Offshore Steel Structures Research Articles

Fatigue Evaluation of Offshore Steel Structures Considering Stress Concentration Factor

The installation of offshore structures and facilities in the marine environment, usually for the production and transmission of oil, gas exploration, electricity, and other natural resources is referred to as offshore construction. Since offshore structures are subjected to changing threats to the environment year-round. Fatigue behavior prediction noticed on these structures should be considered during the design stage. Fatigue is one of the failure mechanisms of offshore steel structures, and it must be investigated properly during system design. The fatigue analysis of offshore structures under drag wave force, total wave force, total moment about the sea bed, and other variables are reviewed thoroughly. The structure's dynamic response becomes a critical aspect in the whole design process. The fatigue analysis was carried out using MATLAB software, material properties of the offshore structure, and wave spectrum characteristics in this study. This study shows the JONSWAP spectrum and stress concentration analysis prediction. The offshore support structure that is predicted during the design phase will help to keep the stress concentration factor below the fatigue threshold and anticipate safe life design, according to the results of the fatigue study. The fatigue performances of tripod and jacket steel support structures in intermediate waters depth are compared in this project (20-50 m). The North Atlantic Ocean is used as a reference site, with a sea depth of 45 meters. The tripod and jacket support structures will be designed by using current industry standards. Keywords: [Fatigue evaluation, North Atlantic Ocean and Failure].

Reliability Improvement of Offshore Structural Steel F690 Using Surface Crack Nondamaging Technology

Microcracks can rapidly grow and develop in high-strength steels used in offshore structures. It is important to render these microcracks harmless to ensure the safety and reliability of offshore structures. Here, the dependence of the aspect ratio (As) of the maximum depth of harmless crack (a<sub>hlm</sub>) was evaluated under three different conditions considering the threshold stress intensity factor (ΔK<sub>th</sub>) and residual stress of offshore structural steel F690. The threshold stress intensity factor and fatigue limit of fatigue crack propagation, dependent on crack dimensions, were evaluated using Ando's equation, which considers the plastic behavior of fatigue and the stress ratio. a<sub>hlm</sub> by peening was analyzed using the relationship between ΔK<sub>th</sub> obtained by Ando's equation and ΔK<sub>th</sub> obtained by the sum of applied stress and residual stress. The plate specimen had a width 2 W = 12 mm and thickness t = 20 mm, and four value of As were considered: 1.0, 0.6, 0.3, and 0.1. The a<sub>hlm</sub> was larger as the compressive residual stress distribution increased. Additionally, an increase in the values of As and ΔK<sub>th(l)</sub> led to a larger a<sub>hlm</sub>. With a safety factor (N) of 2.0, the long-term safety and reliability of structures constructed using F690 can be secured with needle peening. It is necessary to apply a more sensitive non-destructive inspection technique as a non-destructive inspection method for crack detection could not be used to observe fatigue cracks that reduced the fatigue limit of smooth specimens by 50% in the three types of residual stresses considered. The usefulness of non-destructive inspection and non-damaging techniques was reviewed based on the relationship between a<sub>hlm</sub>, a<sub>NDI</sub> (minimum crack depth detectable in non-destructive inspection), a<sub>cr N</sub> (crack depth that reduces the fatigue limit to 1/N), and As.

Formation and Properties of Superhydrophobic Al Coatings on Steel.

Thermal sprayed aluminum coatings are widely scalable to corrosion protection of the offshore steel structure. However, the corrosion rate of the Al coating increases considerably due to the severe marine environment. It has remained a challenge to improve the corrosion resistance and protective ability of Al coatings. The superhydrophobic surface provides a potential way to improve the corrosion resistance of metal materials. Hence, the development of superhydrophobic Al coatings with superior corrosion resistance is of great interest. In this work, the feasibility of the preparation of superhydrophobic Al coatings on a steel substrate was explored. First, Al coatings were prepared onto the steel substrate by the arc-spraying process, followed by ultrasonic etching with 0.1 M NaOH solution, and afterward passivated using 1% fluorosilanes. The effects of the etching time on morphology, contact angle, and corrosion resistance of the Al coatings were evaluated. The schematic model of the fluorosilane passivation process on the Al coating surface was provided. The micro/nanoscale surface structure of the low-surface-energy fluorosilanes promotes the wetting angle of 153.4° and a rolling angle to 6.6°, denoting the superhydrophobic properties. The superhydrophobic Al coating surface displays excellent self-cleaning performance due to its weak adhesion to water droplets. The corrosion current density of the superhydrophobic Al coating (1.36 × 10–8 A cm–2) is 2 orders of magnitude lower than that of the as-sprayed Al coating (1.18 × 10–6 A cm–2). Similarly, the charge-transfer resistance is found to be 12 times larger for the superhydrophobic Al coating and the corresponding corrosion inhibition efficiency reaches 98.9%. The superhydrophobic Al coating displays superior corrosion resistance and promising applications in a marine corrosion environment.

A study on the use of fireproof protection in offshore topside steel structures subject to localised fires

A study on the use of fireproof protection in offshore topside steel structures subject to localised fires

Geometrical effects on the degree of bending (DoB) of multi-planar tubular KK-joints in jacket substructure of offshore wind turbines

The degree of bending (DoB) characterizes the member through-the-thickness stress distribution which has a profound effect on the fatigue behavior of tubular joints commonly found in steel offshore structures and the determination of DoB values is essential for improving the accuracy of fatigue life estimation. Multi-planar joints are an intrinsic feature of offshore tubular structures and the multi-planarity might have a considerable effect on the DoB values at the brace-to-chord intersection. Nevertheless, for multi-planar joints which cover the majority of practical applications, much fewer investigations have been reported on the DoB due to the complexity and high cost involved. In the present research, data extracted from the stress analysis of 243 finite element (FE) models, verified based on available parametric equations, was used to study the effects of geometrical parameters on the DoB values in multi-planar tubular KK-joints which are among the most common joint types in jacket substructure of offshore wind turbines (OWTs). Parametric FE study was followed by a set of nonlinear regression analyses to develop three new DoB parametric equations for the fatigue analysis and design of axially loaded multi-planar KK-joints.

The State of the Art of Underwater Wet Welding Practice: Part 2

Developments in underwater wet welding (UWW) over the past four decades are reviewed, with an emphasis on the re-search that has been conducted in the last ten years. Shielded metal arc welding with rutile-based coated electrodes was established as the most applied process in the practice of wet welding of structural steels in shallow water. The advancements achieved in previous decades had already led to control of the chemical composition and microstructure of weld metals. Research and development in consumables formulation have led to control of the amount of hydrogen content and the level of weld porosity in the weld metal. The main focus of research and development in the last decade was on weldability of naval and offshore structural steels and acceptance of welding procedures for Class A weld classification according to American Welding Society D3.6, Underwater Welding Code. Applications of strictly controlled welding techniques, including new postweld heat treatment procedures, allowed for the welding of steels with carbon equivalent values greater than 0.40. Classification societies are meticulously scrutinizing wet welding procedures and wet weld properties in structural steels at depths smaller than 30 m prior to qualifying them as Class A capable. Alternate wet welding processes that have been tested in previous decades — such as friction stir welding, dry local habitat, and gas metal arc welding — have not achieved great success as originally claimed. Almost all of the new UWW process developments in the last decade have focused on the flux cored arc welding (FCAW) process. Part 1 of this paper covered developments in microstructural optimization and weld metal porosity control for UWW. Part 2 discusses the hydrogen pickup mechanism, weld cooling rate control, design, and qualification of consumables. It ends with a description of the advancements in FCAW applications for UWW.

The State of the Art of Underwater Wet Welding Practice: Part 1

Developments in underwater wet welding (UWW) over the past four decades are reviewed, with an emphasis on the research that has been conducted in the last ten years. Shielded metal arc welding with rutile-based coated electrodes was established as the most applied process in the practice of wet welding of structural steels in shallow water. The advancements achieved in previous decades had already led to control of the chemical com-position and microstructure of weld metals. Research and development in consumables formulation have led to control of the amount of hydrogen content and the level of weld porosity in the weld metal. The main focus of research and development in the last decade was on weldability of naval and offshore structural steels and acceptance of welding procedures for Class A weld classification according to American Welding Society D3.6, Under-water Welding Code. Applications of strictly controlled welding techniques, including new postweld heat treatment procedures, allowed for the welding of steels with carbon equivalent values greater than 0.40. Classification societies are meticulously scrutinizing wet welding procedures and wet weld properties in structural steels at depths smaller than 30 m prior to qualifying them as Class A capable. Alternate wet welding processes that have been tested in previous decades — such as friction stir welding, dry local habitat, and gas metal arc welding —have not achieved great success as originally claimed. Al-most all of the new UWW process developments in the last decade have focused on the flux cored arc welding (FCAW) process. Part 1 of this paper covers developments in microstructural optimization and weld metal porosity control for UWW. Part 2 discusses the hydrogen pickup mechanism, weld cooling rate control, design, and qualification of consumables. It ends with a description of the advancements in FCAW applications for UWW.

Prediction of Thermal Spray Coatings Performance in Marine Environments by Combination of Laboratory and Field Tests

Cost-effective corrosion mitigation of offshore steel structures can be achieved by thermal spray coatings. These coatings, when comprised of Al, Zn and their alloys, provide a physical barrier against the environment when intact, and cathodic protection to underlying steel when damaged. Due to the complexity of marine environments, laboratory tests should be combined with field work in order to understand the corrosion protection offered by these coatings. The work presented here was carried out with thermal spray coatings of aluminum alloys (AA1050, AA1100, Al-5Mg) and Zn-15Al prepared by Twin Wire Arc Spray onto low carbon steel substrates. The resulting coatings were ~300 μm in thickness, and 5% of surface area defects were artificially machined in order to expose the steel substrate, simulating mechanical damage or erosion of the coating. Electrochemical data collected over a 90 days period showed a good correlation between laboratory and real marine environment results. Aluminum alloys showed better corrosion protection in fully immersed conditions, while zinc alloys performed better in atmospheric and splash zones. Overall, these results aim to improve design of thermal spray coatings to protect carbon steel in marine environments.

Shear behaviour of cold-formed stainless-steel beams with web openings: Numerical studies

Cold-formed stainless-steel (CFSS) sections are increasingly popular for architectural and structural applications, especially in the corrosive environment due to its resistance to corrosion and other various benefits. The combination of stainless-steel material properties and the lightweight section properties makes the CFSS section the right choice for offshore steel structures. The demand for the stainless-steel sections in the construction industry is limited to a certain extent due to the higher cost; thus, the optimal use of stainless steel is vital. Openings to the web of CFSS Lipped Channel Beams (LCB) are introduced to facilitate the building services to reduce the floor height. Subsequently, the shear capacity is reduced due to the reduction of the web area. However, only very limited researches have been conducted so far to predict the reduced shear capacity of CFSS LCBs with circular web opening. Hence, this paper addresses a numerical study to investigate the shear behaviour and strength of cold-formed austenitic grade 1.4301 and duplex grade 1.4462 stainless steel LCB sections with unreinforced circular web openings. A detailed parametric study was carried out by developing 180 Finite Element Analyses (FEA) models to establish a wide-ranging shear strength database following the validation process with available shear test results. The analysis of the numerical results showed that the currently available reduction factor equations are either conservative or unsafe to use for the CFSS LCBs with circular openings. Hence, three sets of equations with different approaches to predict the shear capacity of CFSS LCBs with circular web opening are developed and presented in this paper.

Thermomechanical performance of offshore topside steel structure exposed to localised fire conditions

This work reports the results of a numerical investigation aiming at assessing the structural safety of an actual offshore topside steel structure exposed to accidental localised fire conditions. Particularly, the paper explores the nonlinear thermomechanical and ultimate strength behaviours obtained by means of two fire approaches: sophisticated CFD (Computational Fluid Dynamics) and “LF-ESF” (Localised Fire with Ellipsoidal Solid Flame), previously developed and validated by the authors. CFD-based approaches, which typically solve nearly compressible flow with input energy given by a combustion model, allow accurate evaluation of a fluid-thermo response for the entire duration of the simulated accident. However, the analysis complexity, massive amount of produced data, excessive computational and time-consuming make CFD approaches unsuitable for the current applied design usage. On the other hand, the proposed LF-ESF approach displays quite accurate estimates in comparison to CFD counterparts. Moreover, the LF-ESF can be directly modelled in FE-based commercial software and used to obtain the steel temperature variation and thermomechanical behaviour. The obtained results indicate that the LF-ESF approach combined with FE-based models can provide reliable fire-safety analyses, ensuring that the main safety (load-bearing) functions of the offshore steel structures are not impaired during accidental fire conditions.

Weldability of offshore structural steel grades S355MLO and S420MLO, produced by TMCP with accelerated cooling and used for offshore wind turbines of new generation

Weldability of offshore structural steel grades S355MLO and S420MLO, produced by TMCP with accelerated cooling and used for offshore wind turbines of new generation

Effects of geometrical parameters on the degree of bending (DoB) in multi-planar tubular XT-joints of offshore structures subjected to axial loading

The degree of bending (DoB) characterizes the member through-the-thickness stress distribution which has a profound effect on the fatigue behavior of tubular joints commonly found in steel offshore structures and the determination of DoB values is essential for improving the accuracy of fatigue life estimation. Multi-planar joints are an intrinsic feature of offshore tubular structures and the multi-planarity might have a considerable effect on the DoB values at the brace-to-chord intersection. Nevertheless, for multi-planar joints which cover the majority of practical applications, much fewer investigations have been reported on the DoB due to the complexity and high cost involved. In the present research, data extracted from the stress analysis of 81 finite element (FE) models, verified using available parametric equations, was used to study the effects of geometrical parameters on the DoB values in multi-planar tubular XT-joints subjected to two types of axial loading. Parametric FE study was followed by a set of the nonlinear regression analyses to develop four new DoB parametric equations for the fatigue analysis and design of axially loaded multi-planar XT-joints.

Hydrogen in Aluminium-Coated Steels Exposed to Synthetic Seawater

Thermally sprayed aluminium (TSA) coatings provide protection to offshore steel structures without the use of external cathodic protection (CP) systems. These coatings provide sacrificial protection in the same way as a galvanic anode, and thus hydrogen embrittlement (HE) becomes a major concern with the use of high strength steels. The effect of TSA on the HE of steel seems to remain largely unknown. Further, the location of hydrogen in TSA-coated steel has not been explored. To address the above knowledge gap, API 5L X80 and AISI 4137 steel coupons, with and without TSA, were prepared and the amount of hydrogen present in these steels when cathodically polarised to −1.1 V (Ag/AgCl) for 30 days in synthetic seawater was determined. One set of TSA-coated specimens was left at open circuit potential (OCP). The study indicates that the amount of hydrogen present in TSA-coated steel is ~100 times more than the amount found in uncoated steel, and that the hydrogen seems to be largely localised in the TSA layer.

Dynamic response of offshore triceratops with elliptical buoyant legs

Oil and gas exploration in ultra-deepwaters necessitates innovative geometric forms for offshore steel structures. Offshore triceratops is one of a new steel compliant structures found suitable for ultra-deepwater applications. It consists of three buoyant legs attached to the deck by ball joints, which partially isolate the deck from the buoyant legs and constitute the novelty. The present study discusses a detailed numerical analysis of triceratops with buoyant legs of elliptical cross section. The focus is to assess the hydrodynamic diffraction characteristics of the platform caused by the change in cross section of buoyant legs from a conventional tubular one to the elliptical ones. Three elliptical sections with varying eccentricities are considered in the dynamic analyses to assess the response behavior of triceratops under regular waves. The results showed an increase in the total force in the buoyant legs in sway degree of freedom with the increase in the eccentricity of the cross section. Besides, reduced transverse vibrations and increased stability are also observed in both the deck and elliptical buoyant legs. Based on the numerical results, it is recommended that elliptical buoyant legs with eccentricity close to 2 are highly suitable for offshore triceratops in ultra-deepwaters.

Degree of bending (DoB) in offshore tubular KT-joints under the axial, in-plane bending (IPB), and out-of-plane bending (OPB) loads

Through-the-thickness stress distribution characterized by the degree of bending (DoB) has a major effect on the fatigue behavior of tubular joints commonly found in steel offshore structures. The determination of DoB values is essential for improving the accuracy of fatigue life estimation using the stress-life (S–N) method and particularly for predicting the fatigue crack growth based on the fracture mechanics (FM) approach. In the present research, data extracted from 648 finite element (FE) analyses carried out on 81 tubular KT-joint models was used to study the effects of geometrical parameters on the DoB values in KT-joints subjected to eight different types of loading including two types of axial loading, three types of in-plane bending (IPB) moment loading, and three types of out-of-plane bending (OPB) moment loading. Generated FE models were validated using experimental data, previous FE results, and available parametric equations. Geometrically parametric investigation was followed by a set of nonlinear regression analyses to develop 21 parametric design formulas for the calculation of the DoB in tubular KT-joints under the axial, IPB, and OPB loadings.

Hybrid Finite Element Method Development for Offshore Structures’ Calculation with the Implementation of Industry Standards

Abstract In the design process of offshore steel structures, it is typical to employ commercial calculation codes in which simulation and evaluation of results are performed on the basis of the available standards (e.g. API, DNV, Lloyds). The modeling and solution rely on finite element methods and cover the simulation of the structure’s properties along with the influence of the marine environment – sea currents, wave and wind loading, as well as the influence of vibrations, buoyancy and accompanying mass of water. Both commercial and open source mathematical modeling software which is available nowadays allows for cost effective and flexible implementation of advanced models for offshore industrial structures with high level of credibility and safety. The models can be built to suit task-specific requirements and evaluated on the basis of the selected criterial system best suited to the needs of the customer. Examples of methodology for environmental and structural model development are presented, along with simulation results covering a wide scope of data, ranging from stress and deformation to resonant characteristics and issues of technological feasibility.

Creep investigations on adhesively bonded fasteners developed for offshore steel structures

Fastening or reinforcement onto an existing steel structure may create constraints such as the use of hot works (i.e. welding) or loss of weathertightness (i.e. drilling holes and bolting). In order to limit these constraints, there may be a strong interest in using adhesively bonded fasteners. Such a solution requires however strong justification especially regarding long-term properties. This paper presents the results of experimental and numerical investigations realized on the creep behaviour of such bonded fasteners developed for offshore steel structures. Experimental investigations were conducted at room temperature following a precise and repeatable implementation protocol. The results of the various investigations revealed a non-linear evolution of creep displacements according to a Burger law. Numerical modelling has therefore been developed on the basis of Burger's law. A preliminary static study aimed at validating the geometric model and analyzing the initial stress state in the adhesive. The creep study was then carried out to compare numerical results to experimental ones. Although additional investigations are needed, numerically determined creep displacements demonstrated a good consistency with the experimental investigations.

Experimental and numerical investigation of residual stress effects on fatigue crack growth behaviour of S355 steel weldments

Fatigue crack growth tests have been conducted on S355 G10+M structural steel which is widely used in the fabrication of offshore structures. Fracture mechanics tests have been performed on compact tension specimens with the crack tip located in the heat affected zone. All tests were performed at room temperature in air and the obtained results are compared with the literature data available on a range of offshore structural steels and also the recommended BS7910 trends using the 2-stage law and simplified law. The specimen orientation, with respect to the location of the extraction within the welded plate, has also been examined and discussed in this work. Residual stress measurements have been performed prior to testing by using the neutron diffraction technique. Finally, a numerical model has been developed in order to calculate the effective stress intensity factor range in the presence of residual stresses. The results have shown that the residual stresses play a key role in the fatigue life of the welded structures, especially in the near threshold region.

Evaluation of Protective Coatings for High-Corrosivity Category Atmospheres in Offshore Applications.

The interest in renewable energies obtained from the resources availed in the ocean has increased during the last few years. However, the harsh atmospheric conditions in marine environments is a major drawback in the design of offshore structures. The protective systems that are employed to preserve offshore steel structures are regulated by several standards (ISO 12944, NORSOK M-501), which classify the corrosivity category of offshore installations as C5-M and Im2. In this work, three coatings employed in offshore components protection have been evaluated according to these standards by performing weathering aging tests in different climatic cabinets. The coatings studied were a thermally sprayed carbide coating with an organic sealant (C1), a thermally sprayed aluminum (TSA) coating with an organic topcoat (C2), and an epoxydic organic coating reinforced with ceramic platelets (C3). The only coating that reached the higher categories in all the tests was the C2 coating. The C1 coating presented ferric corrosion products coming from the substrate in some of the tests, and blistering was detected in the C3 coating.

Probabilistic analysis of the DoB in axially-loaded tubular KT-joints of offshore structures

The degree of bending (DoB) characterizing the through-the-thickness stress distribution has a profound effect on the fatigue behavior of tubular joints commonly found in steel offshore structures and the determination of DoB values is essential for improving the accuracy of fatigue life estimation. Probability density functions of the involved random variables are necessary for the fatigue reliability analysis of offshore structures. The objective of present research was the derivation of probability density function (PDF) for the DoB in tubular KT-joints commonly found in jacket-type offshore platforms. A total of 162 finite element (FE) analyses were carried out on 81 FE models of KT-joints subjected to two types of axial loading. Generated FE models were validated using experimental data, previous FE results, and available parametric equations. Based on the results of parametric FE study, a sample database was prepared for the DoB values and density histograms were generated for respective samples based on the Freedman-Diaconis rule. Thirteen theoretical PDFs were fitted to the developed histograms and the maximum likelihood (ML) method was applied to evaluate the parameters of fitted PDFs. In each case, the Kolmogorov-Smirnov test was used to evaluate the goodness of fit. Finally, the Generalized Extreme Value model was proposed as the governing probability distribution function for the DoB. After substituting the values of estimated parameters, six fully defined PDFs were presented for the DoB in tubular KT-joints subjected to two types of axial loading.