FEM Model and Mechanical Behavior of Flexible Risers

9th International Conference on Fracture & Strength of Solids
June 9-13, 2013, Jeju, Korea
FEM Model and Mechanical Behavior of Flexible Risers

Jingyuan Li1, Hua Wang1, Kai Zhang1,
Xiaochuan You2, Jinsan Ju1,*
1
Dept. of Civil Engineering, China Agricultural University, Beijing, China

2
Dept. of Engineering Mechnics, Tsinghua University, Beijing, China
Abstract: This paper presents a detailed finite-element model for a 10 layers unbonded flexible riser.
The model is created by using about half million nodes of shell and solid elements. It takes full account
of the main features of the riser such as geometric nonlinearity, contact interaction, and friction with
very little simplified assumptions. ABAQUS/Explicit analysis module was employed to simulate the
risers mechanical behavior under three load casestension, outer pressure and inner pressure. The
model was solved by a fully explicit time-integration scheme implemented in a parallel environment on
an eight-processor cluster and 32-G memory computer. The calculated stress and deformation of each
layer among the ten layers can be achieved and analyzed. Simulation results for key layers can be
obtained and show a good agreement with those from analytical formula and recommended practical
method. It can be seen that the method in this paper is feasible way to get precise solution for multilayer composite material riser. The detailed finite-element virtual model can be used to predict the
mechanical behavior of the unbounded flexible riser in different load cases instead of mechanical tests.
Keywords: flexible riser, tension, pressure, numerical simulation, mechanical behavior
1. Introduction
The unbonded flexible riser is a pipe composed of several layers without adhesive agents between the
layers. It is widely used in the subsea oil industry for its capacity dealing with large deformation and
displacement due to its lower bending stiffness comparing with rigid steel risers. To achieve the
advantage of flexible risers requires complicated inner structure. Different layers are designed for
specific tasks. One of the problems associated is the difficulty in the analysis particularly under the
very deep water.
Current methods are generally divided into two categories: analytical models and finite-element models.
In the past decades, researchers have conducted several analytical works on this subject. Among the
first pioneers, Kapp [1] derived the stiffness matrix for a helically armored cable subjected to tension
and torsion. He took into account the compressibility of the core and the variation in lay angles. The
research on the response of helically armored cables subjected to tension, torsion, and bending was
conducted by Lanteigne [2]. In his study, the influences of internal radial forces and curvature on the
effective flexural rigidity were investigated. Feret and Bournazel [3] presented a formulation for the
slip of tendons undergoing bending on assumption that armor tendons followed a geodesic path once
slip took place. Kraincanic and Kebadze [4, 5] presented a non-linear formulation in consideration of
the variation of the bending stiffness due to frictional sliding between layers. And an analytical model
of an unbonded flexible pipe was proposed.
However all the analytical models share many simplified assumptions inevitably [6-9], which
significantly limit the application range of the results. On the other hand, the analytical models are
quite complicated due to the large nonlinear of the complex structure [10]. What mentioned above
motivates many researchers into the study of refined finite-element models which takes into account
many details of the real risers that the analytical model can hardly contain. And the detailed FEM
model can be achieved conveniently benefiting from the widely use of computers.
In this paper, a further research on the refined finite-element model of unbonded flexible riser is
conducted. And the mechanical behaviors of the riser in different load cases are obtained.
2. Finite element model

A detailed finite element model is shown in Fig. 1. Ten layers are simulated separately considering the
contact interfaces. All the radial displacement of layers is assumed to be the same and layer separation
is neglected. 0.1 is assumed to be the friction coefficient between layers. Hourglass control is
considered.
Corresponding author: E-mail: jujinsan@tsinghua.org.cn; Tel: +86-010-6273-7130

Hua Wang and Jingyuan Li contribute equally to this work.
1

Tension armor 1
Anti-wear layer
Tension armor 2
Anti-wear layer
Carcass layer
Outer sheath
Inner pressure
protection armor
Interlocking pressure
protection armor
Preparatory pressure protection armor
Anti-wear layer
Fig.1 Ten layers riser

The sequence of layers is presented from inside out in Table 1.
Layer
1
2
3
4
5
6
7
8
9
10
Table 1 Layers of the riser

Type
Carcass layer
Inner pressure protection armor
Interlocking pressure protection armor
Preparatory pressure protection armor
Anti-wear layer
Tension armor 1
Anti-wear layer
Tension armor 2
Anti-wear layer
Outer sheath
The FEM model was created in a global cylindrical coordinate system with its origin located at the
center of the risers bottom. The model consisted of ten separate cylindrical layers.
Carcass layer was modeled by 3D, 4 nodes reduced-integration shell elements S4R. There were 55440
elements and 61610 nodes adopted. The interlocking structure of it shows in Fig.2.

Fig 2.Model of carcass layer
As shown in Fig.3, inner pressure protection armor was modeled by 3D, 8 nodes linear brick, reducedintegration elements C3D8R. 25200 elements and 38052 nodes were adopted here.
Fig.3 model of inner pressure protection armor

Interlocking pressure protection armor and preparatory pressure protection armor were composed of
groove steels, together they made up the pressure protection armor (refer to Fig. 4). Both of the layers
were modeled by 3D, 8 nodes linear brick, reduced-integration elements C3D8R.113280 elements and
264348 nodes were adopted in all.
Fig. 4 Model of the pressure protection armor

There were 3 anti-wear layers modeled between preparatory pressure protection armor, tension armor 1,
tension armor 2 and outer sheath. The model of anti-wear layer shows in Fig.5. There were totally
89000 elements and 178712 nodes adopted. 3D, 8 nodes linear brick, reduced-integration elements
C3D8R was selected for the modeling.

Fig.5 Model of anti-wear layer

As shown in Fig. 6, the lay angles of two helical armor layers were in opposite directions. The inner
tension armor consisted of 58 steel strips while the outer one consisted of 60. Both of them were
modeled by 3D, 8 nodes linear brick, reduced-integration elements C3D8R. There were 7772 elements,
23664 nodes for the inner tension armor and 8040 elements, 24480 nodes for the outer tension armor.
Fig.6 model of tension armor

Fig. 7 shows the detailed dimensions of the risers cross section.
Layer angle for
protection armors 88o
Outer Radius=256mm
Lay angle for

helical armors 30o
Inner Radius=178mm
Fig. 7 Detailed dimensions of the risers cross section

Due to the complication and scale of the structure, modeling in ABAQUS/CAE is difficult and time4

consuming. A parametric modeling procedure of ANSYS was adopted in this paper. After modeling in
ANSYS, the model would be solved in ABAQUS/Explicit analysis module [11].
With the help of the parametric modeling procedures, only the geometry parameters of the layers and
the components of each layer were needed, such as number of wound steel strips in tension layer etc.
The advantage of this method is obvious for it is convenient to achieve, easy to modify and with high
veracity at the same time.
3. Material properties
The material properties for layers of the flexible riser are shown in Table 2.
Carcass
layer
Steel strip
Q345
Density
(kg/m3)
Young's
modulus
(GPa)
Poisson's
ratio
Table 2 Material properties

Pressure
AntiInner pressure
protection
wear
protection armor
armor
layer
Low-density
Steel strip
Nylon
polyethylene
Q235
braid
Tension
armor
Outer Sheath
Steel strip
Q235
Low-density
polyethylene
7800
920
7800
920
7800
920
207
0.18
207
0.18
207
0.18
0.3
0.38
0.3
0.38
0.3
0.38
4. Load case, calculation results and analyses

Load case study conducted on the finite-element model described above. There were two reference
nodes rigidly connected to the nodes set belong to the each end sections, loads and boundary conditions
were then applied to these two reference nodes. The reference node connected to the bottom end was
constrained in all directions and rotations during the analysis while the other one was totally free. Three
typical loads (tension, outer pressure and inner pressure) were applied on a 3.0m long riser to
demonstrate the accuracy and computational suitability of the method.
4.1 Case 1: Tension load
In this case, a 200 kN concentrated load was applied on the free end of the riser. Numerical calculation
results for the first load case are shown in Fig. 8 and Fig. 9. Fig. 8 shows the axial-deformation of the
riser. The maximum stretching of the riser in axial direction is 2.092mm, and the elongation is about
0.1046%. The Mises-stress contour plot for the middle part of the riser under tension load is shown in
Fig. 9. The Mises-stress results of each layer are listed in Table 3.
Fig. 8 Axial-deformation of the riser under tension load

Fig. 9 Mises-stress contour for the middle part of the riser under tension load
Mises
stress
(MPa)
Carcass
layer
Inner
pressure
protection
armor
40.18
0.63
Table 3 Mises-stress of each layer

Interlocking
Preparatory
pressure
pressure
protection
protection
armor
armor
72.56
52.15
Tension
armor 1
Tension
armor 2
Outer
Sheath
119.6
100.2
0.19
As shown in Fig.9, stress mostly concentrated at the tension armor layers. It means that the tension
armor layers work well when subjected to tension because of their specific structure. The Mises-stress
for the inner tension amour is about 119.6 MPa. It is significantly larger than the results from other
layers. It is in good agreement with result obtained from Recommended practice for flexible pipe [12].
It also can be seen that Mises-stress in inner tension armor is slightly greater than that in outer tension
armor due to the difference in their radii. To have a better view of the maximum stress distribution in
the inner tension armor, the other layers are hidden in Fig. 10.
Fig. 10 Mises-stress contour for the middle part of tension amour 1 under tension load
4.2 Case 2: Outer pressure
A 2 MPa outer pressure load was applied on the riser with the free end clamped. The Mises-stress
contour plot for the middle part of the riser under outer pressure is shown in Fig. 11. The Mises-stress

results of each layer are listed in Table 4.
Fig. 11 Mises-stress contour for the middle part of the riser under outer pressure
Carcass
layer
Mises
stress
(MPa)
54.79
Table 4. Mises-stress of each layer

Inner
Interlocking
Preparatory
pressure
pressure
pressure
protection
protection
protection
armor
armor
armor
0.4826
76.98
82.49
Tension
armor 1
Tension
armor 2
Outer
Sheath
31.97
41.01
0.9855
Under the outer pressure, the stresses mostly concentrated at the pressure protection armor layers
instead. The stress in preparatory pressure protection armor is 82.49 MPa, while the stress in
interlocking pressure protection armor is 76.98 MPa. The reason for the change in distribution of
stresses of the cross section is that the helical geometry of the tension armor determines it can hardly
work well in hoop direction, while the pressure protection armors obtains a high hoop direction
stiffness due to the interlocking structure. In Fig. 12, the other layers are hidden for a better view of
distribution of stress in preparatory pressure protection armor.
Fig. 12 Mises-stress contour for the middle part of preparatory pressure protection armor under outer
pressure
7

4.3 Case 3: Inner pressure

In this case, a 6.4 MPa inner pressure load was applied on the riser with the free end clamped.
Numerical calculation result for the Mises-stress contour plot of middle part of the riser under the
second load case is shown in Fig. 13. The results for the Mises-stress of each layer are listed in Table 5.
Fig. 13 Mises-stress contour for the middle part of the riser under inner pressure
Carcass
layer
Mises
stress
(MPa)
1.35
Table 5 Mises-stress of each layer of the riser

Inner
Preparatory
Interlocking
pressure
pressure
Tension
pressure
protection
protection
armor 1
protection armor
armor
armor
3.46
101.0
114.7
10.35
Tension
armor 2
Outer
Sheath
19.98
0.071
Under the inner pressure, the stresses mostly concentrated at the pressure protection armor. The stress
in the preparatory pressure protection armor layer is 114.7 MPa as shown in Fig.14. The results from
the simulation agree well with the analytical results from Xu [13].
Fig. 14 Mises-stress contour for the middle part of preparatory pressure protection armor under inner
pressure
8

5. Conclusions
From the above investigation, the following conclusions can be drawn:
(1) A detailed finite element model for a ten-layer unbonded flexible riser has been built for the
analysis of the risers responses in three load cases. It took geometric nonlinearity, contact interaction,
and friction into account, which makes it more convincing than the analytical model.
(2) From the FEM model detailed stress and deformation information about each layer of the riser
under different loads can be obtained. The calculation results show a good agreement with those from
analytical formula and recommended practical method.
(3) It suggests that the detailed finite element model can be used to predict mechanical behavior of the
riser in different load cases. Using the numerical method, physical experimental tests will only be
required as one-off checks to validate the virtual model. A defined numerical model enables costeffective parametric investigations, which can in turn lead to improved riser design.
Acknowledgement
Support for this research by National Science Foundation of China (51279206), and Chinese Doctoral
Fund (20100008110010).
References
[1] Knapp R. H. Derivation of a new stiffness matrix for helically armored cables considering tension
and torsion. Int. J. Numer. Methods Eng. 1979;14(4):515-529.
[2] Lanteigne J. Theoretical estimation of the response of helically armored cables to tension, torsion,
and bending. ASME J. Appl. Mech. 1985;52(2):423-432.
[3] Feret JJ, and Bournaze CL. Calculation of stresses and slip in structural layers of unbonded
flexible pipes. ASME J. Offshore Mech. Arct. Eng. 1987;109:263-269.
[4] Kraincanic I, and Kebadze E. Slip initiation and progression in helical armoring layers of
unbonded flexible pipes and its effect on pipe bending behavior. J. Strain Anal. Eng. Des.
2001;36(3):265-275.
[5] Kebadze E. Theoretical modeling of unbonded flexible pipe cross-sections. Ph.D. thesis, South
Bank University, London, UK 2000.
[6] Bahtui A, Bahai H, and Alfano G. Numerical and analytical modeling of unbonded flexible risers.
ASME J. Offshore Mech. Arct. Eng. 2009;131(5):021401.
[7] Feret JJ, Bournazel CL. Calculation of stresses and slip in structural layers of unbonded flexible
pipes. Journal of Offshore Mechanics and Arctic Engineering1987;109:263-9.
[8] Harte AM, McNamara JF. Modeling procedures for the stress analysis of flexible pipe cross
sections. Transactions of the ASME1993;115:46-51.
[9] Claydon P, Cook G, Brown PA, Chandwani R. A theoretical approach to prediction of service life
of unbonded flexible pipes under dynamic loading conditions. Marine Structures1992;5(5):399429.
[10] Bahtui A, Bahai H, and Alfano G. A finite element analysis for unbonded flexible risers under
torsion. ASME J. Offshore Mech. Arct. Eng. 2008;130(4): 041301.
[11] ABAQUS theory manual, ABAQUS, Version 6.10 Documentation. 2010.
[12] Recommended practice for flexible pipe. ISO 13628-11:2007
[13] Xu Z.L, Elastic mechanics, Version 2. 1982.

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9th International Conference on Fracture & Strength of Solids

June 9-13, 2013, Jeju, Korea