Structural response of a flexible pipe with damaged tensile armor wires under pure tension

This article studies the structural response of a 6.0” flexible pipe under pure tension considering intact and damaged conditions. In the damaged condition, several wires of the tensile armor layers are assumed to be broken. A three-dimensional nonlinear finite element (FE) model devoted to analyze the local mechanical response of flexible pipes is employed in this study. This model is capable of representing each tensile armor wire and, therefore, localized defects, including total rupture, may be adequately represented. Results from experimental tests validate the FE predictions and indicate a reduction in the axial stiffness of the pipe, a non-uniform redistribution of forces among the remaining intact wires of the damaged tensile armor layers and high stress concentrations in the wires near the broken ones. Moreover, the FE model indicates that significant normal bending stresses may arise in the pressure armor and inner carcass due to an uneven pressure distribution on these layers. Finally, the results obtained are employed to estimate the pull out capacity of the studied flexible pipe.     

A finite element model for flexible pipe armor wire instability

The constructive disposition of metallic and plastic layers confers flexible pipes with high and low axial stiffness respectively when tensile and compressive loads are applied. Under certain conditions typically found during deepwater installation or operation, flexible pipes may be subjected to high axial compression, sometimes accompanied by bending. If not properly designed, the structure may not be able to withstand this loading and fails. From practical experience observed offshore and in laboratory tests two principal mechanisms, which will be discussed in this paper, have been identified regarding the configuration of the armor wires. When the pipe fails by compression the armor wires may exhibit localized lateral or radial deflections, consequently permanent damage is observed in the armor wires with a sudden reduction of the structure’s axial stiffness. The pressure armor may also unlock, thus causing potential fluid leakage.In this work a finite element model is developed to estimate the critical instability load and failure modes. An axi-symmetric model is constructed employing a complex combination of beam and spring elements. For each armor layer only one wire needs to be modeled, hence the computational cost is minimized without compromising the phenomenon characterization. A parametric case study is performed for a typical flexible pipe structure, where the friction coefficient between the wire armors and the external pressure are varied, and the critical instability loads and failure modes are obtained and results are discussed.     

钢丝绳磷化涂层技术

钢丝绳使用过程中受到交变应力的作用,内部相邻钢丝因受力不均匀导致变形不同步时将发生微动;微动使钢丝表面产生磨损,从而使钢丝横截面积减小致应力集中的发生,促进疲劳微裂纹的萌生,微动疲劳是钢丝绳失效的主要原因。磷化涂层钢丝绳专利技术是将制绳钢丝磷化处理后捻制股及钢丝绳,磷化膜使钢丝表面更加耐磨,同时增加润滑脂在钢丝表面的驻留量,减小摩擦力促进滑动,抑制钢丝表面损伤及微动疲劳的发生,从而大幅度延长钢丝绳使用寿命。     

无粘结柔性管抗拉伸层结构分析

柔性管抗拉伸层是复杂的空间螺旋线结构,其结构响应分析对柔性管疲劳分析、强度分析和屈曲分析有重要作用。文章基于曲梁理论,应用斜驶螺旋线假设和测地线假设两种空间曲线公式,以空间细长杆理论及胡克定律本构方程为基础,采用格林应变张量与第二Kirchoff应力张量度量,对深海无粘结柔性管抗拉伸层螺旋形钢缆结构平衡方程进行了推导,编写了分析程序。利用该程序,分析了抗拉伸层钢缆在轴对称载荷下和弯矩作用下的曲率变化和结构响应;同时利用三维直梁有限元模型与曲梁有限元模型建立数值模型,将程序结果与数值模拟模型结果进行了对比,证明了结果可行性。该结果可为柔性管抗拉伸层结构设计提供快速的预估计方法。     

钢丝绳失效机理分析及改进举措

微动疲劳与腐蚀疲劳是造成钢丝绳失效的主要原因。选用纯净度高的帘线钢盘条为原料制造钢丝绳,并对制绳钢丝进行表面处理,提高钢丝的防腐蚀、耐磨损性能,同时通过改进设备和工艺提高捻制质量,可大幅度地提高钢丝绳的质量和使用寿命。光面钢丝绳或将被淘汰。     

Experimental and finite element analysis of fatigue strength for 300 mm2 copper power conductor

The fatigue strength of a 300 mm² stranded copper conductor was investigated experimentally and by finite element (FE) analysis. An analytical model was also developed and validated. Wires taken from the outer layer of the conductor were fatigue tested in tension–tension loading and compared with similar data for wires taken from a 95 mm² conductor. The wire cross section was deformed due to the compacting process that was applied during fabrication. When corrected for stress concentrations due to the deformation the data for the two sets of wire fell within the same scatter-band. Full scale testing was carried out in a specially designed rig with constant tensile load and reversed displacement controlled bending with a fixed curvature variation. The loading is a simulation of the loading of a power cable hanging from a floating vessel through a bellmouth. Conductors were tested in two states; dry and lubricated. A finite element model was established for the copper conductor. The model was formulated by a combination of elastic beam and beam-contact elements that included the effects of friction. The effect of local bending due to contact forces was included in the model. Two contact conditions were investigated; the point (trellis) contact between adjacent layers of wire and the inline contact within each layer and between the first layer (centre wire) and the second layer. The FE model was validated by a calibration test of a full scale conductor, and by sensitivity studies varying the size and the number of elements of the model. Fatigue analysis of the conductor was carried out, based on the S–N curve for individual wires. Taking into account the effects of friction and local bending, agreement was obtained between predicted and experimental fatigue strength of the conductor, for the FE model as well as the analytical model.     

无粘接脐带缆轴对称响应与疲劳特性分析研究

为了提高对脐带缆力学特性的研究,便于设计,文中提出了一种脐带缆拉伸载荷作用下的理论模型.在总体控制方程中对拉伸过程中骨架层的径向缩减.针对给定的无粘结脐带缆脐,建立了有限元模型,模拟分析了骨架层的径向缩减对应力分布的影响.通过对拉伸刚度试验对比,理论分析与试验吻合度较高.基于解析模型,分析了径向缩减对拉伸刚度的影响.此外,在应力分析的基础上,对无粘结脐带缆在拉伸载荷作用下的的疲劳特性进行了研究.     

Bending behavior modeling of unbonded flexible pipes considering tangential compliance of interlayer contact interfaces and shear deformations

Rigorous analytical formulations are given to describe the gross slip initiation and progression in tensile armor layers of unbonded flexible pipes. Then two mechanisms are thought to contribute to the decrease of layer stiffness before gross slip begins. The first one considers the micro-slip occurred at the interlayer contact interfaces. The relative displacement between an armor wire and the underlying layer is determined according to the theory of contact mechanics. Shear deformations of the supporting plastic layer are taken into account in the other mechanism where plane sections no longer remain plane. The results of bending moment-curvature relationship from the presented models are compared with the available test data and good correlations are found. The shear model is seen to describe the slip transition better than other models do.     

Helical wire stress analysis of unbonded flexible riser under irregular response

A helical wire is a critical component of an unbonded flexible riser prone to fatigue failure. The helical wire has been the focus of much research work in recent years because of the complex multilayer construction of the flexible riser. The present study establishes an analytical model for the axisymmetric and bending analyses of an unbonded flexible riser. The interlayer contact under axisymmetric loads in this model is modeled by setting radial dummy springs between adjacent layers. The contact pressure is constant during the bending response and applied to determine the slipping friction force per unit helical wire. The model tracks the axial stress around the angular position at each time step to calculate the axial force gradient, then compares the axial force gradient with the slipping friction force to judge the helical wire slipping region, which would be applied to determine the bending stiffness for the next time step. The proposed model is verified against the experimental data in the literature. The bending moment–curvature relationship under irregular response is also qualitatively discussed. The stress at the critical point of the helical wire is investigated based on the model by considering the local flexure. The results indicate that the present model can well simulate the bending stiffness variation during irregular response, which has significant effect on the stress of helical wire.     

压力载荷下非粘结柔性立管应变影响因素分析

基于Abaqus/Explicit准静态和质量放大方法研究了一类典型非粘结柔性立管在压力载荷作用下应变响应特性,对影响立管整体轴向延伸率和绕轴向扭转角度的因素进行了分析。数值模型计入金属层实际截面形状、铺设角度以及几何、接触、材料非线性。计算结果表明：数值解与理论值吻合较好;立管端部边界条件对轴向延伸率影响不大但对绕轴向扭转角度影响较大;抗压铠装层为径向压力主要受力构件,其铺设角度虽然对压溃性能不大,但在应变分析中不可忽略;拉伸铠装层铺设角度对应变影响同样较大。文中数值方法可弥补理论方法限定在小位移、小变形范围,无法计入层间摩擦、材料非线性及初始制造椭圆率等缺陷。     

橡胶-碳纤维复合水润滑轴承材料的研究

为探究橡胶-碳纤维复合橡胶水润滑轴承材料的摩擦学性能,在SSB-100型船舶艉轴承试验机上,对复合橡胶轴承材料和普通橡胶轴承材料进行台架上的摩擦、磨损试验结果表明：复合橡胶轴承材料的力学性能、摩擦、磨损性能均优于普通橡胶,即碳纤维的加入可以改善普通水润滑橡胶轴承的综合性能。     

海底光缆制造中的优化

在计算双层铠装海底光缆拉伸强度的基础上，建立了海底光缆结构参数的优化模型，对于海底光缆的设计制造有一定的指导意义。海底光缆铠装钢丝层之间的滑动对于海底光缆的拉伸强度有重要影响，分析这种滑动产生的原因，提出控制滑动的一些方法，并建立相应的结构参数优化模型。     

码头面层纤维混凝土抗冲击性能的试验研究与评价

在C30素水泥混凝土中分别添加杜拉纤维、尼龙纤维、钢纤维配制纤维混凝土,标准养护28 d后进行抗弯曲冲击试验研究.以初裂次数、终裂次数、冲击韧性评价混凝土抗冲击性能的优劣.试验结果表明:在设定的落锤抗弯曲冲击试验方法基础上添加钢纤维混凝土、杜拉纤维混凝土、尼龙纤维混凝土,其冲击韧性分别是素混凝土冲击韧性的15.1倍、3.4倍、2.7倍.素混凝土冲击破坏突出表现为脆性断裂破坏,纤维混凝土冲击破坏表现为韧性断裂破坏.3种纤维混凝土的抗冲击性能均较素混凝土有较大的提高,其中钢纤维混凝土的抗冲击性能最强,其次是杜拉纤维混凝土.     

复合抗弹结构设计及隔热性能验证

超高分子量聚乙烯纤维增强塑料(UFRP)层合板具有良好的抗侵彻性能,但受温度影响明显,其热损伤的临界温度仅为147℃.为了避免火灾产生的高温使UFRP层合板失去抗弹性能,设计了以船用钢为前/后面板,SiO2气凝胶毡为隔热层,UFRP层合板为抗弹层的复合抗弹结构.在A60耐火等级标准条件下,对复合抗弹结构的有限元模型进行瞬态热分析,探索了复合抗弹结构内部的温度分布与SiO2气凝胶毡隔温层厚度的关系.根据有限元仿真结果,近一步对SiO2气凝胶毡隔热层厚度为20 mm的复合抗弹结构单元开展耐火试验.结果表明:SiO2气凝胶毡具有良好的隔热性能,在A60耐火等级标准条件下,保持复合抗弹结构中UFRP层合板抗弹性能完好所需的SiO2气凝胶毡隔热层厚度至少为20 mm.     

Application of analytical model in the prediction of dynamic responses and fatigue damage of flexible risers: Part I – Improvement of analytical model considering shear deformation and varying tension effects

Flexible risers have been widely utilized for the transfer of oil and gas products from a well to production units. The components of flexible risers, unlike steel risers, experience complex contact phenomena during bending. The contact between helical wires and adjacent layers especially causes a significant level of bending nonlinearity, making it hard to estimate the structural responses. Accordingly, a large-scale dynamic analysis of flexible risers usually involves an analytical model that predicts the bending moment and axial stress of helical wires based on theoretical approaches. The analytical model consists of an axis-symmetrical model and a bending model. Among them, the bending model plays a critical role in the prediction of the bending responses of flexible risers. The conventional bending models usually neglect the shear deformation of internal layers and continuity of sliding force, which leads to a significant error of analysis. Furthermore, the previous bending models assume that the contact pressure on helical wires is constant during bending. In real operating conditions, however, most flexible risers experience a considerable change of tension that governs the slip of helical wires. Hence, the current study presents a new dynamic analysis method for flexible risers. The suggested analytical model improves the bending model based on an accurate estimation of the internal strain field considering the shear deformation and continuous sliding force. Also, this study proposes a stiffness update method to reflect the effect of varying tension in the dynamic analysis. The presented method updates the bending property of flexible risers considering the continuous change of the contact pressure from varying tension. For the validation of suggested method, the current study carries out numerical simulations with a pure bending and varying tension for the internal diameter 7 inches flexible risers. It is identified that the suggested analytical model provides accurate analysis results. Moreover, it is found that the effect of varying tension gives a significant impact on the bending behavior of flexible risers by changing the slip condition of helical wires. Part I of this series of papers describes the detailed formulation method for the analytical model and with some verification examples. The suggested analytical model is expanded to the large-scale dynamic analysis in Part II for the investigation of the effect of shear deformation and varying tension.     

港口起重机钢丝绳传动件高性能技术研究

针对港口起重机设计及使用部门普遍关注的钢丝绳与滑轮的合理选配问题和焊接卷筒壁厚的减薄 问题,从失效机理和设计理论研究出发,经过钢丝绳与滑轮的疲劳磨损试验和卷筒强度、稳定性原型试验,提出了 钢丝绳与滑轮的最佳选配原则和焊接卷筒壁厚的减薄理论与方法。经初步应用证明,采用上述原则与方法,可显 著改善钢丝绳与滑轮的综合匹配效果,并使卷筒壁厚比传统设计方法减薄20%～30%。     

基于雨流计数法及Corten-Dolan准则的轴承疲劳寿命预测

船舶轴承是船舶推进系统中的重要支撑部件，其稳定可靠的工作状态是推进轴系健康服役的重要保障。由于轴承的破坏形式主要为材料疲劳磨损引发的故障失效，故开展船舶轴承的疲劳磨损状态研究就显得尤为重要。本文针对轴承结构疲劳损伤问题，通过MATLAB软件实现雨流计数法原理的计算机语言编写，研究了四点雨流计数法对船舶轴承危险节点的动态应力分析应用，并提取出对应的循环应力载荷谱。考虑平均应力的影响，运用Gerber曲线对统计得到的循环载荷进行等寿命转化。最终利用轴承材料S-N曲线，结合Corten Dolan准则进行疲劳寿命预测计算，得出船舶轴承在相应外部循环载荷作用下的最终寿命。为轴承的设计和优化提供了理论参考依据，对船舶轴系运行管理具有重要的现实意义。     

纳米Al2O3复合镀铁层的结构与性能

为提高船机零部件的耐磨性,减少零部件的磨损,通过在电镀液中添加Al2O3纳米颗粒的方法,制备出含有Al2O3纳米颗粒的复合镀铁层。对制备出的镀层进行硬度、表面形貌、元素成分和摩擦磨损性能分析。结果表明：Al2O3纳米颗粒成功进入了镀层,含有Al2O3颗粒的复合镀层相对普通镀铁层有明显提高；含有40g/L Al2O3的复合镀层的摩擦系数相对普通镀层下降了25%,磨损量也大幅下降；经过摩擦磨损后复合镀层的表面状态良好。     

Finite element study on circular armour wire lateral buckling in umbilicals

The present paper addresses the circular armour wire lateral buckling in umbilicals. An asymmetric non-linear finite element model is developed to analyze a single armour wire subjected to combined constant axial compression and uniform cyclic curvatures. A parametric case study is performed for an armour wire from a nine-hose umbilical cable, where the armour wire pitch number, applied axial compressive load and minimum and maximum curvatures in the applied cyclic bending are varied. The armour wire end shortenings, transverse sliding in cyclic bending, the buckling shapes and equilibrium paths after numerous bending cycles, the critical buckling loads, the stress states at the onset of lateral buckling, and the required number of bending cycles that triggers lateral buckling are obtained and extensively discussed. The critical buckling loads given by the FE model have been compared with an existing analytical formulation, indicating that the analytical model is reliable for small cyclic curvatures. Moreover, an empirical model is proposed for the required number of bending cycles to trigger the lateral buckling and good correlation with the FE results has been observed.     

A finite element methodology for birdcaging analysis of flexible pipes with damaged outer layers

Flexible pipes are commonly exposed to damages on the outer layers due to abrasion with seafloor or improper installation and operation, which may render them vulnerable to birdcaging failures. This paper presents a finite element model for the residual axial compressive strength evaluation of a flexible pipe with local damage on the outer layers. The elastoplastic nonlinearity of tensile armour steel layers and hyperelasticity of polymeric outer sheath are taken into account. This model is verified against existing test data. Parametric studies are then performed by varying the damage size in either the pipe axial or circumferential directions. The flexible pipe axial resistance, deformations, as well as the tensile armour wires layers stress states near the damaged section under different damage and axial compression conditions are discussed. The case studies show that damage on the outer layer, especially the anti-birdcage tape layer, is highly detrimental to flexible pipe residual strength against axial compression. The present results and discussions are instructive in understanding the flexible pipe birdcaging mechanism.