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In this paper, a global-local fretting design methodology for the pressure armour layer of flexible marine risers is outlined. This includes global dynamic riser analysis, geometrical and analytical sub-models and local nub-groove contact finite element analysis. Furthermore, a fretting test rig is developed and utilised to quantify coefficient of friction and wear coefficient under representative nub-groove loading conditions. The combination of the global-local computational methodology and experimental characterisation of pressure armour wire material allows for the development of running condition fretting maps. This identifies design criteria for critical riser global curvatures that are associated with minimum number of cycles to failure. The design methodology presented in this paper is applied to a realistic riser design study, using extreme sea-state loading conditions. In this case study, the predicted pressure armour fretting fatigue lives are found to be in the same range as the plain fatigue lives of the tensile armour layer. The authors would like to thank the Irish Research Council and Wood plc. for funding of this project through the Enterprise Partnership Scheme (EPSPG/2013/638), the National University of Ireland for funding through an NUI Travelling Scholarship. The authors also wish to acknowledge the support of the NUI Galway Engineering Building technical staff; particularly Mr. Bonaventure Kennedy and Mr. Patrick Kelly. peer-reviewed 2021-09-19

This paper presents a combined experimental and computational methodology for fretting wear-fatigue prediction of pressure armour wire in flexible marine risers. Fretting wear, friction and fatigue parameters of pressure armour material have been characterised experimentally. A combined fretting wear-fatigue finite element model has been developed using an adaptive meshing technique and the effect of bending-induced tangential slip has been characterised. It has been shown that a surface damage parameter combined with a multiaxial fatigue parameter can accurately predict the beneficial effect of fretting wear on fatigue predictions. This provides a computationally efficient design tool for fretting in the pressure armour layer of flexible marine risers. The authors would like to thank the Irish Research Council and Wood Group for funding of this project through the Enterprise Partnership Scheme (EPSPG/2013/638), and the National University of Ireland for funding through an NUI Travelling Scholarship. We also wish to acknowledge the help and support we have received from Mr. Kieran Kavanagh (Wood Group Kenny), the NUI Galway Engineering Building technical staff; particularly Mr. Bonaventure Kennedy and Mr. Patrick Kelly and the Faculty of Engineering at the University of Nottingham. peer-reviewed

Beam structures undergoing finite deflections and rotations in space have extensive application in the subsea industry particularly for the analysis of holistic systems with larger numbers of mooring and riser components. In using the finite element analysis approach, there is an increasing requirement for large element sizes which preserve accuracy with regard to the coupling of axial, bending and torsion response. The authors outline a method for improving the current state of practice for the analysis of riser systems. The approach draws on the convected coordinates method, Euler–Bernoulli beam theory, the principle of virtual work and the finite element method. Two quasi-rotation measures are developed including a quasi-material rotation definition for rotational deformation relative to the convected axis of a beam and a quasi-space rotation definition to deal with the path dependent nature of rotations in three dimensions. The novel aspect of this work is to relate the rate of change of the quasi-material rotation vector along the beam axis to a linear transformation of the beam axis rate-of-rotation vector through utilising the convected coordinates axes system. In this way, incremental values of quasi-material rotation are directly linked to incremental values of nodal quasi-space rotation and a global Newton–Raphson solution technique for interconnecting beam elements is straightforward to assemble. Furthermore, this leads to accurate definitions of coupled axial, bending and torque response for beams with significant deflection. The approach has particular advantages in the analysis of subsea riser sections. Also, the accuracy of the solution is preserved for a fewer number of elements compared to alternative solutions for computationally sensitive load cases with highly non-linear loading regimes.

This paper presents a computational methodology for frictional contact mechanics of the pressure armour layer in flexible risers. This will allow, for the first time, quantification of key fretting variables, such as contact pressure, relative slip and sub-surface stresses in this complex geometry, under representative loading conditions. Fatigue lives are calculated using the 3-dimensional critical plane Smith-Watson-Topper multiaxial fatigue parameter. It is shown that COF has a significant effect on predicted trailing-edge tensile stresses in the pressure armour layer and, hence on fretting crack initiation in risers. It is also shown that operating pressure and bending-induced axial displacement significantly affect predicted crack initiation. These results will facilitate representative fretting wear and fretting fatigue testing of pressure armour layer material. Irish Research Council and Wood Group Kenny for funding of this project through the Enterprise Partnership Scheme (EPSPG/2013/638), National University of Ireland for funding through an NUI Travelling Scholarship. peer-reviewed 2018-03-04