OTC 5060

Summary of the 4 Year Research Project: Anchor Chain

w

Cables Offshore
by J. Lereim, Det norske Veritas

Copyright 1985 Offshore Technology Conference

This paper was presented at the 17th Annual OTC in Houston, Texas, May 6-9,1985. The material is subject to correction by the author. Permission to
copy is restricted to an abstract of not more than 300 words.

ABSTRACT OPERATIONAL EXPERIENCE

The present paper summarizes the main aspects
studied in the Veritas Joint Industry research project
entitled "Anchor Chain Vables Offshore -Material
Properties-Reliability". The research project included
experimental and numerical assessments of the strength and
reliability of Chain of Oil Rig Quality. The study covered
fracture, fatigue, stress analyses, NDE-evaluation of
fabrication defects, the reliability of applied NDE method
and an overall fracture and reliability analysis.
INTRODUCTION
Significanf and unacceptable failure rates were
experienced on offshore mooring chains during the last
decade and a great demand for reduction in failure rates
arose. That situation lead to the generation and execution
of the Veritas Joint Industry Research Project entitled
"Anchor Chain Cables Offshore-Material Properties and
Reliability." Most relevant and necessary aspects related to
the reliability of offshore mooring chains of the grade ORQ
were examined during the study. The program included the
following main topics: - corresponding predicted quasistatic values 2 Stlll the actual
1. Fracture Strength and Toughness
2. Fatigue Strength
3. Stress analyses and line tension analyses.
4. Reliability of applied NDE method
5. Size distribution of defects
In spite of the fact that rather moderate nominal
load levels (line tension) appear in mooring lines, failure has
occured at failure rates up to 10% and at load levels which
are typical for normal operating conditions.
The operating requirements limit the normal
operating load to be less than 1/3 of minimum guaranteed
breaking load, while typical operational load level on a
semisubmersible is in the order of 1/5-1/4 of minimum
breaking load. Thus, failure at normal operating conditions
should hardly ever appear. However, during handling and
operation of the wind-lasses, sometimes shock loading may
be generated due to climbing and slip in the wind-
lass/fairlead which may not be recorded by the conventional
load cells. Therefore, local shock loading may appear
superimRosed on the recorded static load level during
handling!. Further, dynamic amplification of the maximum
load present may enhance the load level significantly, which
however may not have been registered by the conventional
load cells. The latter is indicated by recent non-linear
dynamic analyses with values up to 70% higher than the
load level will be well below the actual minimum guaranteed
breaking load and failure is not expected. The local loading
condition will however vary depending on the location along
the mooring line. In the fairleads where the chain enters the
offshore unit, the single links are subject to local bending
where additional stresses appear through the bending, as
well as through bending stresses due to friction between
neighbouring links 3 Thus, the local stress level in fairleads
may be high although the nominal stresses are moderate,
and the risk of link failure is enhanced.

6. Overall Fracture and Reliability Analysis
The reliability analysis utilized the data obtained in
the preceeding subactivities in order to derive the most
important factors that influences the actual reliability level
to be experienced in the mooring chains. On that basis the
most rational actions for possible improvement in reliability
level may be derived.
References, tables and lllustrations at end of paper.
367
Unstable failure of a brittle manner is experienced to
be the major failure mechanism preceeded by little or no
fatigue cracking, while conventional fatigue failure
terminated by a ductile final fracture is far less frequently
reported for semisubmersibles as drllling units or for similar
temporary location.
However, future experience may change this picture
when semisubmersibles and other moored units wlll be used
on a longterm permanent basis. Then fatigue may become as
critical as unstable fracture, and the ultimate fracture
strength, as well as the fatigue strength are of main
concern. Correspondingly, the presence of and influence of
2 SUMMARY OF THE 4 YEAR RESEARCH PROJECT:
fabrication defects will become more important as they
highly influence the combined fatigue and fracture
performance of long term mooring chains.
UNSTABLE FRACTURE STRENGTH
The brittle fracture resistance of ORQ chain links
were examined by testing of 114 full scale bend type
specimens containing surface cracks of various depths. The
chain diameter tested was 76mm, the most commonly used
on offshore mobile units. Testing was performed at -35 0C
which ~as fo~nd from introductory tests to simulate typical
dynamIc loadmg rates at the design temperature of 0 oC4.
The results are shown in Figs. 1 and 2 in terms of the CTOD
fracture toughness and nominal fracture stress versus crack
depths respectively.
The test results for the CTOD fracture toughness
characterization of ORQ chains showed that a large scatter
occurred with unacceptably low values for a significant
fraction of the real size specimens with intermediate and
deep cracks, i.e. crack depth larger than 12mm. See fig. l.
For shallow cracks, still a large scatter was present, but the
toughness level was acceptable with a minimum CTOD value
of approximately 0.25mm for crack depth range 4-8mm. The
extreme lower bound values for the larger crack depths
were mainly due to insufficient normalizing of the flash butt
weld 4 This might be avoided by longer holding time in the
austenitizing temperature range in order to obtain full
normalizing of the weldment. Consequently, a minimum
holding time must be requested to guarantee acceptable
fracture toughness, both in terms of increasing the mean
value, as well as reducing the scatter. The fracture strength
beha.viour ~aried fro~ purely brittle fracture to fully
ductIle, whlle the major part of the test series showed
elastic plastic behaviour prior to cleavage instability.
The corresponding fracture stress derived by elastic
analysis of the 3 point full size bend tests at fracture
showed somewhat less scatter than the CTOD-fracture
toughness, see Fig. 2. These data reflect the actual critical
load level regardless of the amount of plastic deformation
occurring.
The line tension capacity of a chain is of main
conce~n for the designer and operator of a rig, and the
capacIty may seem best described by the actual fracture
stress level capacity reported of the chain. However, the
fracture stress data do not reflect any post critical
deformation capability, which is characterized by the
recorded CTOD fracture toughness. Therefore optimum
fracture strength and toughness should be requested in
terms of a combination of a minimum required fracture
stress level and a minimum required CTOD-fracture
toughness. If the fracture stress is applied in design and
strength assessments, the "safety" margin may be
characterized as the ratio of the fracture stress and the
applied stress at the location of concern, i.e.:
aria)
y = -~~~- ~ . . . . . . . . [1]
a high cycle range, a 3 D Finite Element Crack Growth
where CS" is a function of applied load level, loading
condition and location of the plane of the defect of concern.
Similarly, the CTOD-fracture toughness results may
be applied in the strength assessments of the risk of
fracture when related to the nominal strain at the location
of a defect and the depth of a possible defect.
ANCHOR CHAIN CABLES OFFSHORE OTe 5060
From the obtained results, a simplified chain design
curve was established5 , since the fracture strength test
series was performed by testing full size chain type bend
specimens containing surface cracks. The characteristic
curve is expressed by the following:
CTOD _
- 0.9
( e
-
)1.5 ~ ,. /I' . [21
2ITaey ey
where Q.. is the depth of a semi-elliptic surface crack, ,
the CTOD fracture toughness, and e, the maximum nominal
strain in the cross section at the location of the crack.
FATIGUE STRENGTH
Fatigue tests were performed on 76mm and 40mm
diameter chains of ordinary links and connecting links.
Testing was performed at 3 cyclic load levels only, and in
air environment. Therefore, the experimental fatigue results
should mainly be treated as reference test results and not as
the typical real fatigue strength in corrosive environment.
Although large scatter is present6 ,7 the data for the
ordinary links were in close agreement with existing open
literature data8 Therefore, reliable fatigue strength
results are obtained for the intermediate and low cycle
regimes tested, while there is still a lack of experimental
test results for the small amplitude high cycle range. Of
main concern is however that the major fraction of the
corresponding connecting links showed considerably shorter
fatigue lives at a given cyclic load level than the ordinary
links. See Fig. 3. Thus, special attention should be paid to
the improvement in fatigue strength of connecting links. For
the particular Kenter type connecting links tested, the
redu~ed fatigue strength is mainly due to extremely high
locahzed stress concentrations in the intersections between
various grooves and machined surfaces in the locking
mechanism, as indicated in Fig. 4. All fatigue cracks in the
kenter type links were introduced in this region at a very
early stage of the fatigue 6 ,9. This should be avoided.
Consequently, the high local stress concentrations must be
reduced, for example by increasing the minimum allowable
groove radius and grinding the intersecting corners. A longer
fatigue crack growth period would thus be expected.
Further Baldt type connecting links were also tested.
Longer fatigue lives were expected compared with the
Kenter type links, because of the smoother shape and lower
stress concentrations. For the few spot checks done, large
variations in fatigue life were observed. Fatigue life as
short as for Kenter links was experienced on Baldt type
connecting links which showed rather poor fit between the
different parts in the link. That situation lead to assymetric
load transfer between the links and only minor fractions of
load were carried by the lock side. Contrary, when good fit
was present, the fatigue performance was as good as for
typical ordinary links.
In order to take into account the effect of corrosive
environment and predictions of the fatigue strength in the
analysis was performed lO The derived numerical results
were in excellent agreement with the experimental results
when assuming initial surface crack depths of 0.05-1mm and
O.5-3mm for the bend zone and stud weld zones
respectively, see Fig. 5. Thus, realistic S-N curves for chain
links are derived from a fatigue crack propagation analysis
for corrosive environment by introducing the proper values
of the material parameters C and m in the crack
propagation calculations through Paris' equation.
368
OTe 5060
LINE TENSION AND STRESS ANALYSIS
A line tension load analysis was
performed which estimated the load spectra for extreme
loads as well as for the cyclic line tension at various
waterdepths in the North Sea. The calculation example was
done for an Aker H-3 semisubmersible rig, and the maximum
line tension and the cyclic line tension were described by
two and three parameter Weibull distributions. The
characteristic values of the separate parameters in the
Weibull distribution function are given in table I and 2.
The corresponding stress state in the
separate chain links was established through 3D Finite
Element Analysis as well as through strain gauge
measurements during operation and under laboratory
conditions.
The three basic loading conditions on a link were
defined and analysed;
1. Link in pure tension
2. Tension/Bending of Vertical Link
fair lead/cabelar
3. Tension/bending of horizontal link
fairlead/cabelar (Link in pocket).
For the pure tension loading, the largest stress
occured, as expected, inside the bend region where the
maximum local stress is approx. 1t.1t times the nominal stress
(p/2 it r 2 ), i.e. SCF =1t.4.
Rather moderate stress levels were present in the
weld zone, particularly below the stud where the local stress
normal to the plane of the weld zone is 0.5x nominal stress,
while the maximum local stress in the outer fibres of the
weld zone is slightly higher than the nominal stress. See fig.
6.
The possible tension/bending loading of a vertical link
leads to unfavourable stress profiles inside the bend as well
as in the weld region compared with pure tension loading.
This mismatch may be very harmful, and tension/bending
loading of a vertical link should be avoided. Thus, the
midgroove of present and future fairleads should have a
suffiently deep midgroove in order to let the vertical links
be subjected to pure tension loading only, preventing the
links to touch the bottom of the groove. Due to wear in the
pockets of the fairleads within a certain service period, the
vertical links will be located deeper in the midgroove which
has to be incorporated in the minimum required depth of the
midgroove. A typical profile of the variation in local stress
is shown in fig. 7 for tension/bending loading of a vertical
link with a load angle equivalent to a 5-pocket fairlead i.e.
for a 5 pocket fairlead with a shallow midgroove. As seen,
extremely high stresses may occur in the weld zone as well
as in the bend region and the presence of a crack may easily
lead to failure at an unacceptable low tension load.
Similarly, large stresses may occur in the weld
zone for tension/bending loading of a horizontal link which
is directly a function of load angle as shown in fig. 8.
Consequently the load angle should be kept as low as
possible in the fairleads in mooring systems in order to
minimize the bending stresses in the weld zone and thereby
minimize the risk of failures. The corresponding maximum
stress levels inside the bend region of the link are of the
same order as for a link in pure tension loading, and do not
vary significantly with load angle, while the location varies
with load angle.
J, .. LEREI:M 3
-
DETECTION PROBABILITY OF DEFECTS
This study was concerned with reliability of the
recommended ultrasonic test method for detection of
cracks and defects in the weld zone area hidden by the stud.
31 links of 76 mm diameter were examined, 16 by two
operators and 15 by 8 operators ll . The links were broken
open after the ultrasonic testing in order to measure the
real size of the defects/cracks present in the weld zone. 19
of the examined links contained surface cracks with depth in
the range from 1 to 9 mm and aspect ratio crack-
depth/crack-length less than 0.3. In additon one link
contained an internal crack.
In general, the statistical analysis showed a rather poor
correlation between the estimted and true crack depth, i.e.
a wide scatter in dB values appears at any crack depth
within the range of crack depths examined. This is
demonstrated in fig. 9 in terms of detection probability of
the recommended ultrasonic test method vs real crack
depth. however, the test method used may be slightly
imporved by using -8dB as reference level rather than 0 dB.
See fig. 9a and 9b. Unfortunately, a reduction in reference
in level may detect cracks/defects that are not existing; a
defect free link may be rejected or repaired.
in Consequently, it is highly questionable to use the
previously recommended ultrasonic test method for
detection of cracks/defects in the hidden area of the flash
butt weld unless the method is improved significantly. The
latter is recently done, and the improved test methods are
recommended.
SIZE DISTRIBUTION OF EXISTING DEFECTS
The size distribution of initial fabrication in the weld zone
was derived from examination of 26801 links by the
ultrasonic inspection method 12. Although large
uncertainties exist about the reliability of the NDE method
used, the estimated size distribution was simulated by an
exponential distribution of the type
F(a) = 1 - e- a ...............[3]
The corresponding estimated size distribution of
defects in the bend region is given by the following
exponential distribution:
F(a) = 1 - e -4.7(a-.0l).............................[4]
where a is given in (mm). Further the lower limit
was set .01 mm which is in accordance with the typical
surface roughness of the produced links.
RELIABILITY ANALYSIS
The obtained fracture and fatigue strength data
were subsequently applied in a level II element reliability
analysis in the assessment of the risk of failure. In addition,
the plastic collapse condition in the remaining ligament
ahead of a possible defect was also investigated.
Limit state functions were established for the
brittle fracture condition combined with possible fatigue
crack growth, plastic collapse of net section ligament ahead
of a growing fatigue crack, and conventional fatigue
analysis through the cumulative Miner damage model.
369
4 SUMMARY OF THE 4 YEAR RESRARCH PROJECT: ANCHOR-CHAIN CABLES OFFSHORE. - . . (?TC5060
-. -

The necessary additional input data were the The third main factor, the fracture toughness, is
derived cyclic load and stress level, maximum load and the most favorable factor to modify. No modifications of
stress level 1)13> the reliability of NDE methodsl 1 used~ and the vesseIs are required. More stringent quality controI of
the distribution of defect sizes12 as described in equation 3 the entire fabrication process from the steel mill to the
and 4. final stage of a complete Iink may lead to significant
improvement in average level and removal of the harmful
The data clearly demonstrate that the failure lower extreme values. Thereby the probability of failure
probabilities derived are highest for the fracture mechanics may be drastically reduced. The latter statement is also
based unstable fracture criterion. The corresponding failure reflected in the new Classification Note by Veritas on
probabilities derived for the plastic limit Ioad criterion is in offshore mooring chains15.
the order of 5-6 decades lower. Furthermore, the chain
design curve data show the highest values for the link in the CONCLUDING REMARKS
pocket of the fairlead/cabelar which is subject to
tension/bending loading, loading condition3, see Fig. 11. The following may be concludeck

Figs. 10 and 11 show failure probabilities for line A failure probability and corresponding
tensions of 22% and 33% of the minimum guaranteed failure rate is domimated by an unstable
breaking load of 4.500 kN for 76mm ORQ chain. These load fracture mechanism as the final fracture.
levels correspond to typical and maximum normal operating
tensions respectively. Reduced failure rates may be
obtained most readiIy by improved fracture
Figs. 12 and 13 illustrate the failure probabilities toughness level and not only by increase in
of a single link when incorporating the cumulative Weibull the conventional yield and tensile strength.
distribution of the maximum line tension. Also, the failure
probability of Miner fatigue damage is included for ordinary Fatigue may be dominating only for
links, and connecting links of Kenter type. service periods in excess of 10 years, i.e.
mainly of interest for permanent located
The data conclude that unstable fracture possibly units.
combined with minor or no fatigue crack growth, is the most
likely failure mechanism, at least for the first 10 years of Connecting links of Kenter type had
operation. This is in full agreement with real life statistics considerably poorer fatigue properties than
telling that most failures are of a brittle manner. The ordinary links.
possible amount of fatigue crack growth prior to the final
brittle fracture is not reported in the statistics. Connecting links of the quality tested should
be omitted in lines applied for Iongterm
For a given line tension, increased conventional permanent mooring where fatigue may
strength in terms of increased yield and ultimate tensile become critical.
strength would have insignificant influence on the real
failure rate, because only the failure probability of the ACKNOWLEDGEMENT
plastic limit load analysis would be reduced by such actions
unlessthe fracturetoughnessisenhanced correspondingly. A particular acknowledgement is given toallthe sponsors of
the VERITAS Joint Industry Project, entitled Anchor Chain
REDUCTION IN FAILURE RATES Cables Offshore -Material Properties and Reliability.

There are three main factors that govern the REFERENCES

failure probability of chains. These are:
1 J. Lereim and L.O. L@fman:
I. Stress level. Determination of Stress Distribution in Chain
Links, Veritas Report No. 80-1034.
H Existence and size distribution of defects.
2. H. Ormberg and 1.3. Fylling: Extreme Loads in
HI Fracture toughness. Anchor Systems for Long Term Operation. NTNF
Report, No. 4,5, June 1984, Programme for
Reduced stress level is possible by modifications Marine Structures NTNF, Norway.
in the fairleads/wind-lasses in order to reduce the stress
level in the highest stressed Iinks14. Also, increased chain 3. A. Berg and A. Taraldsen:
diameter for a given line tension will reduce the overall Longterm Mooring and Anchoring of Large
stress level. The latter solution is highly unfavorable Structure and Drilling Units, OTC Paper 3813,
because it Ieadsto higher of the weights mooring on the rig 1980, Houston, Texas.
and needs modification i-n existing mooring equipment.
Modified fairleads/wind-lasses require replacements and are 4. J. Lereim:
not favoured. llFracture Toughness Testing of 76mm Oil Rig
I Quality Chain Links, Veritas Report No. 80-0550.
Reduced defect size distribution seems highly
attractive, but is hard to achieve in practice due- to 5. 3. Lereim:
Iication procedure of ultrasonics I!Anchor Chain Cables Offshore - Sub-proj. No. 1:
:;:;i;%;:p%:fr. Fracture Toughness of Chain Links, An
Additional Analysis, Veritas Report No. 81-0501,
Rev. I, Jan. 1985.

I
 OTC 5060 .T. LEREIM ~

6. 3. Lereim: 11. A. Harbitz:

flFatigue Testing
d 76mm Anchor Chain Cables> Reliability of 76 mm Chain Links Veritas Report
Veritas Report No. 80-0387. No. 80-1106

7. L.C. van Helvoirt: 12. A. Harbitz:

Static and Fatigue Strength of 3 Stud-Mooring I!Ultrasonic Determination of Defect Dimensions
Chain, Shell Report RKER 80-069. in 26801 Chain Links, Veritas Report
No- 81-0471.
8. G. de Laval:
OTC Paper No. 1503, Offshore Technology 13. S. Palm:
Conference, Houston, Texas, 1971. Long Term Distribution of Tension in 3
Diameter Anchor Chain Cables, Veritas Report
9. L.C. van Helvoirt: No. 81-0389.
Static and Fatigue Strength of Kenter and Baldt
Type Detachable Chain Connection Links, Shell 14. J. Lereim:
Report RKER 80-070. overall Summary Report, Veritas Report No.
83-0155, Rev. 1, January 1985
10. S. Palm and 3. Lereim:
Numerical Analysis of Fatigue Crack 15. Det norske Veritas
Propagation in Chain Links, Veritas Report No. Classification Note on Offshore Mooring Chain,
80-0136. 1985.

Table 1 Maximum line tension, Weilbull

distribution Table 2 Weibull distribution of long term cycIic line
LT
F(LT max) = 1- exp _ ma. - To Y tension
[( LTC LTO )1
,,,LT) .MP[(- ~)y
c

Water depth (m) LTo(kN) LTc-LTo(kN) ~ Water depth (m) & LTc(kN) $

60 725 7.38 .506 60 30 .626

100 800 6.47 .525 100 19.6 .670
150 %5n 7.86 .564 150 12.8 .641
300 1175 4.23 .581 300 4.1 .591

;TOD
%:ypmw
1.5 L.,* 1500 %(....*.,.*,
Gf &-*@
mm)
oto~
(MPa) *
#
1.0 . 1000 -:%



*:

e
* .fj#r.

0.5 % .* 500 *

:*

+:

*


# .. G:
+> .
- .3
am?
*

**

5. 10. 15. 20. 25. 5. 10. 15. 20. 25.

CRACK DEPTH , A. (mm). CRACK DEPTH , A. (mm).

Fig. 1 CTOD fracture toughness ORQ Chain. Fig. 2 Fracture Stress ORQ Chain.

-374
0( 1
 SUMMARY OF THE 4 YEAR RESEARCH PROJECT: ANCHOR CHAIN CABLES OFFSHORE OTC 5060
6

Ap
2.
EA 1
P
pr

.5
.4
.3 MPRES5 ION

.2
.1

, I
1(J4 105 106 1(J7 4.

Nf, NO. OF CYCLESTO FAILURE

Fig. 3 Fatigue tests ORQ Chain.

0.5bd=12.0

Fig. 6 Stress and SCF profile in midplane of link in pure

tension loading.

Fig. 4 Severe localized SCF in Kenter link.

4.6 2.2

Fig. 7 Stress and SCF profile in mid plane for

I tension/bending loading of vertical link.
_ BENOZONE CRACK a, zno!.nm
AP Pp. :1010 kN
SIUOWELO CRACK a. .10 m

P 07 - SHELL TEST RESULTS.

pr \

06

05

~ \
Oc
\
J
\
03
\\

.i .
02 \
___
-.
0, I

& 107
lo~ 105
NMBE:OF CYCLES 10 FAILURE

Fig. 5 Derived S-N curves for ORQ-chain.

 800

700
f

600 0: WELD ZONE

A: BEND REGION
IIAX.
500 0
OCAL = 1 12MPa
nom
az
400
MPa)
300 IY 5YIOY20Y 100 Y
* I I
1.9 I
I ~5001kN c1
CTOD 1000 kN i
200
CHAIN I
{~ , I : i
DESIGN
100
CURVE ,
I
II I I
I I
1
P{ . I II I
I

0 10 20 30 40 50 )500~kN ; ;JJT [
I
BEND ANGLE, a
I II
10-5 II
; ANALYSI~
Fig. 8 Variation in stress normal to the weld zonevs I
load angle for tension/bending loading of 1 1 I
I
hoizontal link. I I : 1000 kN ;
I
I
1 I I
I
1, I I
1.0
Pd P
;~ I I
138 I 1; I 1
I I I
0.6
lo-t
I 1; I i
0.4
1, I
I II I i
1 II
0.2
9 1 t! r

0
02.4 681OI2 o 246 8 10 12 106 107 108 109
a(mm) a[mm)
a) b) N, NG OF CYCLES

Fig. 9 Detection probability vs real crack depth for the Fig. 11 Failure probability in horizontal link in 5-pocket
past recommended ultra-sonic inspection method. cabelar. Two load levels.

IY 5YIOY20Y 100 Y I
I I I

I
Q
1.0 m
I 1500 kN ;
I II

Pf - &i%N{&OOOkN
II I
~
CURVE I t
I I I
II 1500 LN
I
II
, LIMIT ;
I
I II
10-5 - II ; k+i;~YSI$
I
1
1 I
I I
I I
I
I I
I
1 1000 }N 1
1, I
I I I
I If I I
10-[- I I
I ;: I I
1, I I
~ Ii I ,1

106 107 108 109

N ,NO OF CYCLES

Fig. 10 Failure probability in free link, pure tension

loading. Two load levels.
8 subf.wutY OF THE 4 YEAR RESEARCH PROJECT: ANCHOR CHAIN CABLES OFFSHORE OTC 5060

IY 5YIOY20Y 100 Y tY 5YIOY20Y 100 Y

1.0 D I 1.0 m
I
II II

\
Q CO;N .
LI~K LItjK
0-5 m I . 10-5 D I
1
I I

ANALYSIS ,
I I

~-lo D ,.-10 D I
1 I 9
I I

I II I 1 II I
i
1 II II
1 I

106 1.07 108 109 If 107 108 1

N , NO OF CYCLES N , NO OF CYCLES

Fig. 12 Failure probability in free link, pure tension Fig. 13 Failure probability in horizontal link in 5-pocket
loading. Accumulated maximum load. cabelar. Accumulated maximum load.