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Umbilicals Design with UmbiliCAD and Helica
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Umbilicals Design with UmbiliCAD and Helica

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  • 1. Umbilical Design Using UmbiliCAD and HelicaFan Joe ZhangSesam Business Development Manager – DNV Software / HoustonAgosto de 2012
  • 2. Introduction to UmbiliCAD  UmbiliCAD® by UltraDeep - A cross-section design, drawing and modeling tool - Drawing contains all material properties - Calculates mass, weights, axial, bending and torsion stiffness - Stress capacity calculation - Analythical methodolgy for stiffness and stress capacity calculation - Tube sizing according to DNV-OS-F101 and ISO 13628-5 - Module for reel capacity calculation - Module for bill of material - DXF export to other CAD tools - Module for Helica calculations - Plugin capability© Det Norske Veritas Ltda. Todos os direitos reservados. 2
  • 3. UmbiliCAD Power cable/umbilical Steel tube umbilical Control umbilical© Det Norske Veritas Ltda. Todos os direitos reservados. 3
  • 4. Why UmbiliCAD?  No need to be an advanced draftsman  Early cross section analysis – first results within hours in stead of days - Linear analysis with no stick/slip Capacity Curve 1200 100% Utilisation 1100 80% Utilisation 1000 900 800 Tension [kN] 700 600 500 400 300 200 100 0.0 0.0 0.04 0.08 0.12 0.16 0.2 0.24 0.28 Curvature [1/m]© Det Norske Veritas Ltda. Todos os direitos reservados. 4
  • 5. Introduction to Helica  Helica™ by DNV - A cross-section stress analysis tool - Short-term fatigue analysis - Long-term fatigue analysis - a tailor-made software for cross-sectional analysis of flexible pipes and umbilicals - Load-sharing between elements considering axis-symmetric analysis - Calculation of cross-sectional stiffness properties (axial, torsion and bending stiffness) - Helix element bending performance analysis to describe stresses in helix elements during bending considering stick/slip behaviour due to interlayer frictional forces.© Det Norske Veritas Ltda. Todos os direitos reservados. 5
  • 6. Helica  Cross-sectional load sharing analysis - Load-sharing between elements considering axis-symmetric analysis - Calculation of cross-sectional stiffness properties (axial, torsional and bending stiffness) - Helix element bending performance analysis to describe stresses in helix elements during bending considering stick/slip behaviour due to interlayer frictional forces  Short-term fatigue analysis - To assess the fatigue damage in a stationary short-term environmental condition considering fatigue loading in terms of time-series of simultaneous bi-axial curvature and effective tension produced by global dynamic response analysis - Helica uses results from DeepC as the response database for time domain global dynamic analysis as loading  Long-term fatigue analysis - To assess the long-term fatigue damage by accumulation of all short-term conditions© Det Norske Veritas Ltda. Todos os direitos reservados. 6
  • 7. Helica  Cross-sectional bending characteristics - Relative motion between layers/components - Friction, stick/slip behaviour (Tension dependent) - Moment/curvature hysteresis - Non-linear amplitude dependent - Above effects automatically accounted for Moment Curvature© Det Norske Veritas Ltda. Todos os direitos reservados. 7
  • 8. UmbiliCAD and Helica Bundle  UmbiliCAD and Helica is a bundeled software UmbiliCAD exports cross section geometry and material properties to Helica, set up load cases, and build the model for analysis.  Helica can be run from UmbiliCAD and results and plots can be presented in UmbiliCAD  The Helica model can also be exported and run manually in Helica for batch processing.© Det Norske Veritas Ltda. Todos os direitos reservados. 8
  • 9. Demo Case Umbilical Component and Cross-section Design© Det Norske Veritas Ltda. Todos os direitos reservados. 9
  • 10. Cross-section Parameter Valu e Un it Ou ter Diameter 1 4 3 .1 [mm] Mass Emp ty 3 0 .8 [k g /m] Mass Filled 3 2 .6 [k g /m] Mass Filled An d Flo o d ed 3 5 .2 [k g /m] Su b merg ed Weig h t Emp ty 1 4 .3 [k g f/m] Su b merg ed Weig h t Filled 1 6 .1 [k g f/m] Su b merg ed Weig h t Filled An d Flo o d ed 1 8 .7 [k g f/m] Sp ecific Weig h t Ratio 2 .1 [-] Su b m. Weig h t. Dia. Ratio 1 3 0 .8 [k g f/m^2 ] Ax ial Stiffn ess 4 3 1 .5 [MN] Ben d in g Stiffn ess 2 4 .9 [k Nm^2 ] Ben d in g Stiffn ess (frictio n free) 1 5 .0 [k Nm^2 ] To rsio n Stiffn ess 1 4 8 .6 [k Nm^2 ] Ten sio n /To rsio n Facto r -0 .0 2 [d eg /m/k N]© Det Norske Veritas Ltda. Todos os direitos reservados. 10
  • 11. The Dynamic Umbilical Design Process© Det Norske Veritas Ltda. Todos os direitos reservados. 11
  • 12. CLIENT Function.list Functional Requirements Cross-section Component Design Standards and Codes drawing (UmbiliCAD) (ISO 13628-5) Mechanical Cross-section Design Properties (UmbiliCAD & Helica) Capacity Curves Local Analysis (Helica) Global Design and Analysis (DeepC Riflex) Global Analysis Global Extreme Analysis Global Fatigue Analysis Global Fatigue Report (e.g. 100 year hurricane (Full scatter diagram Analysis Report DeepC Riflex) DeepC Riflex) Local Fatigue Analysis Local Fatigue (e.g. in BS, sag, hog etc. Analysis Report Helica)© Det Norske Veritas Ltda. Todos os direitos reservados. 12
  • 13. Component and Cross-section Design  Using UmbiliCAD and Helica© Det Norske Veritas Ltda. Todos os direitos reservados. 13
  • 14. Local Analysis  Using Helica - Compute cross sectional properties Parameter Valu e Un it Ou ter Diameter 1 3 3 .2 [mm] Mass Emp ty 3 5 .9 [k g /m] Mass Filled 3 9 .4 [k g /m] Mass Filled An d Flo o d ed 4 2 .4 [k g /m] Su b merg ed Weig h t Emp ty 2 1 .6 [k g f/m] Su b merg ed Weig h t Filled 2 5 .1 [k g f/m] Su b merg ed Weig h t Filled An d Flo o d ed 2 8 .1 [k g f/m] Sp ecific Weig h t Ratio 3 .0 [-] Su b m. Weig h t. Dia. Ratio 2 1 0 .8 [k g f/m^2 ] Ax ial Stiffn ess 6 7 7 .3 [MN] Ben d in g Stiffn ess 2 1 .3 [k Nm^2 ] Ben d in g Stiffn ess (frictio n free) 1 6 .7 [k Nm^2 ] To rsio n Stiffn ess 2 7 .5 [k Nm^2 ] Ten sio n /To rsio n Facto r 0 .0 0 [d eg /m/k N] Capacity Curve Helix position : 270.0000 500 100% Utilisation 600 450 80% Utilisation 400 500 350 Total helix stress 400 Tension [kN] 300 250 300 200 200 150 100 100 50 0 0.0 -0.0004 -0.0003 -0.0002 -0.0001 0 0.0001 0.0002 0.0003 0.0004 0.0 0.04 0.08 0.12 0.16 0.2 0.24 0.28 0.32 Curvature Curvature [1/m]© Det Norske Veritas Ltda. Todos os direitos reservados. 14
  • 15. Global Design and Analysis  Using DeepC Riflex - Coupled or de-coupled analysis Wave loading Forced floater motions Non-linear load model Non-linear structure© Det Norske Veritas Ltda. Todos os direitos reservados. 15
  • 16. Global Analysis  Using Helica to get capacity curve - The capacity curve presents all load combinations that result in the specified maximum allowable equivalent stress due to: - Tension - Pressure - Bending - Torsion - All cross-section members are considered Bend stiffener region© Det Norske Veritas Ltda. Todos os direitos reservados. 16
  • 17. Local Fatigue Analysis  Using Helica  Load sharing analysis - Axi-symmetrical analysis to establish tension in each element - Bending analysis including the hysteretic, friction induced stick/slip behavior of the helix elements© Det Norske Veritas Ltda. Todos os direitos reservados. 17
  • 18. Local Fatigue Analysis – Short-term Fatigue Analysis  Purpose of the analysis is assessment of fatigue damage in a stationary short- term environmental condition  Specification of: - Helix element - Longitudinal locations - Helix positions/hot-spots - SN-curve  Helix stresses calculated: σ (t ) - Fatigue stress time series Fatigue stress - Stick/slip friction due to bending Time Stress range - Bending about local axis - Stresses due to tension (from axisymmetrical analysis)  Rainflow cycle counting  Fatigue damage calculation© Det Norske Veritas Ltda. Todos os direitos reservados. 18
  • 19. Local Fatigue Analysis – Long-term Fatigue Analysis  Purpose of the analysis is to assess the long-term fatigue damage by accumulation of all short-term conditions  Required input: - Fatigue results for all short-term conditions - Probability of each short-term condition© Det Norske Veritas Ltda. Todos os direitos reservados. 19
  • 20. Size of problem – numerical performance  270 TD simulations with 1 hour duration (20.000 time steps)  Rectangular tensile armours, 4 hot-spots  12 helix locations  Fatigue damage calculated at 76 locations along riser (including bend stiffener area)  Total of 985.000 1 hour stress time series generated by cross-sectional y analysis yl xl Computation time – standard single core lap-top Model Total Per case φ Tube, no friction 0.38 hours 5 seconds x Helix, no friction 3.8 hours 50 seconds Helix with friction 5.8 hours 77 seconds Global TD analyses not included in computation time© Det Norske Veritas Ltda. Todos os direitos reservados. 20
  • 21. Example Local Fatigue Analysis© Det Norske Veritas Ltda. Todos os direitos reservados. 21
  • 22. Analysis process  Calculate cross section parameters - Mass/weight in UmbiliCAD - Axial, bending and torsion stiffness from Helica  Global analysis using DeepC - Riflex - Inpmod - Riser definition – Cross section parameters from first step - Environment definition – wave heights, current etc. with corresponding direction - Riflex – Stamod - Static analysis - Riflex – Dynmod - Dynamic analysis  Short-term fatigue analysis using Helica  Long-term fatigue analysis using Helica  Design of umbilicals is also based on ULS – this is part of UmiliCAD/Helica analysis, but not covered in this presentation© Det Norske Veritas Ltda. Todos os direitos reservados. 22
  • 23. Lay-out of the riser 27 Environment conditions© Det Norske Veritas Ltda. Todos os direitos reservados. 23
  • 24. Step 1 Create cross-sections and calculate mass properties  UmbiliCAD will do both Parameter Valu e Un it Ou ter Diameter 1 1 7 .0 [mm] Mass Emp ty 2 3 .0 [k g /m] Mass Filled 2 6 .5 [k g /m] Mass Filled An d Flo o d ed 2 8 .7 [k g /m] Su b merg ed Weig h t Emp ty 1 2 .0 [k g f/m] Su b merg ed Weig h t Filled 1 5 .5 [k g f/m] Su b merg ed Weig h t Filled An d Flo o d ed 1 7 .7 [k g f/m] Sp ecific Weig h t Ratio 2 .6 [-] Su b m. Weig h t. Dia. Ratio 1 5 1 .1 [k g f/m^2 ] Ax ial Stiffn ess 4 7 6 .3 [MN] Ben d in g Stiffn ess 2 9 .0 [k Nm^2 ] Ben d in g Stiffn ess (frictio n free) 2 3 .7 [k Nm^2 ] To rsio n Stiffn ess 4 3 .5 [k Nm^2 ] Ten sio n /To rsio n Facto r 0 .0 0 [d eg /m/k N]© Det Norske Veritas Ltda. Todos os direitos reservados. 24
  • 25. Step 2 Calculate stiffness using Helica© Det Norske Veritas Ltda. Todos os direitos reservados. 25
  • 26. Step 3 Run global response analysis using Riflex  For a fatigue analysis, responses under multiple environment conditions (wave scatter) may be analyzed. Batch executions are normally used. (run-riflex.bat)  Motion RAOs of the vessel will also be used. (trafile.tra)  In this example, the analysis setup contains 27 weather directions. Inpmod.inp run-riflex.bat Stamod.inp executing… Dymod.inp Trafile.tra© Det Norske Veritas Ltda. Todos os direitos reservados. 26
  • 27. Capacity curve vs. time-domain time series  Responses should be within the 80% or 100% capacity curves© Det Norske Veritas Ltda. Todos os direitos reservados. 27
  • 28. Step 4 Run fatigue analysis using Helica  Calculate short term fatigue for critical area for each of the bins. - In this example the critical areas are the BS area of SDTube2 and SDTube4 (inner layer of cross- section).  When all bins are completed, fatigue is accumulated and long term fatigue is calculated by Helica.  Following input files are normally needed: - Helica Fatigue analysis input file (BS- SDTube2_fat_ana.inp) - Helica Cross Section (helica.inp, could be generated by Helica) - Fatigue setup, (where to calculate fatigue etc (BS-SDTube2_fat_geo.inp) - Fatigue probabilities (fat_conditions.inp) - SN curves (SN-lib.inp)© Det Norske Veritas Ltda. Todos os direitos reservados. 28
  • 29. Helica fatigue analysis input file  Defining the parameters used in Helica fatigue analysis, e.g. - Analysis time window - Helix element positions - If friction will be considered - Etc. Here ‘2’ means friction will be considered using updated contact force.© Det Norske Veritas Ltda. Todos os direitos reservados. 29
  • 30. Long term fatigue histograms Case19_layer3_compone nt1_location11_hotspot5© Det Norske Veritas Ltda. Todos os direitos reservados. 30
  • 31. Summary – Why UmbiliCAD and Helica?  To facilitate the deepwater challenge 1) : - “Increased importance of higher order cross-sectional effects” - Tension/radial displacement coupling - Internal friction - “These effects may considerably affect dynamic umbilical performance in deep waters”  Main benefits - No need for specialist competence in a CAD system – drawings, cross sectional properties and early design capacity curves made in hours instead of days - Outstanding numerical performance gives answer in days instead of weeks - Extreme design – capacity curves for entire cross-section in compliance with applicable design codes - Fatigue stress analysis of helix elements considering stick-slip behaviour in bending - Calculation of consistent fatigue stresses by direct application of global response time series from DeepC as external loading - Short-term fatigue life calculation capabilities including Rain-flow cycle counting - Long-term fatigue life calculation capabilities including assessment of long-term stress cycle distribution© Det Norske Veritas Ltda. Todos os direitos reservados. 31
  • 32. Safeguarding life, property and the environment www.dnv.com© Det Norske Veritas Ltda. Todos os direitos reservados. 32

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