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INTERNATIONAL ISO
STANDARD 13628-11

First edition
2007-09-15

Petroleum and natural gas industries —

Design and operation of subsea
production systems —
Part 11:
Flexible pipe systems for subsea and
marine applications
Industries du pétrole et du gaz naturel — Conception et exploitation des
systèmes de production immergés —
Partie 11: Systèmes de canalisations flexibles pour applications sous-
marines et en milieu marin

Reference number
ISO 13628-11:2007(E)

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ISO 13628-11:2007(E)

Contents Page

Foreword............................................................................................................................................................. v
Introduction ....................................................................................................................................................... vi
1 Scope ..................................................................................................................................................... 1
2 Normative references ........................................................................................................................... 1
3 Terms, abbreviated terms, definitions and symbols......................................................................... 2
3.1 Terms and definitions........................................................................................................................... 2
3.2 Symbols and abbreviated terms ......................................................................................................... 4
4 System, pipe, and component description ........................................................................................ 6
4.1 Introduction ........................................................................................................................................... 6
4.2 Flexible pipe systems........................................................................................................................... 8
4.3 Flexible pipe description.................................................................................................................... 15
4.4 Ancillary components ........................................................................................................................ 24
5 Pipe design considerations ............................................................................................................... 35
5.1 General................................................................................................................................................. 35
5.2 Design overview.................................................................................................................................. 35
5.3 Failure modes...................................................................................................................................... 40
5.4 Design criteria ..................................................................................................................................... 43
5.5 Load cases .......................................................................................................................................... 50
6 Materials .............................................................................................................................................. 55
6.1 Scope ................................................................................................................................................... 55
6.2 Materials — Unbonded pipe .............................................................................................................. 55
6.3 Materials — Bonded pipe ................................................................................................................... 60
6.4 Alternative materials........................................................................................................................... 64
6.5 Polymer/elastomer test procedures.................................................................................................. 66
6.6 Metallic-material test requirements .................................................................................................. 69
7 System design considerations.......................................................................................................... 72
7.1 General................................................................................................................................................. 72
7.2 General system requirements ........................................................................................................... 72
7.3 Flowline design requirements ........................................................................................................... 75
7.4 Riser design requirements ................................................................................................................ 79
7.5 Ancillary components ........................................................................................................................ 82
7.6 System interfaces ............................................................................................................................... 86
8 Analysis considerations .................................................................................................................... 87
8.1 Introduction ......................................................................................................................................... 87
8.2 Analysis techniques ........................................................................................................................... 87
8.3 Loads.................................................................................................................................................... 96
8.4 Global-response evaluation............................................................................................................... 99
9 Prototype testing .............................................................................................................................. 103
9.1 General............................................................................................................................................... 103
9.2 Design programmes ......................................................................................................................... 104
9.3 Classification of prototype tests ..................................................................................................... 104
9.4 Test requirements............................................................................................................................. 105
9.5 Test protocol ..................................................................................................................................... 109
9.6 Procedures — Standard prototype tests........................................................................................ 111
9.7 Procedures — Special prototype tests........................................................................................... 116
10 Manufacturing ................................................................................................................................... 130
10.1 General............................................................................................................................................... 130

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10.2 Manufacturing — Unbonded pipe ................................................................................................... 130

10.3 Manufacturing — Bonded pipe ........................................................................................................ 135
10.4 Marking............................................................................................................................................... 137
10.5 Storage ............................................................................................................................................... 140
11 Handling, transportation, and installation...................................................................................... 141
11.1 General ............................................................................................................................................... 141
11.2 Handling ............................................................................................................................................. 141
11.3 Transportation ................................................................................................................................... 143
11.4 Installation ......................................................................................................................................... 144
11.5 Pre-commissioning and commissioning........................................................................................ 157
12 Retrieval and reuse ........................................................................................................................... 161
12.1 General ............................................................................................................................................... 161
12.2 Retrieval ............................................................................................................................................. 161
12.3 Reuse.................................................................................................................................................. 163
13 Integrity and condition monitoring ................................................................................................. 167
13.1 General ............................................................................................................................................... 167
13.2 General philosophy........................................................................................................................... 167
13.3 Failure modes and potential pipe defects ...................................................................................... 168
13.4 Monitoring methods.......................................................................................................................... 169
13.5 Recommendations ............................................................................................................................ 171
Annex A (normative) Flexible-pipe high-temperature end-fitting qualification test protocol —
Volatile-content polymers ................................................................................................................ 184
Annex B (normative) Polyvinylidene fluoride (PVDF) coupon crude-oil exposure-test procedure....... 194
Annex C (normative) Flexible-pipe high-temperature end-fitting qualification test procedures:
Low-volatile-content polymers ........................................................................................................ 197
Annex D (normative) Polymer coupon crude-oil exposure-test procedure ............................................. 207
Bibliography ................................................................................................................................................... 210

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ISO 13628-11:2007(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 13628-11 was prepared by Technical Committee ISO/TC 67, Materials, equipment and offshore
structures for petroleum, petrochemical and natural gas industries, Subcommittee SC 4, Drilling and
production equipment.

This first edition of ISO 13628-11 cancels and replaces ISO 10420:1994, which has been technically revised.

ISO 13628 consists of the following parts, under the general title Petroleum and natural gas industries —
Design and operation of subsea production systems:

⎯ Part 1: General requirements and recommendations

⎯ Part 2: Unbonded flexible pipe systems for subsea and marine applications

⎯ Part 3: Through flowline (TFL) systems

⎯ Part 4: Subsea wellhead and tree equipment

⎯ Part 5: Subsea umbilicals

⎯ Part 6: Subsea production control systems

⎯ Part 7: Completion/workover riser systems

⎯ Part 8: Remotely Operated Vehicle (ROV) interfaces on subsea production systems

⎯ Part 9: Remotely Operated Tool (ROT) intervention systems

⎯ Part 10: Specification for bonded flexible pipe

⎯ Part 11: Flexible pipe systems for subsea and marine applications

A part 12 dealing with dynamic production risers, a part 13 dealing with remotely operated tools and interfaces
on subsea production systems and a part 15 dealing with subsea structures and manifolds are under
preparation.

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ISO 13628-11:2007(E)

Introduction
This part of ISO 13628 is based on API RP 17B and on matching ISO procedures and API procedures. This
ISO standard has been technically updated and revised to cater for the needs of the international oil and
natural gas industries. This part of ISO 13628 provides information complementary to ISO 13628-2 and
ISO 13628-10.

Users of this International Standard should be aware that further or differing requirements can be needed for
individual applications. This International Standard is not intended to inhibit a vendor from offering, or the
purchaser from accepting, alternative equipment or engineering solutions for the individual application. This
can be particularly applicable where there is innovative or developing technology. Where an alternative is
offered, the vendor should identify any variations from this International Standard and provide details.

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INTERNATIONAL STANDARD ISO 13628-11:2007(E)

Petroleum and natural gas industries — Design and operation

of subsea production systems —
Part 11:
Flexible pipe systems for subsea and marine applications

1 Scope
This part of ISO 13628 provides guidelines for the design, analysis, manufacture, testing, installation and
operation of flexible pipes and flexible pipe systems for onshore, subsea and marine applications. This part of
ISO 13628 supplements ISO 13628-2 and ISO 13628-10, which specify minimum requirements for the design,
material selection, manufacture, testing, marking and packaging of unbonded and bonded flexible pipe,
respectively.

This part of ISO 13628 applies to flexible pipe assemblies, consisting of segments of flexible pipe body with
end fittings attached to both ends. Both bonded and unbonded pipe types are covered. In addition, this part of
ISO 13628 applies to flexible pipe systems, including ancillary components.

The applications covered by this part of ISO 13628 are sweet- and sour-service production, including export
and injection applications. This part of ISO 13628 applies to both static and dynamic flexible pipe systems
used as flowlines, risers and jumpers. This part of ISO 13628 does cover, in general terms, the use of flexible
pipes for offshore loading systems.

NOTE Refer also to Reference [30] for offshore loading systems.

This part of ISO 13628 does not cover flexible pipes for use in choke and kill lines or umbilical and control
lines.

2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

ISO 13628-2:2006, Petroleum and natural gas industries — Design and operation of subsea production
systems — Part 2: Unbonded flexible pipe systems for subsea and marine applications

ISO 13628-3:2000, Petroleum and natural gas industries — Design and operation of subsea production
systems — Part 3: Through flowline (TFL) systems

ISO 13628-10:2005, Petroleum and natural gas industries — Design and operation of subsea production
systems — Part 10: Specification for bonded flexible pipe

NACE TM0177, Laboratory testing of metals for resistance to sulfide stress cracking and stress corrosion
cracking in H2S environments

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ISO 13628-11:2007(E)

3 Terms, abbreviated terms, definitions and symbols

For the purposes of this document, the following terms, definitions, symbols and abbreviated terms apply.

3.1 Terms and definitions

3.1.1
annulus
space between two concentric plastic sheaths of an unbonded flexible pipe cross-section

3.1.2
Arrhenius plot
log-linear scale used to plot service life against the inverse of temperature for some polymer materials

3.1.3
basket
device used for storage and transport of flexible pipe

NOTE All pipes are laid freely into the basket.

3.1.4
bird-caging
buckling of the tensile-armour wires, usually caused by extreme axial compression, which results in significant
radial deformation

3.1.5
buoyancy module
buoys used in significant numbers at discrete points over a section of riser to achieve wave-shape riser
configurations

NOTE See 4.4.6.

3.1.6
carousel
device used for storage and transport of very long lengths of flexible pipe and which rotates about a vertical
axis

NOTE Pipe is wound under tension around the centre hub.

3.1.7
Chinese fingers
woven steel wire or fabric sleeve that can be installed over a flexible pipe and drawn tight to grip it for support
or applying tension to the pipe

3.1.8
end fitting
termination in a flexible pipe

3.1.9
flexible pipe system
fluid conveyance system for which the flexible pipe(s) is/are the primary component and which includes
ancillary components attached directly or indirectly to the pipe

3.1.10
free-hanging catenary
riser configuration that spans the water column in a catenary shape modified by the bending stiffness of the
riser

NOTE See Figure 4.

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ISO 13628-11:2007(E)

3.1.11
integrated service umbilical
ISU™1)
structure in which the inner core is a standard flexible pipe construction

NOTE 1 Umbilical components are wound around the core pipe and covered with a protective outer sheath (see 4.3.6).

NOTE 2 ISU is a trademark of Coflexip Stena Offshore.

3.1.12
lazy wave
free-hanging catenary modified by a section with distributed buoyancy modules

NOTE See Figure 4.

3.1.13
lazy-S
free-hanging catenary modified by a section with concentrated buoyancy modules

NOTE See Figure 4.

3.1.14
multibore
multiple flexible pipes or umbilicals contained in a single construction with an outer sheath extruded over the
bundle

NOTE See 4.3.7.

3.1.15
multiple configuration
riser system with more than one riser connected at a mid-depth location

3.1.16
ovalization
out-of-roundness of the pipe, calculated as follows:

Dmax − Dmin
Dmax + Dmin

where Dmax and Dmin are maximum and minimum pipe outside diameter, respectively.

3.1.17
piggy back
attachment of two parallel and adjacent independent pipes, rigid or flexible, over a significant length

3.1.18
prototype test
test to establish or verify a principal performance characteristic for a particular pipe design, which may be a
new or established design

3.1.19
rapid decompression
sudden depressurization of a system during which gas in the pipe expands rapidly and can cause blistering or
collapse of the internal pressure sheath or other gas-saturated layers

1) ISU™ is an example of a suitable product available commercially. This information is given for the convenience of
users of this part of ISO 13628 and does not constitute an endorsement by ISO of this product.

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ISO 13628-11:2007(E)

3.1.20
reel
large-diameter structure used for storage of long lengths of flexible pipe, which rotates about a horizontal axis

3.1.21
riser base
structure positioned on the seabed, used to provide a structural and pressure-tight connection between a
flexible riser and a flowline
NOTE 1 See 4.4.8.

NOTE 2 It may be a PLET or a PLEM.

3.1.22
riser hang-off
structure for supporting a riser at the connection to a platform
EXAMPLE Jacket, semi-sub, tanker, etc.

3.1.23
steep wave
lazy wave with a touchdown point fixed to the seabed
NOTE See Figure 4.

3.1.24
steep-S
lazy-S with a touchdown point fixed to the seabed
NOTE See Figure 4.

3.1.25
subsea buoy
concentrated buoyancy system
NOTE This system generally consists of steel or syntactic foam tanks, as used in S-type riser configurations (4.4.5).
See also buoyancy module (3.1.4).

3.1.26
tensioner
mechanical device used to support or apply tension to a pipe during installation

3.1.27
umbilical
bundle of helically or sinusoidally wound small-diameter chemical, hydraulic, and electrical conductors for
power and control systems

3.2 Symbols and abbreviated terms

The following symbols and abbreviated terms are used in this document.

CPE chlorinated polyethylene

CR polychloroprene

DA dynamic application

DBS dibutyl sebacate

DOF degrees of freedom

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ISO 13628-11:2007(E)

EPDM ethylene propylenediene monomer rubber

FAT factory acceptance test

FPS floating production system

FPSO floating production storage and offloading

HDPE high density polyethylene

HIC hydrogen-induced cracking

HNBR hydrogenated nitrile rubber

ID inside diameter

ISU integrated service umbilical

MBR minimum bend radius

MDPE medium density polyethylene

MWL mean water level

NBR nitrile butadiene rubber

NR natural rubber

OD outer diameter

PA polyamide

PE polyethylene

PP polypropylene

PLEM pipeline end manifold

PU polyurethane

PVC polyvinyl chloride

PVDF polyvinylidene fluoride

REF riser end fitting

ROV remotely operated vehicle

SA static application

SBR storage bend radius

SSC sulfide stress cracking

TFL through flowline

UV ultraviolet

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ISO 13628-11:2007(E)

VIV vortex-induced vibration

XLPE cross-linked polyethylene

Cd hydrodynamic drag coefficient

Cm hydrodynamic inertia coefficient

Dmax maximum pipe outside diameter

Dmin minimum pipe outside diameter

σu material ultimate stress

σy material yield stress

4 System, pipe, and component description

4.1 Introduction

4.1.1 General

Clause 4 provides a general overview of flexible pipe systems, pipe cross-section designs and ancillary
components. In addition, Clause 4 gives an overview of all aspects of flexible pipe technology and identifies
the clauses and subclauses of this part of ISO 13628 and of ISO 13628-2:2006 and ISO 13628-10:2005 to be
consulted for relevant issues.

In general, flexible pipe is a custom-built product that can be designed and manufactured in a variety of
methods. It is not the intent of this part of ISO 13628 to discourage novel or new developments in flexible pipe.
On the contrary, it is recognized that a variety of designs and methods of analysis are possible. For this
reason, some topics are presented in general terms to provide guidance to the user while still leaving open the
possibility of using alternative approaches.

The reader should be aware that flexible-pipe technology (concepts, design and analysis methodologies and
criteria, components manufacturing and testing, operational roles and demands, maintenance and inspection,
etc.) is in a state of rapid and continuing evolution. Potential users shall, therefore, apply care in their
application of the recommendations within this part of ISO 13628.

4.1.2 Recommended practice and specification overview

4.1.2.1 This part of ISO 13628 provides the current best practice for design and procurement of flexible
pipe systems and gives guidance on the implementation of the specification for standard flexible-pipe products.
In addition, the recommended practice shows guidelines on the qualification of prototype products.

4.1.2.2 All aspects of flexible-pipe technology, from functional definition to installation, are addressed in
either this part of ISO 13628 or in ISO 13628-2 and ISO 13628-10. Some issues are addressed in all three
documents. The various stages in the procurement and use of flexible pipes are defined in Figure 1.

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Figure 1 — Flexible pipe overview

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ISO 13628-11:2007(E)

4.2 Flexible pipe systems

4.2.1 Definition of system

4.2.1.1 The flexible pipe system is an important part of the overall field development and can influence or
be influenced by the design and specification of other components in the development. The definition of the
flexible pipe system should therefore commence at the initiation of the overall project as development
strategies evolve. Aspects of the development strategy that can influence the flexible pipe system include field
layout (template versus satellite wells) and production-vessel type (platform, tanker including turret location,
semi-sub, etc.). Current limitations in flexible-pipe technology, such as application range and manufacturing
capability, can also fundamentally influence potential overall field development options.

4.2.1.2 It is necessary to address the flexible pipe system and the flexible pipe or pipes within that system.
It is necessary to consider the relevant parameters, as well as the interactions between the pipe design and
the system design. Critical parameters that can affect the pipe design should be identified early in the process
and can include the following:

a) severe internal conditions, such as high H2S content (sour service);

b) extreme external environmental conditions;

c) difficult installation conditions (such as extreme environment);

d) frequent, cyclic, large-amplitude pressure and temperature fluctuations;

e) large vessel offsets.

4.2.1.3 To define accurately all relevant parameters, interaction between the purchaser and manufacturer
is required at an early stage in the project. An important aspect of this is the identification of critical system
issues, such as interfaces. See 7.6 for potentially critical interfaces that should be considered at project
commencement.

4.2.1.4 ISO 13628-2 and ISO 13628-10:2005, Annex A, provide purchasing guidelines, which may be
used in the definition of the flexible pipe system and which address all aspects from general design
parameters to detailed flowline- and riser-specific requirements.

4.2.2 Applications

4.2.2.1 General

4.2.2.1.1 Flexible pipe for offshore and onshore applications is grouped into either a static or dynamic
category (Figures 2 and 3). It is used for a multitude of functions, including the following:

a) production: oil, gas, condensate, water;

b) injection: water, gas, downhole chemicals;

c) export: semi-processed oil and gas;

d) services: wellhead chemicals, control fluids.

4.2.2.1.2 The static and dynamic categories place different physical demands on the pipe. While both
require long life, mechanical strength, internal and external damage resistance and minimal maintenance,
dynamic service pipes also require pliancy and high fatigue resistance.

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a) Early field production scheme b) Flowlines repositioned for mature field

production scheme

c) Flexible pipe connected to a J-tube d) Flexible pipe connected to the manifold

Key
1 J-tube
2 flexible pipe
3 rigid pipe
4 manifold
5 flexible pipe spool piece
6 rigid steel flowline

Figure 2 — Examples of static applications for flexible pipe

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ISO 13628-11:2007(E)

a) FPS b) FPS with rigid riser

c) Floating tanker/terminal mooring

Key
1 flexible riser
2 subsea buoy
3 rigid riser
4 anchor chain

Figure 3 — Examples of dynamic applications for flexible pipe

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4.2.2.2 Static applications

4.2.2.2.1 The use of flexible pipe for static applications is primarily for flowline and fixed jacket-riser service.
Flexible pipe is used in these applications to simplify design or installation procedures, or for its inherent
insulation or corrosion-resistant properties. In addition, reduction of installation and end-connection loads and
moments may be achieved using flexible pipe. Examples of where the use of flexible pipe results in simplified
flowline design or installation include the following (see Figure 2):

a) subsea flowline end connections where expensive or difficult operations, such as exact orientation
measurements for spool pieces or the use of large alignment equipment to reposition the flowline, can be
eliminated;

b) situations involving gross movements and damage to flowlines because of mudslides can be reduced
through the use of slack sections of flexible pipe;

c) applications in which field hardware and flowline location change with the field’s production characteristics,
which can necessitate the recovery and reuse of the flowlines;

d) applications with uneven seabed to avoid seabed preparation;

e) in deepwater or severe environment applications, where flexible pipe installation is economically attractive
relative to rigid pipe installation.

NOTE Instead of mobilizing an expensive pipe-laying spread, it is often preferable to use flexible pipe installed from a
dynamically positioned vessel.

4.2.2.2.2 Flexible pipe flowlines generally range in internal diameter from 0,05 m to 0,5 m (2 in to 20 in)
although some low-pressure, bonded flexible pipes, such as oil suction and discharge hoses, have internal
diameters up to 0,91 m (36 in). Section lengths are limited by transport capabilities and diameter is limited
only by current manufacturing capability.

4.2.2.2.3 The functional requirements of a flexible-pipe flowline are generally the same as for a steel-pipe
flowline. Significant dynamic loading or motions are generally not experienced, so the flexibility properties of
flexible pipe simplify the project transport and installation phases.

4.2.2.3 Dynamic applications

4.2.2.3.1 Dynamic applications use flexible pipe between supply and delivery points if there is relative
movement between these two points while in service. These types of applications usually involve an offshore
floating production facility or terminal connected to another floating facility, fixed structure or fixed base
(Figure 3). Examples of dynamic applications include the following:

a) flexible-pipe risers for offshore loading systems;

b) flexible-pipe riser connections between floating production facilities and subsea equipment.

4.2.2.3.2 Figure 4 illustrates schematics of the riser configurations typically used. In general, the critical
sections in the riser configurations are at the top (or bottom), where there are high tensile forces (and large
curvatures); at the sag bend, where there is large curvature (at low tension); and at the hog of a wave
buoyancy section, where there is large curvature (at low tension).

4.2.2.3.3 The present dynamic applications of flexible pipes have only been for the production phase.
However, with the advent of downhole motors, flexibles may also be used as drilling risers, as described by
FPS 2000 [23].

4.2.2.3.4 In addition to riser systems that use flexible pipe throughout, systems that combine flexible pipe
and rigid pipe in the flow path have been used. Described as hybrid riser systems, they typically use a lower
rigid-riser section (such as a free-standing riser) and an upper flexible-pipe section (jumper line).

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a) Free-hanging catenary

b) Steep-S c) Lazy-S

d) Steep wave e) Lazy wave

Figure 4 — Examples of flexible riser configurations

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ISO 13628-11:2007(E)

4.2.2.4 Jumper lines

4.2.2.4.1 In addition to flowlines and risers, jumper lines, a further category, may be used for either static or
dynamic applications. Examples of flexible pipes used in jumper-line applications include the following
(Figure 5):

a) static applications:

1) intra-field connection of wellheads and manifolds (typically in lengths less than 100 m),

2) connection of topside wellheads and platform piping on tension leg platforms (TLPs);

b) dynamic applications:

1) connection of wellhead platforms and floating support vessels,

2) lines in FPSO turret motion transfer systems.

4.2.2.4.2 The functions of the dynamic jumper lines (excluding internal turret lines) are similar to riser
systems. Their operation, however, is somewhat different. The lines are generally more exposed to wave
loading, and the configuration varies between the connected condition and the stand-off condition, which
imposes extra requirements on the end connectors and bend stiffeners. The performance of these
components should be evaluated carefully for dynamic jumper-line applications.

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