Failure analysis of articulated paddings at crossing interface between crossing cable and crossed pipeline

Abstract

While subsea crossings are undesirable for many reasons, they are unavoidable due to the sheer density of subsea assets . The use of articulated paddings is a cost-effective and practical method to achieve the required vertical separation between the crossing and the crossed pipelines or cables, though, not without limitations. In this paper, the failure of articulated padding at several points along a subsea cable in operation was investigated. The articulated padding has experienced partial fractures at numerous crossing locations and in some places has fallen off the cable completely. A complete failure mode analysis was conducted where several possible modes of failure were considered in detail. In-place finite element (FE) analyses of the articulated padding components and the corresponding environment were also performed. The FE modelling concluded that the original design loads were significantly lower than the expected worst-case load scenarios. To replicate the failure mode, two abrasion tests were also conducted and the results of which were studied. It was concluded that the predominant failure mode (partial fracture to the articulated padding discs) was likely a combination of the increased dynamic loads, excessive lateral movement causing unexpected levels of fretting, unbalanced free span causing unexpected stress concentration factors and reduction in material mechanical properties. All above factors have contributed to the root cause of the system failure and instigated the predominant mode of failure “partial fracture”.