On prediction of torque in flexible pipe reeling operations using a Lagrangian–Eulerian FE framework

• A novel Lagrangian–Eulerian formulation giving a nearly fixed mesh is applied.
• Findings indicate that unfavorable handling of the pipe yields torsional failure.
• Residual curvature in the plastic layers induces severe torque responses.
• Strategies to avoid critical situations in load-out operations are proposed.
• A consistent linearization of the axial-torsional constitutive model is presented.

In this paper a new framework for FE simulation of reeling operations that utilizes a Lagrangian–Eulerian description of the beam kinematics is proposed. In contrast to the conventional Lagrangian approach, the material is enabled to flow with an axial velocity through a nearly space-fixed beam mesh. This gives far more effective and robust simulations since the length of the beam model reduces significantly and because the contact geometry undergoes less changes. The main ingredients of the Lagrangian–Eulerian framework and a flexible pipe beam model are presented. An idealized spoolbase-vessel load-out operation is considered in order to gain insight into the torsional failures experienced by subsea contractors in recent years. Here, three different mechanisms were found to provoke torsional failure of the pipe. Strategies to avoid the torsional failures and FE modeling remarks are provided.