Assessment of Fatigue Damage

Application to risers and umbilicals

Stefan Palm 07.05.2008

Objectives

Give introduction to principles for assessment of fatigue damage with reference to design codes and engineering practice Give an overview of typical fatigue loads, analysis methodology and fatigue capacity Show a few examples for typical riser configurations

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Typical riser fatigue assessment procedure

Task Define fatigue loading. Identify locations to be assessed. Global riser fatigue analysis. Local joint stress analysis. Identify fatigue strength data. Identify thickness correction factor. Fatigue analyses. Further actions if too short fatigue life.
Comment Based on operating limitations including WF, LF and possible VIV load effects. Structural discontinuities, joints (girth pipe welds, connectors, bolts), anode attachment welds, repairs, etc. Calculate short-term nominal stress range distribution at each identified location.

Determination of the hot-spot SCF from parametric equations or detailed finite element analysis. S-N curve depends on environment, construction detail and fabrication among others.

Apply thickness correction factor to compute resulting fatigue stresses.

Calculate accumulated fatigue damage from weighted short-term fatigue damage.

Improve fatigue capacity using: - more refined stress analysis - fracture mechanics analysis - change detail geometry - change system design - weld profiling or grinding - improved inspection /replacement programme

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Content

Fatigue loading Analyses methodologies Critical hotspots and SN-curves Damage calculation Combined damage from two different processes Fatigue considerations for typical riser configurations
- Steel Catenary Risers (SCR) - Top Tensioned Risers (TTR)

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Fatigue load history

Long-term description of individual waves
H \ T 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 10.5 11.5 12.5 13.5 14.5 15.5 16.5 17.5 18.5 19.5 20.5 21.5 22.5 23.5 24.5 25.5 26.5 27.5
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1.5 4 6 8 6563543 15665333 11341123 4560268 749462 9371771 12490552 6030618 38841 1991649 5671979 3978348 2557 326059 2059422 2267390 220 46297 655471 1161634 22 6170 187711 547886 2 776 48968 239758 90 11805 98656 8 2589 37831 1 540 13929 103 4931 18 1676 3 547 167 48 13 3 1

10 1584350 2014398 1481485 989181 639748 398108 240142 138934 77371 40916 20643 9997 4663 2095 903 371 145 55 20 7 2 1

12 569519 551039 396341 275053 183157 121309 80648 53372 35332 22965 14584 9023 5406 3137 1760 955 501 252 121 56 24 11 4 1

14 226896 147376 90799 61169 40824 27030 17611 11415 7446 4927 3357 2292 1565 1065 721 479 311 198 122 73 42 24 13 7 3 2 1

16 97258 42996 21387 12542 7931 5134 3327 2153 1362 861 561 363 239 160 109 74 50 33 22 15 10 6 4 3 1 1

18 44501 13543 4966 2308 1225 706 439 280 182 119 80 51 34 22 14 9 6 4 3 1 1

20 21500 4293 1136 397 175 81 43 24 15 10 6 4 2 2 1 1 1

22 10893 1370 254 61 20 7 3 1 1

24 5760 484 62 10 1

26 7722 313 24 1

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Content

Fatigue loading Analyses methodologies Critical hotspots and SN-curves Damage calculation Combined damage from two different processes Fatigue considerations for typical riser configurations
- Steel Catenary Risers (SCR) - Top Tensioned Risers (TTR) - Umbilical, Bellmouth area

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Global riser response analysis - Fatigue stress in steel pipe

Time histories of fatigue stress calculated for a selected number of hotspots around the pipe circumference at relevant locations along the riser

M y (t ) M x (t ) T (t ) r cos( ) + r sin( ) + (t ) = I I A
where
I= A=

(OD 64

ID 4

)
r t

(OD 2 ID 2 )

r is radius out to the location where the fatigue is to be checked (inside, outside or midwall)

steel pipe thickness used in stress calculation is normally reduced by half of the corrosion/wear allowance t=tsteel-0.5*tcorr

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Fatigue stress in component of flexible riser or umbilical

Simplified method often used where one assume that e.g. pipe in umbilical cross section is located at the center of the pipe having the same curvature as the global model:
- (t ) = x (t ) E r sin( ) + y (t ) E r cos( ) where is curvature and r is radius to hotspot e.g. (OD-t)/2 for midwall stress end E is module of elasticity

Calculation of stress in each component in cross section

- Need purpose made software to find relation between the global responses and stress in each component (i.e. cross section analyses) - Important to consider friction stress due to contact pressure

Testing of components and complete cross-sections required for designs outside previous experience

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SCR

umbilical
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flexible riser

Slide 8

Content

Fatigue loading Global Load Effect Analyses methodologies Fatigue analysis and SN-curves Damage calculation Combined damage from two different processes Fatigue considerations for typical riser configurations
- Steel Catenary Risers (SCR) - Top Tensioned Risers (TTR) - Umbilical, Bellmouth area

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Method for fatigue analysis

Fatigue analysis based on SN-data

- SN-data determined by fatigue testing of considered weld detail - based on linear cumulative damage - most commonly used for risers

Fatigue analysis based on Fracture Mechanics

- used as supplement to SN data - document sufficient time interval from crack detection during inspection and time of unstable fracture - document that fatigue cracks occuring during operation will not exceed the crack size corresponding to unstable fracture

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Fatigue capacity for constant stress range

The basic fatigue capacity is given in terms of S-N curves expressing the number of stress cycles to failure, N, for a given constant stress range, S:

N = aS

where a and m are empirical constants established by experiments.

1000

log()=intercept of log N-axis m= negative inverse slope)

Stress range, S

Equivalently:

100

log( N) = log(a ) m log(S)

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10

1 1.00E+04 1.00E+05 1.00E+06 1.00E+07 1.00E+08 1.00E+09

1.00E+10

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Num ber of cycles, N

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Corrosion fatigue test set-up

Test specimen with corrosion chamber

Testing setup with 4 segment specimens linked together

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Pipieline girth weld test specimen

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1000

Stress range (MPa)

RP C203, original N 100 Failure Design curve

10 1,E+04

1,E+051,E+05 1,E+06

1,E+07 1,E+06

1,E+08 1,E+07

1,E+08

Number of load Number cycles of load cycles

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Fatigue cracking failure modes

fatigue cracking from weld toes/roots into the base material

frequent failure mode most common weld in risers is symmetric, single sided with welding from outside more difficult to inspect/have control of the root weld toe discontinuities generally present and behave like pre-excisting crack crack initiation time short

fatigue cracking from a surface irregularity or notch into the base material (e.g corrosion)
- concern for components with stress cycles of high magnitude - crack initiation time is long, crack propagation time is short

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Fatigue crack growth

Crack size

Large defect/Unstable fracture

Base material

Initiation period Ni
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Propagation period
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Crack size

Large defect/Unstable fracture

Weld

Base material

Ni (weld)
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Ni
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Fatigue crack growth Paris law

Paris law:

da = C ( K ) m dN

K = g a
K a g C m stress MPa stress intensity factor MPam-1/2 crack length/size m function dependent on crack size and geometry (e.g. presence of stress concentrations) dimensionless constant dimensionless constant (typically in the range 3-5)

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Fatigue crack growth testing

2 off compact tension crack growth test specimens instrumented with strain gauges

Testing arrangement showing corrosion chambers

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Compact tension specimen fatigue crack growth

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Measurement of crack growth rate

Base Material - Sea Water 1,E-02

1,E-03 da/dN mm/cycle

1,E-04

1,E-05

1,E-06 1 10 dK MPam1/2
Base Material 5+6 Regres BS-B BS-B +2 sd BS-A BS-A +2sd

100

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Fatigue crack growth

20 18

16

14

C r a c kh e ig h t, a[m m ]

12

da = C (K ) m dN

10

Crack growth, Ds=40MPa, a0=2mm Crack growth, Ds=50MPa, a0=2mm Crack growth, Ds=60MPa, a0=2mm

0,E+00

5,E+05

1,E+06 Number of cycles, N

2,E+06

2,E+06

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Fatigue crack growth intiation period

Crack size

Macroscopic defect Initiation period Propagation period

Ni
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Examples of Riser fatigue critical hotspots

Threaded connectors
- example of use: coupling between riser joints in C/WO and drilling risers - critical location: hotspot with SCF>1 at transition between pipe and connection

Bolted flanges
- example of use: coupling between riser joints in permanent TTR - critical location: weld between flange and pipe, flange w/bolts

Welds
- example of use: SCR - critical location: weld root and cap

Base material in the pipe

- critical location: areas with large responses

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Selection of SN curves

construction details; fabrication process welded, clad, forged, machined, etc; base material or weld; welds - hotspots on the inner surface and outer surface weld details and tolerances, weld type (welding with or without backing, double sided weld); stress concentration factors from concentricity, thickness variations, out of roundness and eccentricity; angularity; environment - air, free corrosion or cathodic protection in sea water.

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Weld classes DNV RP C203

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Weld classes DNV RP C203

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SN-curves

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SN-curves (DNV RP-C203)

Non-welded sections: B1 SN-curve Longitudinal seam weld: B2 SN-curve Cast nodes: C SN-curve Forged nodes:
An SCF is used that accounts for the actual fabrication tolerances.
Eq. (2.9.1)

B1 SN-curve if DFF=10 C SN-curve if DFF < 10

Eq. (2.9.1)

The nominal stress on the outside of the pipe to be used for fatigue assessment of outside hotspots The nominal stress on the inside of the pipe to be used for 30 April 2009 Version fatigue assessment of the inside hotspots
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Fabrication tolerances
Stress concentration factor due to fabrication tolerance:

SCF = 1 +

3( 0 ) t

Eq. (2.9.1)

is total eccentricity (thickness + ovality) 0 is eccentricity inherent in SN data (=0.1t) t is pipe thickness D is pipe outer diameter Total eccentricity is sum of fabrication tolerance of thickness and ovality:

thickness = (t max t min ) / 2 ovality = Dmax Dmin

(no pipe centralisation) (pipe centralisation during contruction) (pipe centralisation during contruction and rotated until good fit)
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ovality = ( Dmax Dmin ) / 2 ovality = ( Dmax Dmin ) / 4

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Eccentricity

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Thickness effect
Fatigue strength of welded joints to some extent dependent on thickness Reduced capacity due to increased local stress in toe for increased thickness Thickness effect accounted for by modification of the stress
1.15

1.10

1.05

1.00

Reference thickness tref=25mm k is thickness exponent (recommended k=0.15 for pipes)

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(t/t ref) k

0.95

0.90

0.85

tref=0.025, k=0 tref=0.025, k=0.15

0.80 0.000

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0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

pipe thickness t (m )

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0.060

S-N curves for different environment (media)

1000

DNV F1-curve CP DNV F1-curve in air DNV F1-curve free corrosion

Stress range (MPa)

factor 1.2
100

factor 3

factor 4.5

10 1.00E+04 1.00E+05 1.00E+06 1.00E+07 1.00E+08 1.00E+09

Num ber of cycles

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Bi-linear S-N curves

1000

(a1;m1)
Stress Range, S 100

SSW (a2;m2)

a1 S m1 N= m2 a 2 S

S > Ssw S Ssw

10

Ssw = 10
NSW
1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 1.E+09 1.E+10

log( a1 )log( Nsw ) m 1

1 1.E+03

Log(Nsw) is typically 6-7

No of cycles, N

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SN-curves Umbilicals/flexible risers

Project specific data based on testing applied for:

- armour wires (flexible risers, umbilical) - copper conductors (umbilicals) - super duplex pipes (umbilicals) - DNV-RP-C203 => SN-curve for small diameter super duplex steel pipe (pipe OD=10-100 mm)

Sn-curve applicable for umbilicals that have been reeled: number of cycles under reeling < 10 strain range during reeling < 2%
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When to use SN-curves and da/dN ?

SN-curves: The detail has to be specified and possible to be represented by one of the classes. Alterantively, component specific design curve can be established by testing.

Fatigue crack growth caclulcations (da/dN): The initial and final crack sizes have to be known. Crack growth parameters in Paris law, m and C, has to be known. Some standardised m/C values given in BS 7910. Otherwise, have to be determined by testing. Detailed stress distribution has to be known
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Content

Fatigue loading Analyses methodologies Critical hotspots and SN-curves Damage calculation Combined damage from two different processes Fatigue considerations for typical riser configurations
- Steel Catenary Risers (SCR) - Top Tensioned Risers (TTR) - Umbilical, Bellmouth area

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30 April 2009

Slide 41

Fatigue capacity for variable stress range

The Miner-Palmgren rule is adopted for accumulation of fatigue damage from stress cycles with variable range:

n( S i ) D= i N ( Si )
n(Si) : Number of stress cycles with range Si N(Si) : Number of stress cycles to failure given by S-N curve D : Fatigue damage : Usage factor (0.1-0.3)

Equivalently:
D=
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1 m n ( S ) S i i a i

Single slope S-N curve

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Fatigue analysis - Short term fatigue damage

Long term stress range distribution:
Block no. Stress range () 1 2 3 4 5 6 7 8 : : : Nb 120-130 3 0-10 10-20 20-30 30-40 40-50 50-60 60-70 70-80

Number of stress blocks (Nb) and each block stress range () calculated from the analysis. Number of stress cycles (ni) with range is counted Number of stress blocks (Nb) should not be less than 20 Total fatigue damage for the short term sea state found by summation (Palmgren-Miner):

Number of cycles (ni) 1928372 2342732 1338753 453132 34321 4332 433 223

Dshort _ term

1 m = ni (SCF i ) a i =1
Nb

Example of stress histogram for one seastate

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Damage accumulation fatigue crack growth calculation

20

18

Nf
Unstable fracture D = (Number of load cycles)/Nf

16

14

C r a c kh e ig h t, a[m m ]

12

da = C (K ) m dN

10

Crack growth, Ds=40MPa, a0=2mm Crack growth, Ds=50MPa, a0=2mm Crack growth, Ds=60MPa, a0=2mm

0,E+00

5,E+05

1,E+06 Number of cycles, N

2,E+06

2,E+06

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Damage accumulation
Crack size

Large defect/Unstable fracture

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Detailed fatigue analysis necessary?

A detailed fatigue analyses can be omitted if the largest local stress range is less than the stress range at 1.107 cycles (i.e. fatigue limit) Guidance applicable for air and seawater with cathodic protection (i.e. two sloped curves) In case of DFF > 1.0, the allowable fatigue limit needs to be reduced by a factor (DFF)-1/3 If one cycle is above the fatigue limit, fatigue damage from all stress cycles has to be included
Detailed fatigue assessment can be omitted Detailed fatigue assessment required

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Fatigue analysis - Short term fatigue damage

Rainflow counting:

Number of cycles (Nc) in stress time series and stress ranges () calculated by Rainflow counting Fatigue damage calculated for each cycle and total fatigue damage for the short term sea state found by summation (Palmgren-Miner):

Dshort _ term

1 m = (SCF i ) a i =1
Nc

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Fatigue analysis - Long term fatigue damage

Long term fatigue damage as a weighted sum of short term fatigue damages:

DL = Dij Pij
j =1 i =1
where
DL accumulated long-term fatigue damage at given location Dij Short term fatigue damage for seastate i in direction j Pij Probability of occurrence for seastate i in direction j Nd number of wave directions Ns number of sea-states in the wave scatter diagram

Nd

Ns

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Design Fatigue factors

Steel risers:

Design fatigue factors (DFF) versus Safety Class (DNV OS F201)

Low (API-RP-2RD) 3.0 Normal 6.0 High(API-RP-2RD) 10.0

Flexible risers and umbilicals => DFF=10 Fatigue criterion:

DL DFF 1
A risk based fatigue criterion benchmarked against reliability analyses is outlined in DNV RP-F204 Riser Fatigue. Relevant for novel concepts to evaluate the standard DFF and relative importance of each parameter.
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Reflection : Desired properties of integration scheme

Need good physical understanding of the system to select proper analysis methodology Simplified analysis methods need validation Three important contributions to fatigue damage are wave-induced, low-frequency and vortex-induced stress cycles Recommended SN-curves and SCFs for relevant riser/pipeline geometries is given in DNV-RP-C203 Methods for improving fatigue capacity.

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Improving fatigue performance

Reduce stress concentrations

Change geometry: tapering, increase fillet radius, Grinding

Remove defects
Grinding NDT - repair

Reduce stress level

Reduce global response Reduce stress concentrations Increase dimensions

Reduce number of load cycles

Use a bend stiffener instead of a bellmouth

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References

Dynamic Risers. Offshore Standard DNV-OS-F201. October 2003 Submarine Pipeline Systems. Offshore Standard DNV-OS-F101. October 2007 Riser Fatigue. Recommended Practice DNV-RP-F204. July 2005 Fatigue Design of Offshore Steel Structures. Recommended Practice DNV-RP-C203. October 2006 Environmental Conditions and Environmental Loads. Recommended Practice DNV-RP-C205. October 2007

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References

Faltinsen, O.M. Sea Loads on Offshore Structures. Cambridge University Press Tucker, M.J. & Pitt, E.G. (2001) Waves in Ocean Engineering. Elsevier Ocean Engineering Book Series. Vol. 5 Ochi, M. (1998) Ocean Waves The stochastic approach. Cambridge Ocean Technology Series 6. Cambridge University Press. Sarpkaya, T. and Isaacson, M. (1981) Mechanics of wave forces on offshore structures. Van Nostrand Reinhold Co.

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References

Sparks, C.S. The Influence of Tension, Pressure and Weight on Pipe and Riser Deformations and Stresses. Transactions of the ASME. Vol. 106. March 1984. pp.46-54 Newland, D.E. An Introductin to Random Vibrations and Spectral Analysis. Longman Scientific and Technical Blevins, R.D. Flow-Induced Vibration. Krieger Publishing Company

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