Tailored design of top-tensioned composite risers for deep-water applications using three different approaches

Abstract

Risers with high-grade steel are widely used in offshore oil and gas industry at present. The extreme weight, lower fatigue and corrosion resistance of steel risers significantly limited the exploitation depths and the production capacity. Nowadays, it is acknowledged that using fibre-reinforced polymer composites to manufacture risers can be a better option. The prototypes of composite risers fabricated and tested confirm that fibre-reinforced polymer composites have an obvious advantage over steel risers on weight saving. Three different approaches are developed here to minimise composite risers’ weights: (1) enhancing the riser with only axial-direction and hoop-direction fibre; (2) off-axis reinforcements are included using an iterative approach of manual inspection and selection and (3) employing the optimisation technique of surrogate-assisted evolutionary algorithm. These design approaches have been applied to eight different material combinations to achieve the minimum structural weight by optimising their laminate configurations. The designs are conducted in accordance with the Standards, considering both local load cases and global – functional as well as environmental loads using ANSYS 15.0. The results show that comparing with steel risers, weight savings achieved by different design approaches and material combinations are different.