TODAYS MOWII WEBINAR:

Why Good Mooring Systems Go Bad

Fatigue Factors in Mooring Systems for Floating Offshore Wind Turbines
Richard H. Akers, PE
Chief Technology Officer
Maine Marine Composites, LLC

July 16th, 10:00 AM ET

The presentation will begin at 10:03
to allow all attendees time to login

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 Why Good Mooring Systems Go
Bad
Fatigue Factors in Mooring Systems for Floating
Offshore Wind Turbines

Richard H. Akers, PE
Chief Technology Officer
Maine Marine Composites, LLC
Portland, ME USA
http://www.mainemarinecomposites.com

2
Agenda
• Floating Offshore Wind Turbines:
Background
• Mooring Components: Background
• Anchor Failures
• Mooring Failures
• Fatigue Mechanisms
• Rules & Regulations
• Modeling, Simulation, and
Prediction
• Inspections

3
 Floating Offshore Wind Turbines
• Performance of oil & gas platforms well understood
• Key differences between oil & gas platforms and FOWTs
• Additional uncertainties
• Any accidents will receive significant publicity
• Interaction between turbine, control system, floating platform, mooring system not well understood (yet)
• Performance & dynamics
• FOWT likely to be located in shallower water
• Have lower mass The New York Times, “Offshore Wind Farm Approved
• Wind loads have greater influence on global performance & loads in New Jersey,”
• Turbine control systems, angle of attack, nacelle yaw http://green.blogs.nytimes.com/2008/10/03/offshore
• Introduce additional complexity -wind-farm-approved-in-new-
• Can complicate relative severity of “operational” and “survival” conditions jersey/?_php=true&_type=blogs&_r=0, July 15, 2014
• Unmanned
• Economics:
• StatoilHydro Hywind Spar: $62.5 million
• Perdido Spar (world’s deepest oil & gas spar):
$3 billion
• Design margins
• Current practice is for less redundancy on
mooring systems of FOWTs
• Less risk of environmental pollution
4
Floating Offshore Wind Turbines

Hurst, T., “Plans for Floating Offshore Wind Making

Pao, Lucy Y., and Kathryn E. Johnson. "A tutorial on the dynamics and control of wind
Waves in Mass,” Crisp Green, October 10 2009,
turbines and wind farms." American Control Conference, 2009. ACC'09.. IEEE, 2009.
http://crispgreen.com/2009/10/plans-for-floating-
offshore-wind-farm-making-waves-in-mass/.

5
Mooring Components

Sound & Sea Technology,

"Advanced Anchoring and
Mooring Study,"
November 30, 2009

6
Existing Floating Offshore Wind Turbines
Statoil Hydro Hywind Kabashima Island VolturnUS, 12 kW
Spar, 2.3 MW Principle Power Spar, 100 kW (2 3 catenary
Fukushima
3 catenary mooring WindFloat, 2 MW MW full scale) moorings
Wind Farm, 2
chains in 200-220m Semi-taut moorings, 3 catenary 56mm • Experienced scaled
MW
water depth with drag anchors anchor chains 50-year and 500-
single clump weight Survived typhoon year events

“Floating Wind Turbine,” Principle Power, The Japan Times, Utsunomiya et al. Cianbro,
Wikipedia, July 9 2014, “WindFloat The “Floating wind 2014. Dynamic http://www.cianbro.c
http://en.wikipedia.org/w Offshore Wind farm debuts off response of a spar- om/
iki/Floating_wind_turbine Solution,” IBC Deep Fukushima,” type floating wind
Water Wind Farms November 11, turbine at power
Seminar, London, 2013. 2013. generation. OMAE.
7
 Mooring Materials: Chain
Duggal, A.S and
Fontenot, W.L. 2010.
Anchor Leg System
Integrity – From
Design through
Service Life, Offshore
Technology Conf.,
Houston, TX, pp. 1-5.

Break Proof
Weight
Chain Wire Size R3
R3
Stud Stud Average EA
inches mm KN KN Kgs/m N
1.50 38 1.32E+03 8.75E+02 3.20E+01 1.379E+08
1.97 50 2.23E+03 1.48E+03 5.50E+01 2.388E+08
2.52 64 3.55E+03 2.36E+03 9.00E+01 3.912E+08
2.99 76 4.88E+03 3.24E+03 1.26E+02 5.516E+08
3.54 90 6.65E+03 4.41E+03 1.77E+02 7.736E+08
4.02 102 8.32E+03 5.52E+03 2.28E+02 9.936E+08
4.49 114 1.01E+04 6.71E+03 2.85E+02 1.241E+09
5.00 127 1.22E+04 8.08E+03 3.53E+02 1.540E+09 Source: API RP 2SK 8
Mooring Materials: Wire Rope

Fontaine et al. Semi-empirical

modeling for seawater corrosion
of wire rope. ISOPE, Osaka,
Japan, June 21-26, 2009.
Source: API RP 2SK 9
 Anchor Types
Sound & Sea Technology, "Advanced Anchoring
and Mooring Study," November 30, 2009

Toal et al. Gryphon Alpha FPSO –

Experience gained during
moorings replacement and hook-
up. OTC-25322, Houston, Texas,
May 5-8, 2014.
10
Drag/Embedment Anchors
• Lots of drag anchor choices
• Vryhof Stevpris, Stevmanta shown Vryhof Anchors,
http://www.vryhof.com
• Uplift in anchor/mooring design? /products.html,
Accessed July 15, 2014
• Depends on how deep the anchor is imbedded
• Inverse catenary of mooring line (E) allows for uplift up to 20
degrees before anchor loads change
• Proof load test
required
• 50% of breaking
load of chain

Anchor Manual
2010, “The
Guide to
Anchoring,”
Vryhof Anchors. 11
Suction Pile Anchor Sound & Sea Technology, "Advanced Anchoring and
Mooring Study," November 30, 2009

Source: API RP 2SK 12

Suction Pile Failures

• Scouring
• Tilting, loss of friction drag
• Normalized scour depth reduces
quickly with increase of pile
diameter Li, Y., et. al., “Is Scour Important for Pile
• Actual scour depth depends on Foundation Design in Deepwater?,”
OTC-19906, 2009 Offshore Technology
caisson diameter and “stick-up” Open Course, "Offshore Windfarm Design,
Conference, Houston, TX
height Foundations" OE 5662, Delft University Wind
Energy Research Institute
• Prevention
• Geotechnical Analysis (depends on
bottom type, other factors) R
• Add skirts, artificial fronds at base  zlow
of caisson

Riemers. “Self Installing Wind Turbine (SIWT),” SPT

13
Offshore, Network Event Paris, November, 2011.
Suction Pile Failures

Bhattacharjee et al. 2014. Serpentina FPSO mooring

integrity issues and system replacement: unique fast track
approach. OTC-25449, Houston, Texas, 2014. 14
 Abrasion Failure: Synthetic Rope

Banfield et al. Durability of polyester

deepwater mooring rope. OTC-17510,
Houston, Texas, 2005.

Ayers et al. Effects of fiber rope – seabed contact

on subsequent rope integrity. OTC-25136,
Houston, Texas, May 5-8, 2014.

15
Mooring Failure Mechanisms
Excessive Loads
• Load exceeds breaking strength of
mooring components
• Cause/physics
• Extreme storm events
• High pretension causes higher tension from
wave motions
• Decrease in breaking strength due to
fatigue
• Line goes slack and snaps
• How to avoid it (case studies, examples)
• Recommended practice
• API, DNV, ABS mooring design guidelines
• Software analysis
• Accurate model and appropriate choice of Jean et al. Failure of chains by bending on deepwater mooring
environmental conditions systems. OTC-17238, Houston, Texas, May 2-5, 2005.
• Model tests
16
Mooring Failure Mechanisms
Umbilical Failure Li, S., Nguyen, C. 2010.
Dynamic Response of
• Cause/physics Deepwater Lazy-Wave
Catenary Riser. Deep Offshore
• Extreme weather Technology International,
• Low pre-tension leads to Amsterdam, Netherlands.

excessive offset
• Platform excursion so large
that umbilical snaps
• How to avoid it
• Umbilical bend restrictors
and other accessories
• Umbilical designed to
Marine
survive bending, offset, "Ship’s anchors and trawlers can cause
Technology
and tensions damage and failure of undersea cables,"
www.soundandsea.com/OceanEngineeringPa
Reporter, vol
57 (5) June
ges/Survivability.html, downloaded 07/2014
2014, pg. 42.
17
Mooring Failure Mechanisms
Cascading damage
• Cause/physics
• Line snaps, FOWT moves to new
position
• Secondary umbilical or line failure
• Loss of stationkeeping
• Worse for FOWTs than oil and gas
platforms (less redundancy)
• How to avoid it
• Mooring design should account for
• Stationkeeping with one/two failed lines
• Transient effects of a line breaking event

Source: API RP 2SK 18

Fatigue Damage

Brown et al. Phase 2 Mooring

integrity JIP – summary of
findings. OTC-20613,
Houston, Texas, May 3-6,
2010.

Fontaine et al. 2012. Investigation

of severe corrosion of mooring
chain in west African waters.
Proceedings of the Twenty-second
International Offshore and Polar
Engineering Conference, Rhodes,
Greece, pp. 389-394.

19
 Fatigue Damage
Corrosion of Chain
• Cause/Physics Duggal, A.S and Fontenot,
W.L. 2010. Anchor Leg
• Water temperature System Integrity – From
Design through Service Life,
• Water velocity (can disrupt rust build- Offshore Technology Conf.,
up & marine growth) Houston, TX, pp. 1-5.

• Dissolved oxygen
• Abrasion (can disrupt rust build-up
marine growth)
• Microbiologically Influenced
Corrosion Fontaine et al. SCORTH
JIP – Feedback on MIC
• Other factors that have less effect and pitting corrosion
• Alloy composition of steel from field recovered
mooring chain links.
• Water pH OTC-25234, Houston,
Texas, May 5-8, 2014.

20
 Fatigue Damage
Corrosion of Chain Melchers et al.
Corrosion of working

• How to Avoid it
chains continuously
immersed in seawater.
J. Mar. Sci. Technol.
• Design practice: over-design chain 12:102-110, 2007.
to account for material loss
• Empirical models exist for prediction
of corrosion rate
• Current standards suggest
corrosion/wear allowances based on
only a few factors
• Several case studies show corrosion Melchers, R.E.
can exceed allowances in standards 2005. The effect
of corrosion on
• Routine inspection the structural
reliability of steel
offshore
structures.
Corrosion
Science 47, pp.
21
2391-2410.
Fatigue Damage
Corrosion of Wire Rope
• Cause/Physics
• Driven by environmental factors
• Water temperature
• Water velocity
• Dissolved oxygen
• Effectiveness of lubricant
• Rate of zinc dissolution
• How to Avoid it
• Protective measures
• Protective zinc coating
• Empirical models have been proposed
to predict Fontaine et al. Semi-
• Corrosion rates empirical modeling for
• Rate of deterioration of protective seawater corrosion of
wire rope. ISOPE, Osaka,
elements Japan, June 21-26, 2009. 22
Case Study
MMC Investigation of Chain Corrosion
• Investigation of corrosion of US Coast Guard aid-to-
navigation (ATON) buoys
• Significant loss of chain link material in touchdown
region
• Believed to be caused by corrosion & abrasion
• Prevention of rust build-up by abrasion
• Increased contact roughness by sand/shell on seafloor
• Current investigation efforts by MMC
• Field measurements to quantify
material loss
• Examination of logs to assess trends
• Computer models of ATON chain
dynamics in chafe zone

23
Case Study
Severe Pitting Corrosion
• Investigation of FPU off tropical West
Africa
• Pitting corrosion discovered in mooring
chain Fontaine et al. SCORTH JIP –
Feedback on MIC and
• 35% decrease in cross-section after 7 years pitting corrosion from field
recovered mooring chain
• Significantly higher loss than recommended links. OTC-25234, Houston,
allowances in existing codes Texas, May 5-8, 2014.

• Breaking load between 80-90% of original

• Attributed to Microbiologically Influenced
Corrosion (MIC)
Reported by Fontaine et al, 2012 (ISOPE) &
Fontaine et al, 2014 (OTC) as part of Seawater
Corrosion of Rope and Chain (SCORCH) JIP
24
 Fatigue Damage
Material Abrasion
• Cause/Physics
• Contact between surfaces
• Consecutive chain links
• Mooring & seafloor
• Mooring & fairlead
• Function of
• Contact force
• Material hardness
• Relative motion
• How to Avoid it:
• Design so rope never contacts seafloor Brown et al.
• Predict abrasion on chain links based on Phase 2 Mooring
Chain geometry, mooring line dynamics, integrity JIP –
steel hardness summary of
findings. OTC-
20613, Houston,
Texas, May 3-6,
2010.
25
Fatigue Damage
Types of Abrasion
• Adhesive wear: welds
form between wearing www.machinerylubrication.com
surfaces and are sheared
off
• Abrasive wear: hard
material abrades softer
one
• Fretting: small oscillations
between surfaces cause
oxidization

26
Case Study
Wear on Buoy chain
• Installed in 1982 with asymmetric chain mooring layout
• Failure during typhoon 2 months after installation Shoup & Mueller. Failure
analysis of a Calm buoy anchor
• 40-70 knot winds & 30 ft. waves over 3 day period chain system. OTC-4764,
Houston, Texas, May 7-9, 1984.
• Failure caused by material wear
 Fatigue Damage
Out of Plane Bending
• Relatively new source of fatigue
• Cause/Physics
• Chain bending in chainhawse
• High pretension in mooring line
• Deformation of link due to proof loading
• High loads cause links to behave like solid
beam members
• How to Avoid it
• Prediction
• Empirical models
• Analytical beam models
• Finite element models
• Hot-spot S-N analysis
Jean et al. Failure of chains by
bending on deepwater
mooring systems. OTC-17238,
Houston, Texas, May 2-5, 2005. 28
Case Study
Girassol Offloading Buoy
• Offloading buoy designed in accordance with
API RP2SK with design fatigue life > 60 years
• Several chains broke within 1 year due to
fatigue failure

Jean et al. Failure of chains by bending on

deepwater mooring systems. OTC-17238,
Houston, Texas, May 2-5, 2005.

29
Fatigue Damage
Snap Loads
• Cause/Physics
• Slack line followed by
spike in tension as line
goes taut
• Can lead to large increase
in tension close to or
above breaking strength
• How to Avoid it
• Further research needed
• Determine how snap loads
affect fatigue
• Is Miner’s rule violated?
30
Fatigue Damage http://northstar.corsafety.ca/cranetrainin
g/pre04/05pre04.htm

Birdcaging
• Cause/Physics
• Abrupt tension changes and small
bend radii in touchdown region
• Torsion & trenching
• Changes in line behavior due to
corrosive losses
• How to Avoid it
• Avoid rope contact with seafloor

Duggal, A.S and Fontenot, W.L. 2010. Anchor

Leg System Integrity – From Design through
Service Life, Offshore Technology Conf.,
Houston, TX, pp. 1-5.

31
Case Study
Haewene Brim FPSO
• Installed with chain/unsheathed
wire rope mooring system 1998
• Birdcaging discovered on
numerous occasions
• Reported by Leeuwenburgh &
Brinkhuis, 2014 (OTC-25232)

Leeuwenburgh & Brinkhuis. Lifetime

extension North Sea FPSO, mooring system
replacement; integrity and design
challenges. OTC-25232, Houston, Texas,
May 5-8, 2014.

32
Rules and Regulations
Standard Based Design to Avoid
Failure
• For good analysis • Key Standards for Mooring & FOWT
• Good metocean model needed Design:
• Good environmental model needed • American Petroleum Institute
• Pick relevant design and survival load • RP 2SK Design and Analysis of Stationkeeping
cases Systems for Floating Structures
• Cross between reasonable and worst case • American Bureau of Shipping
• Use accepted engineering practices to ensure • Guide for Building and Classing Floating
survival Offshore Wind Turbines
• Guidance Notes on the Application of Fiber
• Environmental cases Rope Mooring
• Flaws in statistical methods • Guide for the Certification of Offshore
Mooring Chain
• Climate change, growing history of weather
events mean changing long term statistics • Bureau Veritas
• Upper limits to wave conditions are neglected • 493NI Classification of Mooring Systems for
in long term statistics Permanent Offshore Units
• When hurricane size increases to a point • Det Norske Veritas
waves start to get smaller • OS-E301 Position Mooring
• OS-E302 Offshore Mooring Chain
• OS-E303 Offshore Fibre Ropes
• OS-E304 Offshore Mooring Steel Wire Ropes
33
Rules and Regulations
Standard Based Design to Avoid Failure
“ABS Guide for Building and
Classing Floating Offshore
Wind Turbine Installations.”
American Bureau of Shipping,
2013.

34
Rules and Regulations
Standard Based Design to Avoid Fatigue
• S-N curves available in standards for mooring
components/materials
• Many design standards
recommend size
corrosion/abrasion allowances for chain
• Growing number of case studies
show allowances are insufficient

Offshore Standard DNV-OS-E301. “Position

Mooring,” October, 2010.

35
 Modeling, Simulation, and Prediction
Stationkeeping Analysis: MMC Tools
• CAD: Development of platform/hull model
• ANSYS-Aqwa
• Radiation/Diffraction analysis in frequency
domain
• Determine wave loads, Response Amplitude
Operators (RAOs) of platform/vessel
• NREL FAST
• Analysis of turbine performance & loads in
time domain
• Quasi-static mooring line model
• Orcina OrcaFlex
• Nonlinear finite element mooring model in
time domain
• Coupled with FAST for best analysis of FOWT
hydrodynamics including platform, turbine,
moorings
36
 Inspection
• Goals: detect problems, evaluate remaining life (potential life extension) Allan et al. Mooring system life extension using
• Maintenance subsea inspection technologies. OTC-24184,
Houston, Texas, May 6-9, 2013.
• Retrieve & inspect critical components regularly
• Rotate/replace chain links
• Inspection
• Visual Inspection: high level inspection for
significant & obvious damage, clean, identify
areas of potential risk
• Measurement: quantify corrosion, abrasion,
other observed damage
• 3D Modeling: assess remaining strength of
components
• Monitoring equipment
• Many floating systems: can’t tell if mooring is intact
• Some mooring failures detected months after failure
• Measurement options
• Line tension measurement using load cells
• Angle measurement using inclinometers
• Position & heading measurement using Differential GPS
37
Conclusions
• Mooring systems are underappreciated
• Design standards lack details
• Corrosion/abrasion allowances
• Affect of snap loads
• Selecting environmental conditions
• Inspection needed to prevent failures
• Significant additional research needed
• Cause of corrosion/abrasion
• Selection of design load & survival conditions
• Effect of snap loads on mooring integrity

38
References
1. “ABS Guide for Building and Classing Floating Offshore Wind Turbine Houston, TX, pp. 1-5.
Installations.” American Bureau of Shipping, 2013. 12.Fontaine et al. 2012. Investigation of severe corrosion of mooring
2. “Floating Wind Turbine,” Wikipedia, July 9 2014, chain in west African waters. Proceedings of the Twenty-second
http://en.wikipedia.org/wiki/Floating_wind_turbine International Offshore and Polar Engineering Conference, Rhodes,
3. Allan et al. Mooring system life extension using subsea inspection Greece, pp. 389-394.
technologies. OTC-24184, Houston, Texas, May 6-9, 2013. 13.Fontaine et al. SCORTH JIP – Feedback on MIC and pitting corrosion
4. American Petroleum Institute (API). Design and Analysis of from field recovered mooring chain links. OTC-25234, Houston,
Stationkeeping Systems for Floating Structures. API Recommended Texas, May 5-8, 2014.
Practice 2SK Third Edition, Washington DC, 2005. 14.Fontaine et al. Semi-empirical modeling for seawater corrosion of
5. Anchor Manual 2010, “The Guide to Anchoring,” Vryhof Anchors. wire rope. ISOPE, Osaka, Japan, June 21-26, 2009.
6. Ayers et al. Effects of fiber rope – seabed contact on subsequent 15.Hurst, T., “Plans for Floating Offshore Wind Making Waves in Mass,”
rope integrity. OTC-25136, Houston, Texas, May 5-8, 2014. Crisp Green, October 10 2009,
7. Banfield et al. Durability of polyester deepwater mooring rope. OTC- http://crispgreen.com/2009/10/plans-for-floating-offshore-wind-
17510, Houston, Texas, 2005. farm-making-waves-in-mass/.
8. Bhattacharjee et al. 2014. Serpentina FPSO mooring integrity issues 16.Jean et al. Failure of chains by bending on deepwater mooring
and system replacement: unique fast track approach. OTC-25449, systems. OTC-17238, Houston, Texas, May 2-5, 2005.
Houston, Texas, 2014. 17.Leeuwenburgh & Brinkhuis. Lifetime extension North Sea FPSO,
9. Brown et al. Phase 2 Mooring integrity JIP – summary of findings. mooring system replacement; integrity and design challenges. OTC-
OTC-20613, Houston, Texas, May 3-6, 2010. 25232, Houston, Texas, May 5-8, 2014.
10.Cianbro, http://www.cianbro.com/ 18.Li, S., Nguyen, C. 2010. Dynamic Response of Deepwater Lazy-Wave
Catenary Riser. Deep Offshore Technology International, Amsterdam,
11.Duggal, A.S and Fontenot, W.L. 2010. Anchor Leg System Integrity –
Netherlands.
From Design through Service Life, Offshore Technology Conf.,
39
References cont.
19. Li, Y., et. al., “Is Scour Important for Pile Foundation Design in 29. Shoup & Mueller. Failure analysis of a Calm buoy anchor chain
Deepwater?,” OTC-19906, 2009 Offshore Technology Conference, system. OTC-4764, Houston, Texas, May 7-9, 1984.
Houston, TX 30. Sound & Sea Technology, "Advanced Anchoring and Mooring
20. Marine Technology Reporter, vol 57 (5) June 2014, pg. 42. Study," November 30, 2009
21. Melchers et al. Corrosion of working chains continuously immersed 31. The Japan Times, “Floating wind farm debuts off Fukushima,”
in seawater. J. Mar. Sci. Technol. 12:102-110, 2007. November 11, 2013.
22. Melchers, R.E. 2005. The effect of corrosion on the structural 32. The New York Times, “Offshore Wind Farm Approved in New
reliability of steel offshore structures. Corrosion Science 47, pp. Jersey,” http://green.blogs.nytimes.com/2008/10/03/offshore-
2391-2410. wind-farm-approved-in-new-
23. Offshore Standard DNV-OS-E301. “Position Mooring,” October, jersey/?_php=true&_type=blogs&_r=0, July 15, 2014
2010. 33. Toal et al. Gryphon Alpha FPSO – Experience gained during
24. Open Course, "Offshore Windfarm Design, Foundations" OE 5662, moorings replacement and hook-up. OTC-25322, Houston, Texas,
Delft University Wind Energy Research Institute May 5-8, 2014.
25. Pao, Lucy Y., and Kathryn E. Johnson. "A tutorial on the dynamics 34. Utsunomiya et al. 2014. Dynamic response of a spar-type floating
and control of wind turbines and wind farms." American Control wind turbine at power generation. OMAE.
Conference, 2009. ACC'09.. IEEE, 2009. 35. Vryhof Anchors, http://www.vryhof.com/products.html, Accessed
26. Principle Power, “WindFloat The Offshore Wind Solution,” IBC Deep July 15, 2014
Water Wind Farms Seminar, London, 2013. 36. www.machinerylubrication.com
27. Riemers. “Self Installing Wind Turbine (SIWT),” SPT Offshore, 37. www.substech.com
Network Event Paris, November, 2011.
28. Ship’s anchors and trawlers can cause damage and failure of
undersea cables,
www.soundandsea.com/OceanEngineeringPages/Survivability.htm,
downloaded 07/2014 40
 Thank you for attending todays webinar. For questions or comments on the
MOWII Webinar series or any other activities please feel free to contact us or visit
us on the web.
This webinar has been recorded and will be posted on our website.

www.mainewindindustry.com

Paul Williamson
Portland Maine
207-242-3521
[email protected]

Please Join us for the Next MOWII Webinar: Subject and Time to be announced

For more information on this and other Ocean & Wind Energy events visit us on the web at:
www.mainewindindustry.com