength
g. Reduction in hoop compressive yield stress (caused by the manufacturing
process)
h. Maximum expected dynamic bending strain during installation and operation
6. The wall thickness design shall also take into account the dynamic stresses along the
entire structure length that occur during installation, normal operation, extreme, and
accidental conditions.
11.4.4 Static Analysis

1. Static analyses shall be performed to cover installation, hydrostatic tests, and
operational load cases in the mean, far, and near positions. Maximum stresses shall be
within the allowable stresses defined by ASME B31.4 and API RP 2RD.
2. Static analysis shall be performed using Purchaser-accepted software that is widely
accepted by the industry.
3. The offloading lines configuration shall be confirmed by means of the static analysis,
which shall demonstrate it has resulting reaction loads and curvatures under
acceptable ranges for all the envelope conditions of vessel excursions and internal
filling fluids.
4. The selection of the configuration shall include definition of the position for the
offloading lines hog, which shall be kept away from the wave zone to avoid potential
fatigue problems.
11.4.5 Dynamic Analysis

1. Dynamic analyses (extreme cases) shall be performed for the 10 year Operating Storm
with shuttle tanker present, and the 100 year Extreme Storm without shuttle present in
the mean, far, and near positions.
2. Dynamic analysis shall be performed for all cases of buoyancy with lines full of water
or product(s). In dual line cases this shall include all combinations.
3. The dynamic analysis shall be performed using Purchaser-accepted software that is
widely accepted by the industry.
4. Modal analysis of the system shall be performed to identify natural periods, risks for
resonance, and other associated aspects.
5. Dynamic responses of the offloading lines shall be obtained as part of a coupled
analysis in which the interaction between these lines, the buoy, and its mooring is
taken into account.
6. Hydrodynamic force calculations shall be performed for all segments of the offloading
line including the segments with strakes where VIV exists.
a. The overall diameter of the strakes and Morison’s equations shall be used for drag
calculations.
b. The drag coefficient shall be adjusted to account for VIV effects.

7. The simulation time for the dynamic analysis shall be long enough to capture at least
the low frequency (LF) effect and maximum stress values, and to provide enough data
for statistical result calculations.
8. Supplier shall extract all relevant results, including motions envelopes, top connection
angles, stress distribution, and vessels loads, in order to confirm the offloading lines
configuration.
11.4.6 Installation Analysis

1. Static and dynamic installation analyses shall be performed for all phases of
installation to confirm the feasibility of offloading lines installation and to provide
input parameters for wall thickness design.
2. The fatigue damage induced in the offloading lines during installation shall be
determined.
3. Special events such as buoyancy module installation and removal, first end, and
second end transfer operations for the offloading lines installation shall be addressed.
4. Installation analyses shall be performed using the actual stinger configuration, ramp
angle, and RAOs of the proposed installation vessel.
5. The analyses shall be performed using Purchaser-accepted software that is widely
accepted by the industry.
6. The analyses shall take into consideration the installation vessel offset envelope
during lay, consistent with the expected environmental loading and dynamic
positioning capability. A limiting environmental loading associated with a maximum
offset shall be established.
7. The effect of plastic strains that may be imposed on the offloading lines, from reeled
installation or from the stinger over bend during S-lay, shall be evaluated and
considered in the analysis.
8. The installation analysis shall define limiting environmental conditions and the
allowable operations envelope during installation and transfer operations, so the pipe
is not overstressed and to maintain the loads within the installation vessel’s dynamic
positioning capabilities.
9. The installation analysis and procedure shall define the maximum depth (external
pressure) that the offloading lines will be subjected to in the empty condition (if that is
the case). The result shall verify wall thickness.
11.4.7 Fatigue Analysis

1. The design of the offloading lines shall use a safety factor of 10 for the fatigue life,
including operating and installation phases.
2. The fatigue analysis shall address damage associated with first and second order
vessel motions and VIV, including possibly the buoy heave motion-induced VIV.
3. The offloading lines configuration and their dimensions and relevant material
properties shall be clearly defined.
4. Dynamic responses of the offloading lines shall be obtained as part of a coupled
analysis in which the interaction between these lines and the buoy and its mooring is
taken into account.

5. Flex joint stiffness and extension length are key parameters and shall be defined in
order to optimize the offloading lines fatigue life. Flex joint stiffness characteristics
and behavior shall be accurately represented in the analysis simulations.
6. The calculation of fatigue damage shall adopt a target fatigue S-N curve for welds and
base material, compatible to the adopted material, installation, and fabrication
standards.
a. The fatigue analysis for welds shall be based on ISO/DOE S-N curves with a
3:1 slope.
b. The 97.5-percent survivability limit based on the test data shall exceed the target
S-N curve.
7. The fabrication welding procedures shall be qualified at least three standard
deviations better than the S-N curve selected.
a. Supplier may consider qualifying welds to an S-N curve with a slope greater than
3:1. Qualifying the welds to that criterion requires more tests to achieve a level of
confidence comparable to that implied in the slope of 3:1 assumption.
b. The data shall include additional tests to failure or 3 standard deviations better
than the target S-N curve, in the ~108 cycle region.
1) Purchaser shall authorize the actual number of tests.
2) Purchaser shall review and accept the use of this alternative approach prior to
implementing and testing.
8. Supplier shall conservatively assume that the target S-N curve has a single slope and
that there is no threshold stress level below which fatigue damage does not occur
(endurance limit). Fatigue damage may therefore occur for all conditions investigated.
9. Summation of total fatigue damage shall be by Miner’s Rule.
10. Appropriate stress concentration factor (SCF) shall be adopted and the SCF values
shall represent the material and geometrical offloading line features, adopted
fabrication, and installation standards and procedures.
11. VIV shall be performed using Purchaser-accepted software that is widely accepted by
the industry. The natural frequencies and the corresponding mode shapes shall be
calculated using industry standard program.
12. The buoy heave induced effect shall also be considered and included in the fatigue
damage summation.
11.4.7.1 Fatigue Testing

1. The primary objective of fatigue testing is to confirm that the girth welds can achieve
the required fatigue performance for the following:
a. Actual pipe size and material
b. Welding process
c. Inspection method
d. Defect acceptance criteria
2. Supplier shall describe the proposed plan to ensure that the oil offloading line design
is fatigue tested and pre-qualified prior to construction.

3. An ECA fracture mechanics-based analysis shall be adopted and the following five
areas shall be interactively assessed:
a. Design—pipe material, the adopted design methodology, target SN curves and
SCFs, as well as the resulting stress histograms.
b. Fabrication—pipe specification, pipe end preparation, pipe alignment criteria and
procedure, welding method and procedure, and automated ultrasonic testing
(AUT) system.
c. Installation—fatigue damage during installation.
d. Flaw acceptance criteria—derived from the assessment of the above items and
based on fracture mechanics, using the prototype testing results and AUT system
inspection accuracy and probability of detection.
e. Testing—fabricate and inspect specimens to accepted specifications and fatigue
test to confirm performance.
11.4.7.2 Basic Requirements for the Fatigue Test Method Qualification

1. At least nine weld girths shall be tested and manufactured in a manner that replicates
the procedure that Supplier proposes to employ during production.
2. Specimens shall be tested in as-welded condition.
3. Relevant geometrical parameters of the pipes and welds shall be measured, such as
longitudinal misalignment, initial and residual out-of-roundness, and thickness
variations.
4. The following shall be part of the basic requirements for the test method qualification:
a. Fatigue testing of full scale joints and corresponding girth welds.
b. Fatigue and fracture assessment, AUT accuracy, and probability of detection in
the derivation of a flaw acceptance criteria.
11.4.8 Layout and Interference Analysis

1. Supplier shall evaluate deflections envelopes and patterns in order to assess the
potential for interference (clearance and clashing) during installation and in-place
condition, between lines and other components of the system.
2. Interference analysis shall be carried out for Normal Operating Condition and
Damaged Offloading Line Condition, as defined in Section 5.3.
a. Interference shall not be allowed under Normal Operating Condition.
b. Under Damaged Offloading Line Condition, Supplier shall design, supply, and
install a fully developed mitigation system that completely addresses interference
between offloading lines and other components of the system.

11.4.9 Engineering Critical Assessment

1. An ECA shall be used for weld flaw acceptance of the oil offloading lines girth welds.
This ECA shall be developed according to Section 3, “Assessment for Fatigue” in
BSI BS 7910.
a. AUT inspection criteria shall be significantly reduced from the critical size
obtained from the ECA, and shall include the maximum undersizing accuracy
error obtained from an AUT system qualification test.
b. Supplier shall provide a characterization of the proposed AUT system that is
quantified in terms of probabilities of detection.
c. Supplier shall maintain inspection reliability with a systematic audit of hardware
setup, signal processing, and operator interpretation. Only operators experienced
with inspection criteria for fatigue-sensitive girth welds shall be used to interpret
AUT data.
2. Welds shall be put into service in the as-welded condition. That is, the completed weld
shall not be conditioned by grinding or machining of the root area or the outside weld
reinforcement.
11.4.10 Special Requirements for Installation Methods that Plastically Deform

the Pipe
1. Where Supplier installation plan uses the reeled method (or other method that infers
plastic deformation to the pipe), Supplier shall ensure the proposed plan and the
offloading line design are prototype-tested and prequalified prior to construction.
2. Supplier’s installation plan shall specifically address the capability of the welded joint
in the plastically strained condition to accommodate the in-service fatigue loading
spectrum to ensure structural integrity and reliability of service of the proposed
offloading lines design.
3. A fracture mechanics-based analysis shall be adopted and the following four areas
shall be interactively assessed:
a. Design—the adopted design methodology, S-N curves and stresses magnification
factors, as well as the resulting stress histograms.
b. Fabrication—pipe specification, pipe end preparation, pipe alignment criteria and
procedure, welding method and procedure, and AUT technique.
c. Installation—bending, unbending, and straightening processes as applied in the
proposed vessel and the consequent induced bending-curvature histories to the
pipe, into the plastic range of the material.
d. Flaw acceptance criteria—derived from the assessment of the three above items
and based on Fracture Mechanics, using the prototype testing results.

11.4.11 Fatigue Qualification Requirements for Installation Methods that Plastically

Deform the Pipe
11.4.11.1 Testing Program

At least nine weld girths shall be tested and manufactured in a manner that replicates the
procedure that Supplier proposes to employ during production.
1. Specimens shall be tested in both as-welded condition and after being plastically
deformed in the bending simulator. The influence of bending and straightening
processes on the material, geometrical properties of the pipes, and girth welds shall be
assessed.
2. Relevant geometrical parameters of the pipes and welds such as longitudinal
misalignment, initial and residual out-of-roundness, and thickness variations shall be
measured.
3. The following shall be part of the basic requirements for the test program:
a. Fatigue testing of full scale plastically strained prototype joints and corresponding
girth welds.
b. Fatigue and fracture assessment, AUT accuracy, and probability of detection in
the derivation of a flaw acceptance criteria.
c. Fabrication and inspection of specimens to accepted specifications, and fatigue
testing to confirm performance.
11.4.11.2 Certification
The selected classification society shall certify the activities in Table 3 for the offloading
lines.
Table 3: Certification Requirements (1 of 2)

Activity Description
Prototype Testing The prototype testing program shall be reviewed and followed and the
Program assumptions and results of the laboratory testing program, combined with
fracture mechanics analyses, shall be certified to be as follows:
• Acceptable to ensure structural integrity and endurance throughout
offloading line design life.
• Compatible with the design and representative of the actual conditions
employed during the fabrication and installation.
Design Design certification shall consist of a review (to be performed by the
classification society) of documentation of the offloading line system
design, addressing effects of the installation process and relevance to the
other interfacing areas.
Fabrication The following key issues shall be observed:
• Alignment and welding criteria and procedures
• Welding and NDE qualification program (procedures and personnel)
• Geometric tolerances and SCFs
• Overmatching of the welds
• Consistent yield strength
• Weld defects size, ECA
• Inspection technique (capability and accuracy)
• Influence of ovalization

Table 3: Certification Requirements (2 of 2)

Activity Description
Installation Review of the reeling procedure shall at minimum confirm the correct
implementation of the reeling parameters obtained in the design phase,
including the reeling tension, the straightener settings, and the reeling
system geometric configuration. The following key issues shall be
observed:
• Reeling procedure
• Straightening trial procedure
• Pipelay procedure
11.4.12 Corrosion
11.4.12.1 Internal Corrosion

1. Supplier shall consider, based on fluid characteristics and flow regime for the entire
project life, internal corrosion of the following:
a. Offloading lines
b. Offloading line end fitting
c. Valves
d. Connectors
e. Other components exposed to the transported fluids
2. A comprehensive analysis shall be prepared by Supplier for Purchaser review and
comment, with conclusive definitions about the selection of a system or a measure to
mitigate short- and long-term internal corrosion.
a. This evaluation shall be carried out prior to line detail design phase, in which the
flexible pipe or steel pipe lining coatings and allowances are specified.
b. The accepted technical effective solution shall be the most convenient and cost
effective for Purchaser, in terms of project implementation and system operation.
c. The problem and solution shall encompass all pipeline components internally
exposed to the fluid regimes, such as valves, end-fitting, connectors, seals, and
terminations.
11.4.12.2 External Corrosion

1. Offloading lines shall be protected externally by a three-layer anti-corrosion coating
system.
a. Coating specifications shall be provided to Purchaser for review and comment.
b. The coating shall be in accordance with DNV RP F106.
2. The offloading line field joints shall be protected externally by an anti-corrosion
coating system.
a. Field joint coating specifications shall be provided to Purchaser for review and
comment.
b. The field joint shall comprise either three-layer polyethylene/polypropylene,
fusion bonded epoxy, or liquid epoxy field joint coating.

c. A heat shrink sleeve (HSS) field joint solution may be proposed subject to
Purchaser review and comment and independent verification agency (IVA)
approval.
1) Any HSS application procedure shall address qualification of personnel to
apply sleeves and to qualify the procedure under similar conditions in the
field.
2) The supply and inspection of pipeline field joint coatings shall be in
accordance with the requirements and provisions of DNV RP F102.
3. Particular attention in design shall be given to the corrosion protection system or
method used to protect the oil offloading line sections inside the I-tubes/moon pools at
the FPSO.
11.4.12.3 Cathodic Protection

1. The offloading lines shall include sacrificial anodes to provide CP. The anode design
shall be based on the requirements of DNV RP B401.
2. Supplier shall determine the anode spacing during detailed design. Anodes shall be
sized for the design life of the offloading lines.
3. The method by which the anodes are attached to the lines requires special attention,
and shall be designed to withstand installation and operational in-place conditions.
4. The supply and inspection of pipeline anodes shall be in accordance with the
requirements and provisions of NACE SP0387 and DNV RP B401.
5. Electrochemical testing shall be performed in accordance with DNV RP B401 or
NACE TM0190. Chemical analysis shall be carried out in accordance with
ASTM E34 and ASTM A227, or Purchaser-reviewed and -commented upon
equivalent.
6. All materials comprising the anodes shall be new and of current manufacture.
a. Material shall be of the highest grade, and shall be free of defects and
imperfections that may hamper performance.
b. Materials for sacrificial anode systems shall be confined to
aluminum-zinc-indium alloys.
c. Sacrificial anodes containing mercury as an alloying element shall not be
permitted.
d. Supplier shall submit for Purchaser review and IVA acceptance sacrificial anode
selection and chemical composition.
11.4.12.4 Electrical Insulation

The offloading lines shall be electrically insulated from the F(P)SO and buoy in order to
isolate their CP systems from the offloading protection system.

11.4.13 Offloading Lines Ancillary Devices and Equipment
11.4.13.1 Strakes
1. Helical strakes may be installed on the offloading lines to inhibit VIV.
Note VIV has the potential to cause fatigue damage and the application of helical
strakes eliminates or reduces this potential damage.
2. The strakes shall be carefully designed to address the following considerations in
addition to VIV criteria:
a. Transportation
b. Installation (attachment to the offloading lines)
c. Installation of the offloading lines
d. Maintenance
11.4.13.2 Anti-Fouling Protection

1. Oil offloading lines shall have anti-fouling protection to prevent marine growth in the
region where marine growth can occur.
2. Marine growth shall be considered in the analysis and design of all offloading system
components, per Section 11.4.9 above.
11.4.13.3 Pull-In Systems

1. Supplier shall design, fabricate and install the FPSO supporting structure and Hull
reinforcements at the offloading line pull-in and attach points. Design and loads are to
be finalized during detailed design by Supplier.
2. A pull-in system shall also be mounted on the buoy structure by Supplier to allow for
the transfer and final coupling of offloading lines.
3. The pull-in systems shall be designed to pull in the offloading lines in the event they
become flooded with seawater. Connections of the pull-in systems shall be designed
for loads in excess of the minimum line breaking strength.
11.4.13.4 Support Structures

The support structures, which serve as the attachment points to the FPSO and the buoy,
shall be designed to support the dynamic and fatigue loads of offloading lines over their
design life.
11.4.13.5 Buoyancy Modules

1. Buoyancy modules, if used, shall be applied to the offloading lines over sections of
their mid-length so that they support the offloading line designed configuration under
operational conditions.
a. The modules shall offer sufficient buoyancy to ensure the configuration and
durability over the design life of the offloading lines.
b. To avoid slippage or detachment, the modules shall be keyed to the offloading
lines during all operational conditions, so that the designed offloading line
configuration is not altered.

2. The design of modules and the definition of their spacing shall cover the potential for
deleterious effects of localized buoyancy forces.
11.4.13.6 Buckle Arrestors, J-Lay Collars, Pipeline Fittings, and Forgings

1. In the event J-lay collars or buckle arrestors, or both, are employed as part of the oil
offloading lines, they shall be made of forged carbon steel and girth-welded to the line
pipes at the required regular distance along the lines.
a. A specification of the forged materials shall be submitted to Purchaser for review
and comment.
b. Forgings and fittings shall, as a minimum, conform to the following requirements
of MSS SP-75:
1) Design
2) Dimensions
3) Materials
4) Manufacturing
5) Testing
6) Inspection
7) Nondestructive examination (NDE)
8) Marking
2. For all forgings and fittings, the manufacturer shall furnish certified material test
reports that contain all information specified by MSS SP-75, as well as the results of
any additional tests and inspection.
3. Forgings and fittings shall be ultrasonically examined over 100 percent of the surface
area within 5.90 inches (150 mm) from the welding end.
a. A 100-percent volumetric coverage ultrasonic inspection shall be required for all
forgings and fittings.
b. The ultrasonic inspection shall be per Article 5 of ASME BPVC, Section V.
4. For each material grade used, welding spools made of the same material as the forging
and fittings shall be provided for use in establishing and qualifying field welding
procedures.
5. Supplier shall assess the structural integrity of the J-lay collar under various
installation and operating conditions for all relevant cases of static and dynamic
loading.
6. The structural configuration shall be derived based on the offloading line diameter and
wall thickness, as well as the requirement for the collar to have sufficient length to
allow the use of welding and NDT systems for field joint fabrication.
7. In addition, the collar/buckle arrestor configuration shall provide a reduced stress
intensification factor and this factor shall be considered in the fatigue analysis.

11.4.14 Hydrotest and Pre-Commissioning

1. Hydrostatic pressure testing and design of pigs shall comply with Purchaser
requirements for pigging, hydrostatic pressure testing, and pre-commissioning.
2. Alternative design shall be submitted for Purchaser acceptance.
3. Visual inspection of oil offloading lines prior to line filling shall not be required.
11.4.15 Contingency and Maintenance

1. Significant damage to the offloading lines (pipe or flex joint) may entail the
replacement of the entire line or sections of a flexible line.
2. Supplier shall design methods for the removal and replacement of a damaged line or
section.
3. Documented procedures for removal and replacement shall be supplied to Purchaser
as part of the Operations and Maintenance documentation program.

APPENDIX A
ADDITIONAL REFERENCES
The following references are not cited in this specification but are listed here for further reference.
American Institute of Steel Construction (AISC)
AISC-SCM Steel Construction Manual
RP 2SK Design and Analysis of Stationkeeping Systems for Floating Structures
RP 2SM Recommended Practice for Design, Manufacture, Installation, and
Maintenance of Synthetic Fiber Ropes for Offshore Mooring
Spec 6D Specification for Pipeline Valves
Spec 6FA Specification for Fire Test for Valves
RP 14C Recommended Practice for Analysis, Design, Installation, and Testing of
Basic Surface Safety Systems for Offshore Production Platforms
RP 14E Recommended Practice for Design and Installation of Offshore Production
Platform Piping Systems
Spec 17E Specification for Subsea Umbilicals
Std 520 Sizing, Selection, and Installation of Pressure-Relieving Devices in
Refineries
Std 521 Pressure-relieving and Depressuring Systems
Std 607 Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic
Seats
B31.3 Process Piping
Boiler and Pressure Vessel Code (BPVC)
Section VIII, Rules for Construction of Pressure Vessels
Section IX, Qualification Standard for Welding and Brazing Procedures,
Welders, Brazers, and Welding and Brazing Operators
American Welding Society (AWS)
D1.1/D1.1M Structural Welding Code—Steel
International Maritime Organization (IMO)
International Convention for the Prevention of Pollution from Ships (MARPOL), (excluding
Regulations 13F and 13G) 1973/1978 Consolidated Edition, 1997,
with amendments in force
International Convention for The Safety of Life at Sea (SOLAS), Consolidated Edition
SP0176 Corrosion Control of Submerged Areas of Permanently Installed Steel
Offshore Structures Associated with Petroleum Production

Oil Companies International Marine Forum (OCIMF)

OCIMF Effective Mooring
OCIMF Guidelines for the Handling, Storage, Inspection and Testing of Hoses in
the Field
OCIMF International Safety Guide for Oil Tankers and Terminals (ISGOTT)
OCIMF Recommendations for Oil Tanker Manifolds and Associated Equipment
OCIMF Ship to Ship Transfer Guide (Petroleum)
OCIMF Single Point Mooring Maintenance and Operations Guide
The codes and standards from the following organizations can be used for reference and guidance
on the Offloading System. The codes should be used to supplement the Rules listed above and in
Section 2.0.
American Society for Testing of Materials (ASTM)
American Welding Society (AWS)
Instrumentation, Systems and Automation Society (ISA)
National Electrical Manufacturers Association (NEMA)
Manufacturers Standardization Society (MSS)
International Standards Organization (ISO)
American Institute of Steel Construction (AISC)
The Society for Protective Coatings (SSPC)
National Fire Protection Association (NFPA)

FFS-SU-5274 Deepwater CALM Buoy Offloading System

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FFS-SU-5274 Deepwater CALM Buoy Offloading System

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FFS-SU-5274

DEEPWATER CALM BUOY OFFLOADING SYSTEM

APPLICATION: FLOATING/FIXED PLATFORMS

This document is the confidential property of Chevron U.S.A. Inc. Neither

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1.0 Scope ..........................................................................................................................4

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11.0 Mid-Water Offloading Lines ....................................................................................32

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2.1 Classification and Rules

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Oil Companies International Marine Forum (OCIMF)

2.2 Purchaser Documents

2.3 Industry Codes and Standards

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British Standards Institution (BSI)

2.4 Conflict Resolution

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4.0 FUNCTIONAL REQUIREMENTS AND DESCRIPTION

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5.0 GENERAL DESIGN

5.1 Design Life

5.2 Load Cases

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5.3 Maintenance and Reliability

5.4 Marine Growth

6.0 OFFLOADING SYSTEM REQUIREMENTS

6.1 Offloading Buoy

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3) Able to be replaced by manual lubrication methods.

6.2 Mooring System Components

6.2.1 General Requirements

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6.2.2 On Buoy Components of Moorings

6.2.3 Anchor Leg Components

6.3 Mooring System Anchors

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6.4 Marine Hoses (Floating)

6.4.1 General Requirements for Loading Hoses

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d. Two hang off or snubbing chains.

6.4.2 Other Hose System Requirements

6.4.3 Marine Hose Breakaway Couplings (Optional)

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2. Breakaway couplings shall have the following characteristics:

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o. The couplings shall be subjected to the following tests to Purchaser satisfaction:

6.5 Surge Protection Systems

6.6 Mooring Hawsers

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6.7 Ancillary Equipment

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6.8 Telemetry System

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6.9 Safety and Security

6.10 Spare Parts

Table 1: Spare Parts (1 of 2)

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Table 1: Spare Parts (2 of 2)