2004-0634_R0 JIP - Subsea Umbilicals - Proposed Draft for Revision of ISO 13628-5

TECHNICAL REPORT

DET NORSKE VERITAS

JOINT INDUSTRY PROJECT

SUBSEA UMBILICALS: PROPOSED DRAFT FOR REVISION OF ISO 13628-5

REPORT NO. 2004-0634 REVISION NO. 0

ISO/TC 67/SC 4 N 297 Annex A

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DET NORSKE VERITAS Veritasveien 1 N-1322 Høvik Norway Tel: +47 67 57 99 00 Fax: +47 67 57 99 11 http://www.dnv.com

Date of first issue: Project No.:2004-06-04 71310154 Approved by: Organisational unit:Kim Mørk Head of Section

Riser, Moorings and Fundations

Client: Client ref.:Joint Industry Project

Summary:

Encouraged by the industry, DNV has taken the initiative to invite to a Joint Industry Project (JIP) that shall address issues that are not sufficiently covered by the current ISO standard for subsea umbilicals, ISO 13628-5.

This report presents the issues raised so far, and how these issues may be implemented in ISO 13628-5. The suggested changes are presented in chapter 2. An overview of the ISO standard, illustrating the identified changes, is presented in Appendix A.

This revision of the report, rev. 0, is a very preliminary draft. It is intended to work as a basis for further discussions in the project regarding which changes that should be prioritized in the further work. The project participants are still welcome to bring up additional issues to be addressed in the project.

Report No.: Subject Group:2004-0634 Indexing terms Report title: Key words Service Area

Technology Qualification Market Sector

Subsea Umbilicals: Proposed Draft for Revision of ISO 13628-5

Umbilicals International Standard

Upstream, Oil and Gas

Work carried out by: Yngve J. Arnesen, Olav Aamlid, Andreas Echtermeyer, Kjell Hagen, Rolf B. Johansen, Nils Sødahl,

Work verified by: Andreas Echtermeyer and Nils Sødahl

Date of this revision: Rev. No.: Number of pages:2004-06-04 0 11

No distribution without permission from the client or responsible organisational unit (however, free distribution for internal use within DNV after 3 years)

No distribution without permission from the client or responsible organisational unit.

Strictly confidential Unrestricted distribution

© 2002 Det Norske Veritas AS All rights reserved. This publication or parts thereof may not be reproduced or transmitted in any form or by any means, including photocopying or recording, without the prior written consent of Det Norske Veritas AS.

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Table of Content Page

1 INTRODUCTION ....................................................................................................... 1

2 PROPOSED CHANGES ............................................................................................. 1 2.1 Task 1-2: General aspects 1 2.1.1 Establish safety philosophy 1 2.1.2 Establish philosophy entire sub-sea system reliability 1 2.1.3 Establish philosophy for qualification and testing 2 2.1.4 List typical engineering tasks in a project 2 2.2 Task 1-3: Design 2 2.2.1 Global analysis 2 2.2.2 On-bottom stability analyses: 3 2.2.3 Vortex Induced Vibrations (VIV): 4 2.2.4 Interaction and clashing: 4 2.2.5 Minimum Bending Radius (MBR) 4 2.2.6 Maximum Handling Tension (MHT) 4 2.2.7 Cross section analysis 4 2.2.8 Joints, termination and splice 5 2.2.9 Terminations and ancillary equipment design 6 2.3 Task 1-4: Metal pipes 7 2.3.1 Wall thickness 7 2.3.2 Maximum acceptable accumulated strain 7 2.3.3 Plastic deformation 7 2.3.4 Corrosion testing 8 2.3.5 NDE 8 2.3.6 Welding and mechanical testing 8 2.3.7 Link to design 8 2.4 Task 1-5: Installation and operation 8 2.4.1 Installation procedures 8 2.4.2 Repair 8 2.4.3 Electrical aspects 9 2.5 Task 1.6 Aspects related to production 9 2.6 Task 1-3 Joints - Mechanical performance of termination 9

3 REFERENCES........................................................................................................... 11

Appendix A Overview of ISO 13628-5

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1 INTRODUCTION Encouraged by the industry, DNV has taken the initiative to invite to a Joint Industry Project (JIP) that shall address issues that are not sufficiently covered by the current ISO standard for subsea umbilicals, ISO 13628-5.

A work-shop was arranged by DNV at Høvik, Norway, in November 2003. Present at this work-shop were representatives from the Scandinavian industry; oil companies, umbilical manufacturers and steel suppliers. Several issues that need to be addressed were identified. Based on the outcome of this work-shop DNV prepared a JIP proposal to the work-shop participants, ref /11/.

During the work-shop arranged at Høvik in November 2003, some of the issues that need to be addressed were identified. This report presents the issued raised so far, and how these issues may be implemented in ISO 13628-5. The suggested changes are presented in chapter 2. An overview of the ISO standard, illustrating the identified changes, is presented in Appendix A.

This revision of the report, rev. 0, is a very preliminary draft. It is intended to work as a basis for further discussions in the project regarding which changes that should be prioritized in the further work. The project participants are still welcome to bring up additional issues to be addressed in the project.

2 PROPOSED CHANGES The following tasks have been defined based in the November 2003 work-shop and the first participant meeting in April 2004. The task numbers are identical to those used in the project proposal. Appendix A illustrates how these changes may be implemented in ISO 13628-5.

2.1 Task 1-2: General aspects These aspects will be included in chapter 4 of ISO 13628-5. This may require that this chapter is re-structured and re-named. Further, other relevant paragraphs of the ISO document have to be reviewed and the safety principles have to be implemented.

2.1.1 Establish safety philosophy The principles and requirements stated in the current DNV Offshore Standard for dynamic risers (DNV OS-F201) /1/ shall be adopted and modified to fit subsea umbilicals.

2.1.2 Establish philosophy entire sub-sea system reliability Minimum requirements to the scope of reliability analyses shall be defined, and the general principles of such analyses shall be stated. The focus shall be on the total system, including electrical systems.

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2.1.3 Establish philosophy for qualification and testing The principles and requirements of the DNV Recommended Practice for qualification of new technology (DNV RP-A203) /2/ shall be adopted and made specific for subsea umbilicals. Specific testing procedures shall also be addressed.

2.1.4 List typical engineering tasks in a project Examples of typical distribution of work and preferred roles for the different companies can be included in an appendix to the ISO document.

2.2 Task 1-3: Design

2.2.1 Global analysis It is proposed to maintain the overall structure of section 6 of the current ISO document. However, the section should be significantly expanded / revised to include minimum requirements to global load effect analyses. Redundant requirements given in section 6 and 9 should be coordinated (e.g. Dynamic service life, Seabed stability). An informative annex should be established to give additional guidance on global load effect analyses. A consistent cross-reference to local load sharing analysis should be given throughout the document to provide umbilical specific design analysis guidance. The following generic issues will be addressed:

• Brief introduction to relevant global analyses procedures • Discussion of umbilical specific nonlinearities and link to recommended analyses

procedures • Guidance on modelling of special components (bend stiffener, bellmouth, buoyancy

modules, seabed interaction etc.) • Guidance on modelling of cross-sectional nonlinearities • Guidance on relevant structural damping models for umbilicals. Link to test data/ cross

sectional structural analyses. Amplitude dependency will be addressed. • Principles for verification of simplified analyses procedures. • Guidance on modelling of marine growth • Guidance on selection of hydrodynamic coefficients (e.g. distributed buoyancy modules).

Principles to obtain an overall conservative selection of hydrodynamic coefficient (i.e. areas with damping or loading) will be discussed

These issues will be specially adapted for umbilicals with basis in guidance given in DNV OS-F201’Dynamic Risers’ /1/ and API RP 2RD /3/. The following issues related to extreme load effect analyses will be addressed:

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• Global cross-sectional capacity check format (combined tension-curvature capacity

curves) Link to local cross-sectional testing/analyses procedures as well as load case category (e.g. accidental or intact condition). Discuss effect of friction in local load sharing analyses.

• Statistical extreme response assessment principles (e.g. estimation principles, assessment of statistical uncertainty and link to required duration of simulations)

• Required output from global extreme load effect analyses (e.g. combined tension-angle response for design of bend-stiffeners)

• Special issues related to installation analyses will be addressed The following issues related to global fatigue analyses will be addressed:

• Analysis procedures (blocking of wave scatter diagram, regular/irregular analyses, floater offset etc)

• Procedures for calculation of fatigue stress in relevant structural components of the umbilical (metal tubes, tensile armour, electrical cables) based on results from global analyses (curvature and effective tension). Link to cross-sectional analyses to determine load sharing between elements will be given. Main focus will be on industry accepted procedures together with principles for validation/calibration against more advanced analyses and/or testing.

• Discuss effect of friction on stress cycles and methods for incorporating friction effects in fatigue analyses. Friction effects depends on cross-sectional design as well global system design (Generally considered to be an important deepwater effect due to high effective tension giving high contact pressures between the cross-sectional components)

• Fatigue damage calculation (Hot-spots, SCF’s cycle counting) • Reference to accepted SN-curves for relevant cross-sectional components. Give

principles for testing/qualification of new SN curves (reference to existing document) • Reference to relevant documents e.g. DNV RP C203 ‘Fatigue Strength Analysis of Steel

Structures’ /4/ and DNV RP F204 ‘ Riser Fatigue’ /5/. • System condition to be considered in fatigue analyses (e.g. rate of marine growth ,

corrosion, wear) • Special issues (e.g. fretting, wear, testing/qualification etc)

2.2.2 On-bottom stability analyses: The following issues related to on-bottom analyses will be addressed:

• Criteria for static on-bottom stability of umbilicals. This is of relevance for field-layout evaluations/routing as well as installation (lay) of static umbilicals. Straight as well as curved on-bottom configurations will be considered. Guidance on principles selection of friction coefficients will be given.

• Reference to DNV RP F109 ‘On Bottom Stability of Offshore Pipeline Systems’ /6/ will be given for general on-bottom stability assessments. Special guidance for application of DNV RP F109 /6/ for umbilicals will be given.

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2.2.3 Vortex Induced Vibrations (VIV): The following issues related VIV will be addressed:

• Guidance on special considerations regarding VIV analyses of umbilicals (e.g. structural stiffness and damping for typical VIV response)

• Free-span VIV analysis guidance. Reference to DNV RP F105 ‘ Free Spanning Pipelines’ /7/ with special guidance to umbilical applications

2.2.4 Interaction and clashing: The following issues related Interaction/clashing will be addressed:

• Outline general methodology for interference analysis considering hydrodynamic interaction. Reference to DNV RP F203 ‘Riser Interference’ for general description.

• Focus on ‘no clashing’ design scenario. • Special modelling considerations (e.g. marine growth, fluid content in adjacent risers )

2.2.5 Minimum Bending Radius (MBR) ISO 13628-5 says the following about MBR (Section 9.5): The minimum radii to which the umbilical can be bent for storage or service without affecting its performance shall be as stated in the manufacturer’s written specification. The minimum bend radii of the electrical cables, hoses, tubes and optical fibres shall also be as stated in the manufacturer’s written specification. The above does include a definition of MBR. More specific details on how to determine the radii will be included, e.g. specific limits related to the material properties (no straining beyond a stated limit etc).

2.2.6 Maximum Handling Tension (MHT) ISO 13628-5 says the following about MHT (Section 9.2): The maximum working load for the umbilical shall not be less than the values stated in the manufacturer’s written specification. The above does not include an adequate definition of MHT, but an adequate definition may be written based e.g. on the definition of MBR.

2.2.7 Cross section analysis This should include guidance on transforming global loads (bending moment, torque, axial loads (and shear forces if ever relevant)) to the individual umbilical elements. ISO 13628-5 does not include this. If one is to include (nonlinear) interaction between elements (e.g. contact forces and friction), these calculations are complex and cannot be presented as analytical equations. A general description of the phenomenon and their effects will be given. Approximate (and conservative) analytical equations (industry practice) will be stated.

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“Design envelopes” (axial tension vs. curvature) capacity/limit states for “all” relevant components; metal tubes, hoses (plastic tubes), electrical cables (and insulation), optical cables, fillers, armouring, inner sheets and outer sheets, will be discussed. Further, the use of testing and/or advanced numerical analysis to qualify simplified analysis procedures will be discussed.

2.2.8 Joints, termination and splice Termination interface (electrical cables): The ISO-standard simply states that the electrical cables will be terminated in some form of waterblocking arrangement. The same section also displays a NOTE: This part of ISO 13628-5 does not provide detailed specifications of electrical terminations for use subsea. Adding guidelines are therefore recommended. The ISO-standard does not differ between a splice box/joint and a termination interface. The former typically is used to join together component lengths or sub-components to achieve the required production length, whereas the latter typically refers to mechanisms which form the transition between the umbilical and the subsea termination or subsea umbilical distribution unit. To the extent that this may influence the choice of a mechanical solution, this shall be spelled out/explained in this Section. Typical termination components employed are electrical connectors and/or penetrations which come in a wide variety of solutions/designs. Examples (figures) shall be included / displayed as typically shown in API RP 17B /8/. In general, an umbilical is a custom-built product that can be designed and manufactured in a variety of methods. It will therefore not be the intent of the examples to discourage novel and new developments in connectors / penetrations. On the contrary, it is recognised that a variety of designs are possible. The figures will only provide some guidance to the user while still leaving open the possibility of using alternative approaches. Experience/solutions will be sought among the JIP-participants. Termination interface (optical fibre cables): The ISO-standard simply states that the design of optical fibre cables shall recognise that the cables will be terminated in some form of waterblocking arrangement. The same section also displays a NOTE: This part of ISO 13628 is not applicable to the design of optical fibre terminations for subsea use. Adding guidelines are therefore recommended. As for electrical cables (see above) the ISO-standard does not differ between a splice box/joint and a termination interface. To the extent that this may influence the choice of a mechanical solution, this should be explained in this Section. In certain applications a mechanical splice may be requested, whereas in other cases a fusion-splice solution may be preferred. A non-permanent device for connecting two fibres or fibres to some equipment (converter) may call for a fibre optic connector of some sort. Examples, e.g. connectors, ought to be included/displayed as typically employed in API RP 17B /8/. Typical connector- and splice-loss mechanisms (i.e. examples) should be visualized/demonstrated. Again, it will not be the intent of the shown examples to discourage novel and new developments in fibre optic connectors. On the contrary, it is recognised that a variety of designs are possible. The figures will only provide some guidance to the user while still leaving open the possibility of using alternative approaches. Experience/solutions will be sought among the JIP-participants.

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Termination interface (hoses):This topic (for thermoplastic hoses) is covered relatively extensively in the ISO-standard. More detailed/structured coverage is recommended and visualized with examples/figures similarly as in API RP 17B /8/. Experience/solutions will be sought among the JIP-participants. Termination interface (metallic tubes): Unlike thermoplastic hoses termination interfaces is hardly covered in the ISO-standard. Adding guidelines/guidance will be done. The ISO-standard does not differ between a splice box/joint and a termination interface. The necessity for joining umbilicals (with metallic tubes) to achieve a required production length is probably of limited importance, but in repair situations this issue may nevertheless become relevant. In any instance, a transition between the umbilical and the subsea termination or subsea umbilical distribution unit will require a mechanical coupling/end fitting. Termination components (connector assembly/coupling) employed come in a wide variety of solutions/ designs. Examples (figures) should be included/displayed as typically shown in API RP 17B /8/. It will not be the intent of the examples to discourage novel and new developments in tube connectors/end fittings. On the contrary, it is recognised that a variety of designs are possible. The figures will only provide some guidance to the user while still leaving open the possibility of using alternative approaches. Experience/solutions will be sought among the JIP-participants.

2.2.9 Terminations and ancillary equipment design General: The ISO-standard states: The design of umbilical terminations and ancillary equipment is invariably specific to a particular umbilical system and, as such, detailed specification data are outside the scope of this part of ISO 13628. Some general information is then provided for guidance only. The economical consequences, however, of end terminations that fail in one way or another and which will lead to malfunction/failure of a subsea umbilical, is never discussed. It is therefore recommended that a new section is included, i.e. Section 8.2 Mechanical/electrical/optical performance of terminations. Inclusion (in the added Section) of the following bullet points are recommended: • Methods to describe failure mechanisms of an end termination and their consequences (on

mechanical and electrical performance. Terminations involve both mechanics, corrosion and the complex physics of electric conductivity between to metal surfaces. Here are several techniques to consider, e.g. normal shrimp cable shoes or “Fusion lug” forming the cable shoe of the conductor itself. Also involve moulding/sealing for isolation etc).

• Requirements to ensure that critical failure mechanisms will not take place • Special challenges in long term performance (different failure mechanisms may be activated

over time) • Descriptions of methods to address multiple failure mechanisms with different long term

performance Experience/feed-back will be sought among the JIP-participants. Terminations: A new section, Section 8.2.3 Hose/tube terminations, to be added/included. Sections 8.2.1 and 8.2.2 only cover Armour terminations and Cable terminations respectively. Experience/solutions will be sought among the JIP-participants.

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Armour terminations: Additional text/guidance to be added. Experience/solutions will be sought among the JIP-participants. Cable terminations: Additional text/guidance to be added. Experience/solutions will be sought among the JIP-participants.

2.3 Task 1-4: Metal pipes The following changes are proposed to be included in section 7.10 of the ISO document. (The entire section 7 should be re-structured, i.e. the section should be divided to avoid the high number of sub-sections and the requirements to each component should be stated in the same order within each section).

2.3.1 Wall thickness This section should include criteria for pressure containment, collapse, propagating buckling and combined loading. It is suggested that the ISO document adopts DNV-OS-F101 (Section 5, Design Criteria) /9/, that includes all this. One needs however to ensure that the material requirements are sufficiently stringent, e.g. thickness tolerances, testing and supplementary requirements. ISO 13628-5 includes a pressure containment check (which for most practical applications give similar wall thickness as DNV-OS-F101) /9/ and general statements on the other limit states. One needs to document relatively thoroughly the differences between DNV-OS-F101 /9/ and ISO 13628-5. System pressure needs to be considered (1.5·pd, 1.25·DWP (Section 7.10.4.1)). See also DNV-OS-F101 Appendix A: Supplementary Requirements to ISO /9/. This work shall be coordinated with the ongoing ISO/API work to update API 2RD /3/.

2.3.2 Maximum acceptable accumulated strain Maximum accumulated strain is included in DNV-OS-F101 (Section 5) /9/, including description of required testing for qualification. One needs however to document the differences between DNV-OS-F101 /9/ and ISO 13628-5, and to modify the requirements for umbilical tubing.

2.3.3 Plastic deformation Criteria for maximum plastic deformations are included in DNV-OS-F101 Section 5 /9/, both with respect to maximum bending (one cycle) and accumulated plastic strain. One needs however to document the differences between DNV-OS-F101 /9/ and ISO 13628-5, and to modify the requirements for umbilical tubing.

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2.3.4 Corrosion testing The reference to ASTM G48 testing shall be kept. The alternative test methods, planned to be included in a new ISO standard, based on resent research results from the EU sponsored project “Crevcorr” should be referenced, if possible.

2.3.5 NDE More specific requirements to Non Destructive Examination shall be included. The extent of testing should be specified more in detail. Special considerations related to the relatively small dimensions of umbilical tubes shall be stated.

2.3.6 Welding and mechanical testing Special considerations related to the relatively small dimensions of umbilical tubes shall be stated. Several of the standardized testing procedures cannot be applied to small tubes. In such cases alternative testing methods should be proposed. Special considerations regarding the formation of intermetallic phases in ferritic-austenitic (duplex) steels should be stated, it is proposed to define testing program adjusted to verify the critical properties for tubes to be applied in subsea umbilicals.

2.3.7 Link to design DNV-OS-F101, Section 12 J describes some links between material, design and supplementary requirements /9/. Similar links in ISO 13628-5 should be made more evident.

2.4 Task 1-5: Installation and operation

2.4.1 Installation procedures Umbilical-specific recommendations for installation techniques and equipment shall be discussed.

2.4.2 Repair This section (section 15.23) is designated repairs to an umbilical caused during installation, but without stating the type of repair since “each repair shall be installation-specific”. The installer shall carry out a survey along the entire subsea route of the umbilical including subsea terminations. The umbilical terminations shall be inspected for leakage and damage. Current experience shows that damages inflicted to an umbilical in most cases indeed take place during the installation phase. Repair work carried out offshore on an already installed umbilical does not provide the same work conditions as when performed onshore. Repair work offshore will necessitate some sort of support vessel with high day-work rates. These are negative factors

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that may influence the initiated repair actions. The ISO-standard allows a splice box to be installed in the static section/part of an umbilical and guidance to these work tasks is recommended added to this section. Repair work performed directly on subsea termination interfaces (if possible) should also be clarified/included in the standard. Experience/solutions will be sought among the JIP-participants.

2.4.3 Electrical aspects The following topics have currently been identified. These will mainly require changes in chapter 7 of the current ISO 13628-5, but chapters 2, 11, 13, 14 and 15 may also be affected. • IEC 60502 is a normative reference, but its intended use does not include subsea neither

movable cables. Evaluate implications or find possible alternative standards. • Post-fabrication (FAT) testing. • Time domain reflectometry (TDR). Requirement to instrumentation (uncertainty) needs to be

better specified. Requirements to detectable length and resolution of imperfections. • When has a cable failed? Evaluate or find a standard for maximum acceptable short distance

reduction of cross section of cable. Or, how many strands of a multi stranded cable can be broken before defined as damaged?

• Evaluate entire ISO-13628 regarding requirements and how they can be proved to be fulfilled. I.e. how producer specifications shall be given, how FAT and Post-installation tests shall be performed and how the acceptance criteria shall be defined.

2.5 Task 1.6 Aspects related to production The following changes are proposed: • Write philosophy and high level requirements for this subject. • Link production section into the general safety and functionality philosophy. • We want to achieve and ensure the same quality as assumed in the design. • Consistency of the production process must be ensured. • Critical production parameters must be identified and how to do this. • Standard should help to identify the critical parameters. How to control it in detail is up to

the manufacturer. • Only general aspects will be included in the text.

2.6 Task 1-3 Joints - Mechanical performance of termination The following changes are proposed to the ISO document. • Method to describe failure mechanisms in a joint and their consequence (on mechanical and

electrical performance). • Requirement to ensure that all critical failure mechanisms will not happen.

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• Special challenge is long term performance, because differnt failure mechanisms may be activated over time.

• Describe method to address multiole failure mechanisms with diferent long term performance.

• (Extension / conversion of what has been written about this in DNV-OS-C501) /10/.

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3 REFERENCES

/1/

Det Norske Veritas Offshore Standard, DNV-OS-F201, Dynamic Risers, 2001.

/2/

Det Norske Veritas Recommended Practice, DNV-RP-A203, Qualification Procedures for New Technology, 2001.

/3/

American Petroleum Institute, API RP 2RD, Design of Risers for Floating Production Systems (FPSs) and Tension-Leg Platforms (TLPs), 1998.

/4/

Det Norske Veritas Recommended Practice, RP-C203, Fatigue Strength Analysis of Offshore Steel Structures, 2001.

/5/

Det Norske Veritas Recommended Practice, RP-F204, Riser Fatigue, planned publication in October 2004.

/6/

Det Norske Veritas Recommended Practice, RP-F109, On Bottom Stability of Offshore Pipeline Systems, planned publication in July 2004.

/7/

Det Norske Veritas Recommended Practice, DNV-RP-F105, Free Spanning Pipelines, 2002.

/8/

American Petroleum Institute, API RP 17B, Recommended Practice for Flexible Pipe, 2002.

/9/

Det Norske Veritas Offshore Standard, DNV-OS-F101, Submarine Pipeline Systems, 2000.

/10/

Det Norske Veritas Offshore Standard, DNV-OS-C501, Composite Components, 2003.

/11/ Agreement for Joint Industry Research and Development Project, “Subsea Umbilicals: Development of a Proposed Draft for Revision of ISO 13628-5”, issued in 2004.

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APPENDIX A

OVERVIEW OF ISO 13628-5

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Item Title Proposed change 1 Scope Update. 2 Normative references Update (see also section 2.4 in this

report). 3 Terms, definitions and abbreviated terms Update. 3.1 Terms and definitions Update. 3.2 Abbreviated terms Update. 4 Functional requirements 4.1 General requirements 4.1.1 Umbilical 4.1.2 End terminations and ancillary equipment 4.2 Project-specific requirements

Re-name and re-structure chapter 4 to include safety philosophy and other general aspects as described in section 2.1 of this report.

5 Quality assurance 6 Design requirements 6.1 General 6.2 Design methodology 6.3 Analysis 6.3.1 General 6.3.2 Definition of load classes 6.3.3 Load combinations and conditions 6.3.4 Installation analysis 6.3.5 Dynamic service analysis 6.3.6 Structural analysis

The overall structure of chapter 6 should be maintained. The chapter should be significantly expanded and revised. Redundant requirements found in chapter 6 and 9 should be coordinated. See section 0 of this report.

7 Component design, manufacture and test Cross section analysis should be included. See section 0 of this report. Requirements to electrical components should be revised, see section 2.4 of this report. Further, the entire section 7 should be re-structured, i.e. the section should be divided to avoid the high number of sub-sections and the requirements to each component should be stated in the same order within each section. See section 2.3 of this report.

7.1 General 7.2 Electric cable 7.2.1 General 7.2.2 Operating voltage 7.2.2.1 Power cables 7.2.2.2 Signal cables 7.2.3 Construction 7.2.3.1 General 7.2.3.2 Configuration and type of conductor 7.2.3.3 Power cables 7.2.3.4 Signal cables 7.2.3.5 Conductor coding 7.2.3.6 Lay-up

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7.2.3.7 Fillers 7.2.3.8 Screening 7.2.3.9 Sheath 7.2.3.10 Identification 7.2.3.11 Termination interface See section 0 of this report. 7.3 Performance requirements — Electric cable 7.3.1 Conductor resistance 7.3.2 Insulation resistance 7.3.3 Screening layer resistivity (non-metallic layers) 7.3.4 Performance characteristics 7.3.4.1 Signal 7.3.4.2 Power 7.4 Structural analysis — Electric cable 7.5 Manufacture — Electric cable 7.5.1 Conductor stranding 7.5.2 Insulation extrusion 7.5.3 Lay-up 7.5.4 Sheath extrusion 7.6 Verification tests 7.6.1 Visual and dimensional checks 7.6.2 Conductor resistance test 7.6.3 Resistivity of screening layers 7.6.4 Insulation resistance 7.6.5 High voltage DC test 7.6.6 High voltage AC test 7.6.7 Complete voltage breakdown 7.6.8 Partial discharge test 7.6.9 Rate of application of test voltages 7.6.10 Inductance characteristics 7.6.11 Capacitance characteristics 7.6.12 Attenuation characteristics 7.6.13 Characteristic impedance 7.7 Component acceptance tests — Electric cable 7.7.1 Visual and dimensional inspection 7.7.2 Spark test 7.7.3 DC conductor resistance test 7.7.4 Insulation resistance test 7.7.5 High voltage DC test 7.7.6 Inductance characteristics 7.7.7 Capacitance characteristics 7.7.8 Attenuation characteristics 7.7.9 Characteristic impedance 7.7.10 Cross-talk 7.7.11 Time-domain reflectometry 7.7.12 Delivery to umbilical manufacturer 7.8 Optical fibre cable 7.8.1 General 7.8.2 Fibre type and coding

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7.8.3 Cable construction 7.8.4 Construction 7.8.5 Termination interface See section 0 of this report. 7.8.6 Performance requirements 7.8.6.1 Optical attenuation 7.8.6.2 Fibre strain 7.8.6.3 Cable jointing 7.8.6.3.1 Cable 7.8.6.3.2 Fibre jointing 7.8.7 Verification tests 7.8.7.1 Transmission and optical characteristics 7.8.7.2 Mechanical characteristics 7.8.7.3 Environmental resistance 7.8.7.4 External pressure test 7.8.7.5 Fibre splicing 7.8.8 Component acceptance tests 7.8.8.1 Visual and dimensional inspection 7.8.8.2 Optical time-domain reflectometry (ODTR) 7.8.9 Delivery to umbilical manufacturer 7.9 Hoses 7.9.1 General 7.9.2 Hose sizing 7.9.3 Hose construction 7.9.3.1 General 7.9.3.2 Hose liner 7.9.3.3 Hose reinforcement 7.9.3.4 Hose sheath 7.9.3.5 Identification 7.9.3.6 Termination interface See section 0 of this report. 7.9.4 Performance requirements 7.9.4.1 Design pressure ratios 7.9.4.2 Collapse pressure 7.9.4.3 Change in length 7.9.5 Structural analysis 7.9.6 Hose manufacture 7.9.6.1 Liner extrusion 7.9.6.2 Reinforcement application 7.9.6.3 Sheath extrusion 7.9.7 Verification tests 7.9.7.1 General 7.9.7.2 Test fluid 7.9.7.3 Visual and dimensional checks 7.9.7.4 Change-in-length test 7.9.7.5 Leakage test 7.9.7.6 Burst test 7.9.7.7 Impulse test 7.9.7.8 Cold bend test 7.9.7.9 Collapse test

DET NORSKE VERITAS


7.9.7.10 Volumetric expansion test 7.9.7.11 End fitting anti-rotation test 7.9.7.12 Fluid compatibility tests 7.9.7.12.1 General 7.9.7.12.2 Immersion tests 7.9.7.12.3 Pressure cycling tests 7.9.7.13 Permeability tests 7.9.7.13.1 General 7.9.7.13.2 Liquids 7.9.7.13.3 Gases 7.9.8 Component acceptance tests 7.9.8.1 Visual and dimensional inspection 7.9.8.2 Test fluid 7.9.8.3 Liner burst test 7.9.8.4 Change in length 7.9.8.5 Burst test 7.9.8.6 Proof pressure/decay test 7.9.8.7 Delivery to umbilical manufacturer 7.10 Metallic tubes See section 2.3 of this report. 7.10.1 General 7.10.2 Tube sizing 7.10.2.1 Nominal bore and DWP 7.10.2.2 Tube wall thickness See section 2.3 of this report. 7.10.2.2.1 Wall thickness calculations 7.10.2.2.2 Calculation of stresses 7.10.2.3 Strength criteria 7.10.2.3.1 General 7.10.2.3.2 Stresses due to load combinations for static

umbilicals

7.10.2.4 Allowable strain See section 2.3 of this report. 7.10.2.4.1 General 7.10.2.4.2 Strain ageing 7.10.2.4.3 Strain hardening 7.10.2.5 Buckling 7.10.2.6 Fatigue life determination 7.10.3 Construction 7.10.3.1 General 7.10.3.2 Material 7.10.3.3 Form of tubing 7.10.3.4 Corrosion/erosion protection 7.10.3.5 Tube marking 7.10.3.6 Termination interface See section 0 of this report. 7.10.4 Performance requirements 7.10.4.1 Design pressure ratios 7.10.4.2 Minimum bend radius 7.10.4.3 Corrosion 7.10.4.4 Structural analysis 7.10.5 Tube manufacture

DET NORSKE VERITAS


7.10.5.1 Manufacturing process 7.10.5.1.1 General 7.10.5.1.2 Changes to essential variables 7.10.5.1.3 Metal-making 7.10.5.1.4 Plate and strip manufacture 7.10.5.2 Tube manufacture 7.10.5.3 Degreasing 7.10.5.4 Corrosion protection 7.10.5.5 Internal cleaning 7.10.5.6 Tube welding 7.10.5.6.1 General 7.10.5.6.2 Annealing 7.10.5.6.3 Tube preparation 7.10.5.6.4 Automated or manual production welding 7.10.5.6.5 Weld preparation 7.10.5.6.6 Weld process qualification 7.10.5.6.7 Weld repairs 7.10.5.7 Tube repairs 7.10.6 Verification tests 7.10.6.1 General 7.10.6.2 Visual and dimensional checks 7.10.6.3 Tensile tests 7.10.6.4 Flattening tests 7.10.6.5 Hardness tests 7.10.6.6 Flaring tests 7.10.6.7 Chemical analysis 7.10.6.8 Corrosion test See section 2.3 of this report. 7.10.6.9 Weld qualification See section 2.3 of this report. 7.10.6.10 Non-destructive examination (NDE) See section 2.3 of this report. 7.10.6.11 Burst tests 7.10.7 Acceptance tests 7.10.7.1 Visual and dimensional tests 7.10.7.2 Non-destructive examination (NDE) See section 2.3 of this report. 7.10.7.3 Test fluid 7.10.7.4 Burst test 7.10.7.4.1 Single-heat-number manufacture 7.10.7.4.2 Multiple-heat-number manufacture 7.10.7.5 Pressure test 8 Terminations and ancillary equipment design 8.1 General See section 0 of this report. 8.2 Terminations 8.2.1 Armour terminations See section 0 of this report. 8.2.2 Cable terminations See section 0 of this report. 8.2.3 Pull-in head 8.2.4 Topside hang-off 8.2.5 Subsea termination interface 8.2.6 Subsea umbilical termination 8.2.7 Subsea umbilical distribution unit

DET NORSKE VERITAS


8.3 Ancillary equipment 8.3.1 Joint box 8.3.2 Weak link 8.3.3 Buoyancy attachments 9 Umbilical design Chapter 9 in general:

see section 0 of this report. 9.1 Temperature range 9.2 Maximum working load See section 0 of this report. 9.3 Minimum breaking load 9.4 Minimum bend radius See section 0 of this report. 9.5 Dynamic service life 9.6 Seabed stability 9.7 Service environment 9.8 Cross-sectional arrangement 9.9 Lay-up 9.10 Sub-bundles 9.11 Inner sheath 9.12 Armouring 9.13 Outer sheath 9.14 Length marking 10 Umbilical manufacture and test 10.1 Umbilical manufacture 10.1.1 Lay-up 10.1.2 Inner sheath 10.1.3 Armouring 10.1.4 Outer sheath 10.2 Verification tests 10.2.1 General 10.2.2 Tensile test 10.2.3 Bend stiffness test 10.2.4 Crush test 10.2.5 Fatigue tests 11 Umbilical factory acceptance tests (FATs) See section 2.4 of this report. 11.1 General 11.2 Visual and dimensional inspection 11.3 Electric cable 11.4 Optical fibre cables 11.5 Hoses 11.6 Tubes 12 Storage 12.1 General 12.2 Protection of umbilical services 12.2.1 Electrical services 12.2.2 Optical fibre cables 12.2.3 Hydraulic services 12.3 Spare length 12.4 Repair kits 12.5 Handling for integration tests

DET NORSKE VERITAS


13 Pre-installation activity See section 2.4 of this report. 13.1 Umbilical information 13.2 Route information 13.3 Terminations and ancillary equipment information 13.4 Host facility information 13.5 Subsea structure information 13.6 Host facility visit 14 Load-out See section 2.4 of this report. 14.1 General 14.2 Technical audit of load-out facilities 14.3 Load-out procedure 14.4 Pre-load-out meetings 14.5 Pre-load-out tests 14.5.1 General 14.5.2 Electric cables 14.5.2.1 DC conductor resistance test 14.5.2.2 Insulation resistance test 14.5.3 Optical fibre cables 14.5.4 Hoses/tubes 14.5.4.1 Hydraulic control hoses/tubes 14.5.4.2 Hose proof pressure/decay test 14.5.4.3 Tube proof pressure/decay test 14.6 Load-out operation 14.7 Stopping and starting the load-out 14.8 Handling of the umbilical 14.8.1 General 14.8.2 Twist 14.8.3 Bending 14.8.4 Lifting the umbilical 14.8.5 Transfer across spans 14.8.6 Terminations 14.8.7 Weak link 14.9 Load-out monitoring 14.9.1 General 14.9.2 Electric cables 14.9.3 Optical fibre cables 14.9.4 Hoses/tubes 14.9.5 Visual examination 14.9.6 Umbilical length 14.10 Load-out on a reel or carousel 14.11 Post-load-out tests 15 Installation operations See section 2.4 of this report. 15.1 General 15.2 Requirements for installation vessel and equipment 15.3 Pre-installation survey 15.3.1 General 15.3.2 Requirements of survey 15.3.3 Reporting

DET NORSKE VERITAS


15.4 I- or J-tube pull-in operations 15.4.1 General 15.4.2 Preparatory work 15.4.3 Weather window for pull-in 15.4.4 Initiation of pull-in operations 15.4.5 Visual survey 15.4.6 Recovery of the messenger wire 15.4.7 Umbilical pull-in 15.4.8 Securing the umbilical on the host facility 15.4.9 I- or J-tube sealing and chemical protection 15.4.10 Second end pull-in 15.4.11 Movement of vessel away from the host facility 15.5 Lay-down of subsea termination (first end) 15.6 Lay route 15.7 Handling requirements for the main lay 15.8 Vessel positioning to achieve required touch-down 15.9 Control and monitoring of length laid 15.10 Integrity monitoring during lay 15.10.1 General 15.10.2 Electric cables 15.10.3 Optical fibre cables 15.10.4 Hoses/tubes 15.10.5 Visual inspection 15.11 Burial operations 15.11.1 General 15.11.2 Monitoring during the burial operation 15.11.3 Interaction with umbilical 15.12 Approach to subsea termination position (second

end)

15.13 Lay-down of subsea termination 15.14 Pull-in of subsea termination 15.15 Pipeline crossings 15.16 Arming of weak link 15.17 Post-lay survey 15.18 Post-burial survey 15.19 Post-pull-in test 15.20 Post-hook-up test 15.21 Retrieval of installation aids 15.22 Contingencies 15.23 Repairs See section 2.4 of this report. 15.24 Post-installation survey Annex A Annex B Annex D Annex E

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2004-0634_R0 JIP - Subsea Umbilicals - Proposed Draft for Revision of ISO 13628-5

Documents

american petroleum institute

det norske veritas

responsible organisational unit

manufacturers written specification

long term performance

required production length

describe failure mechanisms

critical failure mechanisms