Subsea Wellhead System Design for Fatigue Performance

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1 Subsea Wellhead System Design for Fatigue Performance F. Justin Rodriguez 11 March March 2015 Subsea Drilling Services

2 Introduction to Fatigue Mechanics of the failure Dislocations accumulate near surface stress concentrations Generates stress risers where cracks initiate Cracks join together and begin to propagate through material Crack propagates to critical point when part can no longer sustain load Source: 1

3 Introduction to Fatigue Wellhead System Loading Loads generated due to: Waves (vessel motion & offset) Currents along water column Vortex-Induced Vibration (VIV) Loads cyclic in nature Transferred to wellhead system through riser 2

4 Fatigue Analysis Process Input Finite Element Analysis (FEA) Input: Geometry Owner: Equipment Manufacturer Riser Analysis Input: Rig, Weather Data Owner: Operator or Equipment Manufacturer Analysis Methodology Input: Industry Code or Internal Specification Owner: Operator Component Stress Response Cyclic Load Profile Calculation Methodology Fatigue Damage Calculation Owner: Equipment Manufacturer / Operator Output Accumulated Fatigue Damage Fatigue Life 3

5 Finite Element Analysis (FEA) Global model determines overall load transfer characteristics of the system 4

6 Finite Element Analysis (FEA) Sub models determine local stress response at each critical feature in the system 5

7 Fatigue Analysis Process Input Finite Element Analysis (FEA) Input: Geometry Owner: Equipment Manufacturer Riser Analysis Input: Rig, Weather Data Owner: Operator or Equipment Manufacturer Analysis Methodology Input: Industry Code or Internal Specification Owner: Operator Component Stress Response Cyclic Load Profile Calculation Methodology Fatigue Damage Calculation Owner: Equipment Manufacturer / Operator Output Accumulated Fatigue Damage Fatigue Life 6

8 Analysis Methodology Methods of Fatigue Assessment Stress-Life Approach (S-N Approach) Based on empirical material data Calculates accumulated damage due to cyclic loading Predicts life based on number of cycles to failure Heavily impacted by geometry optimization Fracture Mechanics approach Calculates crack growth in material due to cyclic loading Assumes initial flaw size Less sensitive to geometry optimization 7

9 Analysis Methodology Purpose of the analysis to determine the number of cycles in a given stress state a piece of material can endure before failure is predicted to occur 8

10 Analysis Methodology Accumulated damage Stress response raised to m-power m is an empirical constant Ranges from ~3 to 5 Small changes in stress response lead to large effects on the accumulated damage

11 Example: Design for Fatigue Performance 10

12 Design for Fatigue Performance Example: Geometry transitions are stress concentrations Cause increased stress response Sharp features are worst 11

13 Design for Fatigue Performance Stress vs. Load Decreasing the slope of the stress vs. load line is the goal 12

14 Design for Fatigue Performance Stress vs. Load σ = 1.00*L Radius = X Radius = 60X A small decrease in stress response can have a substantial effect on the fatigue life σ = 0.65*L 13

15 Design for Fatigue Performance Final Outcome: Fatigue life increased by factor of 5 to 8 depending on other assumptions No impact on function of the system Geometry modification is the only way to improve fatigue life of the wellhead system without potentially impacting other areas of operation 14

16 Conclusions 15

17 Fatigue Analysis Process Input Finite Element Analysis (FEA) Input: Geometry Owner: Equipment Manufacturer Riser Analysis Input: Rig, Weather Data Owner: Operator or Equipment Manufacturer Analysis Methodology Input: Industry Code or Internal Specification Owner: Operator Component Stress Response Cyclic Load Profile Calculation Methodology Output Geometry Modification: - Optimization of wellhead system geometry - No impact to operations Improves fatigue performance of the wellhead system in reality Interpretation of ocean data: Fatigue - Reduction Damage of conservatism Calculation Owner: Equipment Manufacturer / Operator - Tightening of watch circles - Restriction of operational envelopes Accumulated Fatigue Damage Does not actually improve the fatigue performance of the wellhead system Fatigue Life Modification of methodology: - Modification of material characteristics assumptions Does not actually improve the performance of the wellhead system 16

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