TLP Minimum tendon tension design and tendon down-stroke investigation

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1 Published by International Association of Ocean Engineers Journal of Offshore Engineering and Technology Available online at TLP Minimum tendon tension design and tendon down-stroke investigation Qi Ling a a MODEC International Inc., Katy Freeway, Suite 500, Houston, Texas, * Corresponding author. qi.ling@modec.com ABSTRACT Minimum tendon tension is one of the key TLP design parameters. It is required by API RP 2T and classification rules that positive minimum tendon tension shall be maintained under operational design condition to ensure TLP safe operation. For extreme design condition, minimum tendon bottom tension of at least one tendon per corner shall be positive. For survival design condition, if tendon slacking could not be avoided, tendon down-stroke shall be ensured smaller than the distance from the tendon engaged position in receptacle to the lock pin (or unlatching position) with sufficient margin. To investigate tendon down-stroke behavior, tendon bottom fixity is modified to simulate the engagement mechanism between tendon bottom connector and the receptacle. Tendon down-stroke analysis is performed, and relationship between tendon bottom down-stroke and minimum tendon bottom tension observed in global performance analysis is studied. Keywords: TLP, Minimum Tendon Tension, Tendon Slacking, Tendon Down-stroke. 1 Introduction Tension Leg Platform (TLP) is one of the most mature dry tree production platforms for deep water application. The tendon system restrains the platform vertical motions in waves as well as horizontal drift in wind, wave and current. The very large axial stiffness of tendon system limits TLP heave and pitch/roll natural periods to a level much less than the dominant wave energy period so as to avoid the system resonance under wave excitation. The superior heave motion characteristics of TLP make it possible for dry tree application using simple design and low-cost Top Tension Riser (TTR) system. TLP design is a highly iterative process, and need considering functional requirements, site environment criteria, and pre-service and in-service design conditions including construction,

2 2 Journal of Offshore Engineering and Technology (2017) 1: 1-13 transportation, installation and operation. Fundamentally, TLP hull provides the required buoyancy to support the topsides weight and riser loads specified by the functional requirement. TLP hull sizing starts from hydrostatic design in terms of sufficient buoyancy and stability for in-place and pre-service design phases. The submerged volumetric ratio of hull components, i.e., column and pontoon, is designed for optimization of hydrodynamic force cancellation and minimization of tendon dynamic response. TLP global performance is checked from the point view of hydrodynamic design to ensure the sized TLP meet the design criteria. Key global performance parameters include vessel offset, deck acceleration, air-gap, and tendon dynamic response. The extreme values of these key parameters shall be within the design limits for safe operation of riser system, topside equipment, and tendon system (API RP2T, 2010; ABS, 2003; BV, 2012; Mansour, & Huang, 2006) TLP design and analysis require a series of design load cases involving each design phase coupled with design environmental events and associated safety factors. Being applied to design load cases, four (4) types of safety categories are used in API RP2T (2010) for TLP design check. They are Category A for Operational Conditions, Category B for Extreme Conditions, Category S for Survival Conditions and Category C for Fatigue Conditions. In addition, TLP design shall also consider seismic loads and fatigue due to single extreme event. Minimum tendon tension is the most critical global performance parameter for the integrity of tendon system which is the critical element for the safety of TLP as it contributes most of TLP in-place stability. Positive tension at tendon bottom is desired for most design conditions. Low level of tendon slacking without disengaging or buckling the tendon is allowed for survival design condition. 2 TLP Global Performance and Tendon Pretension Design The purpose of global performance analysis is to check hydrodynamic response of the sized TLP configuration for the design load cases so that TLP performance and safety requirements are satisfied as illustrated in Figure 1. Key global performance parameters include maximum vessel offset, maximum deck accelerations, minimum air-gap, maximum tendon tension and minimum tendon tension. They will not reach the extreme at the same time and in the same design condition. Maximum vessel offset shall occur under storm environment at low water level, and is limited per riser system design requirements. Minimum air-gap shall occur under maximum wave storm environment at high water level, and its requirement relates to deck structural strength and the safety of TLP system. Maximum tendon tension will occur under maximum wave storm environment at high water level, and is limited by the sized tendon capacity. Minimum tendon tension shall occur under maximum wave storm condition at low water level, and is very critical for the safety of tendon system, and, therefore, the safety of whole platform.

3 Journal of Offshore Engineering and Technology (2017) 1: Fig. 1 TLP Design Sufficient tendon pretension is required to meet the requirements of TLP offset and minimum bottom tension. High tendon pretension increases TLP lateral restoring stiffness and therefore reduce vessel offset while it also favors for tendon bottom minimum tension. The ratio of tendon pretension to platform displacement is quite high (about 25% ~ 35%) to cover the needs from maximum offset design and minimum tendon tension design. A dream TLP design is to have smaller tendon pretension so that hull buoyancy is more efficiently used to support the topsides payload and a smaller hull can be sized. High tendon pretension requires larger hull displacement, and therefore larger hull size with higher cost. High tendon pretension also causes higher maximum tendon tension, thus, larger tendon size with larger strength capacity, which will increase the cost for tendon material and tendon installation. Tendon pretension shall be carefully designed to achieve a good balance between minimum bottom tension and maximum top tension.

4 4 Journal of Offshore Engineering and Technology (2017) 1: Minimum Tendon Tension and Design Criteria Minimum tendon tension along the tendon length occurs at tendon bottom because tendon pipe itself has wet weight in water though it is ideally designed to be neutral buoyant. It usually happens at down-wave tendon due to larger tendon dynamics and smaller mean tension caused by wind overturning moment. The combinations of wind, wave, and current that yield conservative estimates of maximum tendon tension may not produce conservative estimates of minimum tendon tension. Minimum tension is determined by superposition of tendon pretension, environmental effects, and design margin for tendon pile misalignment tolerance (as well as other tolerances), as illustrated in Figure 2 and simply formulated in Equation 1. Fig. 2 Minimum Tendon Tension Superposition (This Figure is modified per API RP 2T Figure 9) In the calculation of minimum tension, tendon pretension shall be the one at the specific downwave tendon bottom with platform at low tide condition. Minimum drift offset shall be considered for platform set-down and the incurred tension increase so that the worst scenario is addressed. Overturning moment effect on the down-wave tendon tension reduction is caused mostly by wind. Dynamic tension caused by wave is the big part of minimum tension calculation. Both first order wave force effect and higher order wave force effect (ringing and springing loads) shall be considered. Tendon pile usually is installed with a misalignment tolerance, and the misalignment will cause additional tendon dynamics per the platform offset. T min = T pretension (at Low Design Water Level) + T setdown (at min. drift offset) - T overturning (wind, wave drift, current) - T wave + springing + ringing - T foundation misalignment... (1)

5 Journal of Offshore Engineering and Technology (2017) 1: For big wave environment, like Gulf of Mexico (GoM), TLP is designed with high tendon pretension because dynamic tension caused by wave is the governing factor for minimum tension. For shallower water environment, for example, 300m~ 600m water depth, foundation misalignment can have a significant effect on minimum tension because the misalignment of a short and stiff tendon will exaggerate the increase of tendon dynamics incurred with offset. Design criteria for minimum tendon tension is specified in API RP 2T 3rd Ed (2010) for different safety categories. Specifically, it is required that: For Category A, Operational Condition, the minimum tendon tension of all tendons shall be positive. For Category B, Extreme Conditions, the minimum tendon tension in at least one tendon per corner should remain non-negative, i.e. it is not allowed that all tendons at one corner go slack. For Category S, Survival Conditions, minimum tension in at least three corner groups of tendons shall maintain non-negative tension, i.e., the scenario that all tendons at one corner go slack is allowed for Survival Condition, but it is not allowed that all tendons of two corners go slack. In case that a tendon is allowed to go slack, the tendon shall not disengage from the tendon receptacle. The overload analysis shall be performed to verify the down-strokes of the tendon do not exceed the minimum stroke to initiate unlatching. 4 Tendon Down-stroke Investigation For the purpose of safety, it will be desired and ideal that no tendon will lose tension for any design conditions. But it will not be efficient for cost because high tendon pretension design causes larger hull size and tendon size. To design a TLP with lower cost but still sufficient safety, as recommended by API RP 2T, temporary loss of tension is allowed in design under certain circumstances if tendon unlatching would not occur is demonstrated. To reduce the risk of tendon unlatching under overload, tendon lock pin is used recent years in design of tendon bottom connector and receptacle assembly as shown in Figure 3. It is designed to have about 40 inches of distance for the bottom connector to move downward to the lock pin. Survival condition associated with Safety Category S governs minimum tension and loss of tension design. Investigation of tendon down-stroke under survival condition is important to ensure the slack tendon will not cause tendon bottom reach the bottom connector lock pin (or unlatching position if pin is not present). It is meaningful to find out relationship between tendon bottom down-stroke and tendon compression (overload) level. TLP global performance assumes tendon in tension, and fixed tendon bottom boundary condition is used in numerical analysis and wave basin model test. Negative minimum tension indicates

6 6 Journal of Offshore Engineering and Technology (2017) 1: 1-13 loss of tension or slack tendon. In reality, tendon bottom is actually not fixed but vertically free. In case of slack tendon, tendon bottom will move downward freely. Fig. 3 Tendon Bottom Connector Assembly Survival condition associated with Safety Category S governs minimum tension and loss of tension design. Investigation of tendon down-stroke under survival condition is important to ensure the slack tendon will not cause tendon bottom reach the bottom connector lock pin (or unlatching position if pin is not present). It is meaningful to find out relationship between tendon bottom down-stroke and tendon compression (overload) level. TLP global performance assumes tendon in tension, and fixed tendon bottom boundary condition is used in numerical analysis and wave basin model test. Negative minimum tension indicates loss of tension or slack tendon. In reality, tendon bottom is actually not fixed but vertically free. In case of slack tendon, tendon bottom will move downward freely. Though investigation of tendon down-stroke has typically not been implemented in the wave basin model test due to difficulties, it is practicable by numerical analysis approach. 4.1 Tendon Down-stroke Analysis Tendon down-stroke analysis is carried out to investigate the relationship between tendon bottom down-stroke and tendon compression level, and show proper reengagement of the bottom connector with the bottom receptacle as well as adequate robustness against subsequent snatch load during down-stroke events. The global coupled model is built using DNV software DeepC. Modifications are made to the tendon line bottom boundary condition. The fixity of tendon bottom is modified to simulate the engagement mechanism of tendon bottom connector with the receptacle. In details, a short segment with non-linear axial stiffness is defined at bottom of tendon line. Lateral support dummy beams are added at tendon bottom to restrain tendon bottom lateral movements. It is

7 Journal of Offshore Engineering and Technology (2017) 1: required that the non-linear stiffness is quite stiff when tensioned, but soft when compressed as shown in Figure 4. Selection of the large and small stiffness values is critical for the analysis as very stiff and very soft stiffness values of the non-linear stiffness curve defined will cause unreasonable results due to numerical conversion problem. After try-and-error tests, suitable stiffness values are found and used for the analysis. Fig. 4 Non-Linear Stiffness Curve The environment condition used for the investigation analysis is 1000 year Hurricane maximum wave in GoM. To have tendon overloaded for minimum tendon tension, tendon pretension at down-wave tendon is reduced by applying additional overturning moment on the platform towards the down-wave corner. Time Domain (TD) global coupled analysis with original tendon bottom fixed boundary condition was first performed to identify the down-wave tendon bottom down-stroke events and corresponding tendon compression level. Then global coupled analysis with tendon bottom boundary condition modified for free downward movement is performed to investigate the tendon bottom down-strokes at these spotted instants. Figure 5 is the TD simulation result plots showing the tendon tension and down-stroke during the events. It is found for this simulation that at time instant around 9700 sec, the down wave tendon bottom got compression and it cause down-stroke at the same time instant.

8 8 Journal of Offshore Engineering and Technology (2017) 1: Post-processing Results and Findings Fig. 5 TD Simulation Results for Tendon Bottom Down-strokes Using the described approach, numerous realizations are done to get more data points for tendon down-stroke study. Tendon down-stroke vs tendon compression level trend is obtained as shown in Figure 6. It is observed that higher tendon compression level causes larger tendon bottom down-stroke in general, but not in one to one correspondence. At same compression level, for example, -400 kips, near red line in the figure, tendon bottom down-stroke can varies from ft. to ft. approximately. The same down-stroke, for example, -1.1 ft., near green line in the figure, may be caused by compression level varies from -500 kips to -850 kips approximately. The tendon down-stroke range tends to be larger when tendon compression level is high. Compared to the direct results from TD coupled analysis, tendon bottom down-stroke can also be alternatively calculated based on the tendon top motion with the assumption that tendon line is straight. This simplified evaluation of tendon down-stroke is more straightforward and the tendon top motion is not related to the tendon bottom boundary condition. Considering actual tendon line is bended in curved shape, the tendon down-stroke calculated assuming straight tendon line shall be larger than that from coupled analysis, and therefore more conservative. Figure 7 shows the down-stroke data points for both methods, and the results make sense as the down-stroke data points from straight line calculation are below those from coupled analysis indicating larger down-strokes for the simplified evaluation method. As the tendon bottom down-stroke behaves very complicated with highly non-linearity, the conservative down-stroke results from the simplified method assuming tendon straight line are valuable for its straightforward and serving as a conservative approach for the down-stroke

9 Journal of Offshore Engineering and Technology (2017) 1: design. The more complicated TD coupled analysis approach shall be used if the straight line method results in a stroke larger than the allowable. Figures 8~9 show tendon down-stroke events are associated with platform pitch motion. Large pitch motion occur at the same time and it can be explained that large instantaneous platform pitch motion contribute significantly to the tendon down-stroke event. Figure 10 shows relatively difference between the down-strokes of two methods indicating different tendon line curvatures may occur at the time instants. In real case, tendon line curved shape will play a role to affect tendon bottom down-strokes, and different tendon line instantaneous shapes can be caused by multiple factors such as platform motion, tendon line dynamics, and environmental forces at the instant. Figure 11shows the time history of tendon tension and down-stroke during a typical down-stroke event. There is some vibration of tendon tension after the down-stroke event, but significant snatch load is not observed. Fig. 6 Tendon Bottom Down-stroke Trend

10 10 Journal of Offshore Engineering and Technology (2017) 1: 1-13 Fig. 7 Tendon Bottom Down-stroke Trend (with Straight Ling Calculation) Fig. 8 Tendon Bottom Down-strokes and TLP Pitch Motion

11 Journal of Offshore Engineering and Technology (2017) 1: Fig. 9 Tendon Bottom Down-strokes and TLP Pitch Motion (Zoomed-in) Fig. 10 Tendon Bottom Down-strokes from Two Methods

12 12 Journal of Offshore Engineering and Technology (2017) 1: 1-13 Fig. 11 Snatch Load during Tendon Bottom Down-stroke Event 5 Conclusions The conclusions are summarized as follow: For an overloaded tendon, tendon bottom down-stroke behaves highly non-linear, affected by multiple motion and environment factors. In general, the trend is higher tendon compression level causes larger tendon bottom downstroke. For same compression level, different tendon bottom down-strokes are observed. The range becomes larger when compression level is high. Tendon line curved shape varies instantaneously with TLP motion in the storm, and can affect tendon bottom down-stroke significantly at different tendon down-stroke events. Compared to the coupled TD analysis method, the simplified method assuming straight tendon line shape gives more conservative tendon down-stroke results. The more complicated TD coupled analysis approach shall be used if the straight line method results in a stroke larger than the allowable. For shallower water TLP, same compression level causes smaller tendon bottom downstroke due to stiff tendon. On the opposite side, for deep water TLP, small compression level can cause relative large tendon down-stroke. No significant snatch load is observed during tendon bottom down-stroke event. For the researched TLP design with -400 kips compression level at the tendon bottom, the downstroke is about 0.5 ft. or 6 inch. Tendon unlatching will not occur, and the robustness of tendon system is ensured.

13 Journal of Offshore Engineering and Technology (2017) 1: References API RP2T 3rd Ed. (2010). Planning, Designing, and Constructing Tension Leg Platforms. July, ABS (2003). Guide for Building and Classing Floating Production Installations, Supplement 2. August, 2003 BV (2012). Rules for the Classification of Tension Leg Platforms (TLP). July, Mansour, A. M. & Huang, E. W. (2006). Tension Leg Platform Survivability Analysis. Proceedings of OMAE06, 25th International Conference on Offshore Mechanics and Architect Engineering, OMAE Biographies Qi Ling is currently a principal naval architect with MODEC International Inc. He has 18 years of engineering experience in offshore industry with extensive expertise in design and analysis of deep water floating structures using DNV software, SESAM. Through his offshore engineering practice, he has been involved in various TLP and Semi projects including Matterhorn TLP, Independence HUB, South Green Canyon Semi, Browse TLP and Stampede TLP projects. His engineering practice includes global and detail strength verification and fatigue evaluation of TLP and Semi hull structures, naval architecture, global performance and wave basin model test for TLP and Semi designs. Qi received his BS degree in Naval Architecture and Ocean Engineering from Shanghai Jiao Tong Univ. in 1986, and received his MS degree in Ocean Engineering from Virginia Tech in Qi is a member of IAOE.

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