Integrity Assessment and On-Site Repair of a Floating Production Platform

Following the warning of a flooded bow horizontal brace of a semi-submersible production platform, an inspection diving team was mobilized and cracks were found at both bow and aft K-joints. Analysis of the service life of the platform, together with the results of structural analysis and local strain measurements, concluded that cracking was caused by fatigue initiated at high stress concentration points on the gusset plates inserted in the tubular joints. As a consequence of the fractured plates other cracks were nucleated close to the intersection lines of the braces that compose the K-joints. Based on this analysis different repair possibilities were proposed. To comply with the production goals of the Business Unit it was decided to repair the platform on-site and in production in agreement with the Classification Society. The proposed repair contemplated the installation of two flanges on the gusset plates between the diagonal braces by underwater wet (UWW) welding. Cracks at the gusset plates were also removed by grinding and wet welding. Defects located at the braces are being monitored and repaired by the installation of backing bars, by wet welding, followed by grinding and welding from the inside. To carry out the job two weld procedures and ten welder-divers were qualified.

Benchmarking of Truss Spar Vortex Induced Motions Derived From CFD With Experiments

Floating spar platforms are widely used in the Gulf of Mexico for oil production. The spar is a bluff, vertical cylinder which is subject to Vortex Induced Motions (VIM) when current velocities exceed a few knots. All spars to date have been constructed with helical strakes to mitigate VIM in order to reduce the loads on the risers and moorings. Model tests have indicated that the effectiveness of these strakes is influenced greatly by details of their design, by appurtenances placed on the outside of the hull and by current direction. At this time there is limited full scale data to validate the model test results and little understanding of the mechanisms at work in strake performance. The authors have been investigating the use of CFD as a means for predicting full scale VIM performance and for facilitating the design of spars for reduced VIM. This paper reports on the results of a study to benchmark the CFD results for a truss spar with a set of model experiments carried out in a towing tank. The focus is on the effect of current direction, reduced velocity and strake pitch on the VIM response. The tests were carried out on a 1:40 scale model of an actual truss spar design, and all computations were carried out at model scale. Future study will consider the effect of external appurtenances on the hull and scale-up to full scale Reynolds’ numbers on the results.

Validation of Wave Propagation in Numerical Wave Tanks

During the last few years there has been a strong growth in the availability and capabilities of numerical wave tanks. In order to assess the accuracy of such methods, a validation study was carried out. The study focuses on two types of numerical wave tanks: 1. A numerical wave tank based a non-linear potential flow algorithm. 2. A numerical wave tank based on a Volume of Fluid algorithm. The first algorithm uses a structured grid with triangular elements and a surface tracking technique. The second algorithm uses a structured, Cartesian grid and a surface capturing technique. Validation material is available by means of waves measured at multiple locations in two different model test basins. The first method is capable of generating waves up to the break limit. Wave absorption is therefore modeled by means of a numerical beach and not by mean of the parabolic beach that is used in the model basin. The second method is capable of modeling wave breaking. Therefore, the parabolic beach in the model test basin can be modeled and has also been included. Energy dissipation therefore takes place according to physics which are more related to the situation in the model test basin. Three types of waves are generated in the model test basin and in the numerical wave tanks. All these waves are generated on basin scale. The following waves are considered: 1. A scaled 100-year North-Sea wave (Hs = 0.24 meters, Tp = 2.0 seconds) in deep water (5 meters). 2. A scaled operational wave (Hs = 0.086 meters, Tp = 1.69 seconds) at intermediate water depth (0.86 meters) generated by a flap-type wave generator. 3. A scaled operational wave (Hs = 0.046 meters, Tp = 1.2 seconds) in shallow water (0.35 meters) generated by a piston-type wave generator. The waves are generated by means of a flap or piston-type wave generator. The motions of the wave generator in the simulations (either rotational or translational) are identical to the motions in the model test basin. Furthermore, in the simulations with intermediate water depth, the non-flat contour of the basin bottom (ramp) is accurately modeled. A comparison is made between the measured and computed wave elevation at several locations in the basin. The comparison focuses on: 1. Reflection characteristics of the model test basin and the numerical wave tanks. 2. The accuracy in the prediction of steep waves. 3. Second order effects like set-down in intermediate and shallow water depth. Furthermore, a convergence study is presented to check the grid independence of the wave tank predictions.

Sustained Load Cracking of Titanium Alloy Weldments

Failure of critical titanium parts, including some offshore components, has drawn attention to delayed cracking in Ti-6Al-4V alloys, but, given good design and alloy variant selection, such failures are avoidable. Delayed cracking, or sustained load cracking (SLC), can occur at low to moderate temperature (approximately: −50 to 200°C), depending on the titanium alloy and condition. Appropriate testing methods are required to generate stress intensity threshold values (KISLC) that can be incorporated into the design of titanium structures and recommendations are needed on the optimum chemistry and microstructure for greatest resistance. In the present work threshold stress intensity factor data (KISLC) were generated for Ti-6Al-4V alloy sheet, forgings, pipe and weldments using two different rising stress intensity factor test methods. It is concluded that material with a beta-annealed microstructure and low oxygen content (i.e. extra-low interstitial material such as ASTM Grades 23 and 29), has high resistance to SLC and that weld metal and transformed heat-affected zone also perform well, before and after postweld heat treatment, provided interstitial element pick-up during welding is prevented. Purchasing material in a general ‘mill annealed’ condition is not recommended without specifying acceptable microstructures. Further refinement of test method is also recommended for defining KISLC.

CFD Simulations of the Vortex-Induced Vibrations of Model Riser Pipes

The paper reports results from two strip theory CFD investigations of the Vortex-Induced Vibrations of model riser pipes. The first investigation is concerned with the vibrations of a vertical riser pipe that was subjected to a stepped current profile. An axial spatial resolution study was conducted to determine the number of simulation planes required to achieve tolerably converged numerical solutions. It was found that six to seven simulation planes are required per half-wavelength of pipe vibration in order to obtain convergence. The second investigation is concerned with the simultaneous in-plane and out-of-plane vibrations of a model Steel Catenary Riser that was subjected to a uniform current profile. The pipe’s simulated vibrations were found to agree very well with those determined experimentally. This result was achieved despite the questionable usage of simulation planes at high angles to the flow direction.

Laboratory Investigation of Environmentally Induced Cracking of API-X70 and X80 Pipeline Steels

Carbon steels, used in pipelines for the transport of oil and its derivatives, are frequently exposed to fluids. This can result in stress induced corrosion cracking (SCC) and/or hydrogen embrittlement (HE). The present paper evaluates the susceptibility of pipeline steels (API-X70 and API-X80) to SCC and HE, using a slow strain rate test (SSRT) based on the National Association of Corrosion Engineers’ (NACE) norm and a traditional standard NACE test. The (SSRT) method used, employed a sodium thiosulphate solution to evaluate susceptibility to HE, thereby offering a simpler experimental procedure than the standard NACE test. The results confirm the efficacy of the sodium thiosulphate as an H2S–SCC susceptibility test solution when utilised in SSRT testing. Though no secondary cracks were detected in the materials investigated, both steels were observed to suffer a ductility loss upon exposure to this solution. In NACE type tests, the test pieces were subjected to constant loading at 80% of σy. Fracture did not occur for these samples.

Three-Dimensional CFD Analysis of Two Circular Cylinders Arranged Perpendicular to Each Other

A three-dimensional numerical method combining solution of the incompressible Reynolds Averaged Navier-Stokes (RANS) equations with a rigid body structural dynamics response has been developed previously to aid in the prediction of the loads and motions of offshore structures. In this paper, we use the tool to compute the hydrodynamic flow around two tandem cylinders oriented perpendicularly to each other. The flow conditions and gap distances between the cylinders are chosen to match a set of water tunnel experiments carried out at the University of Queensland. Comparisons of Strouhal frequencies and example flowfield visualizations are presented between the experimental measurements and associated CFD results.

A 3-D Finite Volume Method for Green Water Calculations

A 3-D Finite Volume method (FV3D) is developed and applied to green water problems. The Navier-Stokes (N-S) equations are discretized with the 3-D finite volume method on collocated Cartesian grids. The free surface motion is captured with the Volume of Fluid (VOF) method. The velocity and pressure fields are solved by the SIMPLER scheme with an alternating direction implicit solver. FV3D is validated against existing experimental and numerical results for tank sloshing and ship green-water-on-deck cases. This method is applicable to calculation of the green water effect on advanced wave-piercing hull forms.

Effects of Local Metal Loss on Deformability of Line Pipes Subjected to Compressive Load

In this paper, the deformability of line pipe with local metal loss was examined. A full-scale experiment and a finite element (FE) analysis were carried out for line pipe with local metal loss subjected to an axial compressive load. As a result, a good agreement was obtained between the analytical and experimental results. This indicated that the present analytical method was applicable to evaluate the deformability of line pipes with local metal loss subjected to a large ground movement. Parametric studies were then conducted to clarify the relationship between the geometry of the local metal loss and the deformability using the FE analytical method.

West Sole Pipeline Stabilisation

The BP West Sole gas field is located in Block 48/6 in the UK sector of the southern North Sea, about 70 km off the Holderness coast. Production from the gas field is exported to a shore terminal at Easington by two pipelines. Both pipelines were trenched at installation. Pipeline surveys over the last few years show that both pipelines are substantially exposed at the shore approach and inshore sections. This has occurred in part due to the retreat of the cliffs in Easington and subsequent lowering of the sea bed level and also the migration of sand from around the pipelines leaving them largely unburied and sitting on the local clay abrasion platform. It has been concluded that both pipelines require stabilisation sooner rather than later to reduce the risk of pipeline failure. Pipeline stabilisation options need to take account of the environment in which they have been placed. Easington is at a critical position along the Holderness coast. All net sediment transport from the Holderness coastline passes through this section. Any interruption to this movement could result in a change to the adjacent coast. Maintenance of the sediment budget is important to a wider area of the East coast of England. Stabilisation options must not reduce the net amount of sediment moving southwards past Dimlington and must not result in any long term negative impact on the coastal evolution. This paper outlines consultancy required and problems process regarding the geomorphological issues in getting acceptance from government and non-government bodies. A methodology has been developed that allows quantification of impacts of different options on the sediment budget and on the long-term coastal evolution (see also Chen et al 1998, 2001 and 2002). Application of this method aimed at providing understanding and information which is considered to be important in the process of selecting an optimal solution for the pipeline stabilisation in such an environmental sensitive coast.