Design Considerations for Polyester Construction Stretch Removal and its Impact on Mooring System Design

Polyester based mooring systems offer unique challenges from design, analysis and installation perspective. Non-linear elongation behavior of the fiber is key to these challenges. A good understanding of the fiber elongation characteristics is critical to the design of a robust and efficient mooring system. Mooring systems are one of the primary contributors to the CAPEX of the Floating Production Units (FPU) and the drive to develop cost effective systems has led to improvements/changes to mooring systems. Off-vessel tensioning has been in use for several years, but the option has recently received more in-depth consideration. Off-vessel tensioning is becoming the standard for floating systems with the elimination of on-vessel tensioning systems. The elimination of on-vessel tensioning system brings upon new challenges in terms of mooring line installation and tensioning. A key driver for these systems is the polyester rope pre-load criteria primarily used to remove construction stretch and jump the creep curve that the system may experience. The challenges to each project are unique, however, understanding and assessing the key design impacts will be beneficial to the industry. This paper focuses on the design of a polyester based mooring system with focus on polyester fiber elongation characteristics and its impact on the design and installation. A polyester test program is established to understand the rope elongation behavior and impact of various pre-load levels. Installation assessment is also performed to understand the installation vessel requirements to achieve various pre-loads. Based on the studies, design updates are made to the mooring system and a novel two tension regime mooring system is proposed. Design impact of the two pre-tension system on various design criterions are evaluated and presented in this paper. The paper also makes recommendations on target pre-load and elongation to be considered in systems that do not plan to re-tension their system post installation. Authors appreciate that recommendations and observations reported may not be applicable for all types of floaters and mooring system.