Remaining fatigue life assessment of corroded mooring chains using crack growth modelling

Failures caused by the combined actions of fatigue, corrosion and wear are important safety concerns for mooring chains used on floating structures in the oil and gas industry. Prediction of remaining corrosion fatigue life based on surface condition could therefore be a useful tool for the continued safe operation of corroded chains. This paper investigates the use of crack growth modelling for estimating the remaining corrosion fatigue life of mooring chains that exhibit significant pitting corrosion damage. A crack growth modelling approach is used to produce remaining fatigue life estimates for a selection of severely pitted mooring chains. Using fatigue crack growth rate test results for grade R4 high strength mooring chain steel, empirical crack growth laws are presented for free corrosion and cathodic protection conditions at load ratio R = 0.1. Two different methods for establishing equivalent cracks from surface scans of corrosion damage are presented. The mooring chains are proof loaded as part of their manufacturing process. Residual stresses introduced during this process have therefore been determined by finite element analysis and accounted for in the fatigue crack growth predictions. One of the equivalent crack models, accounting for the single dominant corrosion pit, provided quite accurate fatigue life predictions when compared with full scale test results. •Fatigue crack growth rate testing of high-strength offshore mooring chain steel under corrosion fatigue conditions.•Fatigue crack growth modelling used for estimating remaining corrosion fatigue life of pitting corroded mooring chains.•Accounting for compressive residual stresses in fatigue crack growth predictions for offshore mooring chains.