6 - dnv - composites repair jip - new approach to repair of fpso's without hot work using...
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Slide 1
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Slide 2
JOINT INDUSTRY PROJECT UPDATE
“A New Approach to Repair of FPSO’s Without Hot Work”
A. T. Echtermeyer, M. J. Larsen & K. P. FischerDNV, Høvik, Norway
presented by
Johan GärdinMobile Offshore Units / FPSO, DNV SEA & ANZ, Singapore
Telephone +65 [email protected]
www.dnv.com
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Slide 3
Typical FPSO In-Service experience:
Structural and materials protection issues:
• Integrity of Hull (3 of 4 suffer cracking in tank boundaries)
• Integrity of Ballast and cargo piping (construction standards for cargo and ballast piping appear inadequate. Weld failures, corrosion & subsequent leaks)
• General corrosion and coating issues (need for good inspection programme)
(Source OLF, Norway: data for 4 FPSO)
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Slide 4
FPSO In-Service Inspection:
Ballast tank surface area 100,000 – 200,000 m2
The inspectability of most FPSO’s and tankers is a nightmare. Design for inspectability rarely enters the design engineer’s mind
until he has to participate in the inspection himself. ” (R. G. Bea)
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Slide 5
FPSO In-Service Failures:
INADEQUATE PROTECTION INADEQUATE DESIGN or OVERLOAD
Local or General Corrosion Fracture
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Slide 6
Ideal Repair:ADHESIVE PATCH:
•IN-SITU ON LOCATION
•ONLY REPAIR AREA
•NO CUTTING/WELDING
•MOST GEOMETRIES
•VERY!
•VERY!
•EQUIV. TO WELDING
•20 YEARS EXPERIENCE
NO PRODUCTION STOPNO HOT WORK
NO GOING OFF LOCATION
ADAPTABLE TO ANY CASE
COST EFFECTIVE
QUICK
LOW TECHRELIABLE
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Slide 7
Repair TimescalesExtensive welded repairs
Minor welded repairs
Patch repairs
Shut down production
Wait for weather-window
Wait for weather-window
Production interruptions avoided – only damaged area is shut down
Transit to yard
Shut down production
Clean damaged area
Docking + repair
Repair Repair & cure
Start production
Transit to field & hook up
No interruption in productionMonths Weeks
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What Is Adhesive Patch Repair?
Slide 8
Principle:
• A damage (e.g. hole, crack, corrosion) is discovered and needs repair
• A patch is fabricated from a structural laminate
• The patch is adhesively bonded to the substrate to repair the damage
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Slide 9
• MATRIX
What Is an Adhesive Patch?
LAMINATE+• REINFORCEMENT
• ADHESIVE
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Slide 10
What Is an Adhesive Patch?
• ALTERNATIVE PRODUCTION METHODS:
• WET LAY-UP (Dry Reinforcement and Resin applied directly to substrate by roller and cured in situ)
• PRE-PREG (Impregnated patch and adhesive applied to substrate and cured together under heating)
• INFUSION (Dry Reinforcement and low viscosity Resin applied directly to substrate and cured in situ under vacuum bag)
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Slide 11
What Is an Adhesive Patch?
Typical patch materials depend on application:
• MATRIX POLYMERS:• Epoxy, Polyester, Vinylester, Urethane...• REINFORCEMENT:• Glass fibre, Carbon fibre, other high performance fibre
types.• Multi orientation (csm), Woven roving (0°/90°), Uni-
directional, or Combination mats• ADHESIVES:• Structural adhesive: May be identical to the matrix or a
dedicated structural adhesive
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Slide 12
Design, Production, Installation
• Optimum PATCH DESIGN depends on damage type, location, strength requirements, working conditions during application, available time for repair...
• Choice of production and installation METHODmust suit material choice and design of patch repair
• Skilled WORKMANSHIP, good PROCEDURESand QUALITY ASSURANCE during design and production / installation is paramount!
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Slide 13
Limitations to Patch Repair
• Some polymers may be SHE HAZARDS• Substrate CLEANLINESS is critical• STIFFNESS may be difficult to achieve• SHEAR AREA between patch and
substrate must be adequate• PEELING STRESS must be avoided
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Slide 14
Opportunities with Patch Repair
• ‘Smart materials’ for performance monitoring
• Tailor-made directional properties• Lightweight – easy handling
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Slide 15
Current Applications of Patch RepairsCurrently used for rehabilitation within:• Infrastructure / civil engineering• Navy vessels• Process plant piping • Offshore piping and non-structural applications
Extension to FPSOs could be:• Structural applications, such as:
– Reinforcing corroded panels (compensating for loss of thickness)– Bridging of cracks in stiffeners or brackets (relieving hot spot
stress)– Strengthening of decks, frames bulkheads etc. to carry additional
equipment• Non-structural applications, such as:
– Bridging of cracks or holes in platforms etc
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Slide 16
Application Examples, DML
Deck repairs on naval shipsRepair carried out during scheduled maintenance docking:
Avoids time-consuming removal / protection of mechanical / electrical outfitting prior to welding
All photos courtesy of DML Composites
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Slide 17
Application Examples, DML
Rehabilitation of pipelinesRepair can be permanent or temporary
Repair can often be carried out without shutdown of production:
Avoids expensive down-time
All photos courtesy of DML Composites
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Slide 18
Application Examples, DML
Repair of flare tower:Repair carried out offshore
Repair completed without hot work, avoiding fire hazard
All photos courtesy of DML Composites
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Slide 19
Qualification of Patch Repairs for FPSO
DNV is currently developing a qualification guideline for adhesive patch repairs of FPSO
Key objectives include:• Provide a LINK between existing DNV documents for
design of offshore ships and design of composite components
• Provide SPECIFIC GUIDANCE on design and qualification requirements for patch repairs on FPSO
• Develop and test demonstration examples to establish QUALIFICATION TEST requirements
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Slide 20
Use of DNV’s Reliability ExperienceThe basic functional requirements for a patch are simple:• The required strength and stiffness must be restored
• The repair must resist the local environment
• The growth of the damage must be stopped
• Additional strengthening may be required if the damage is due to a design flaw
Acceptance criteria for patch repairs are developed based on:• DNV experience with FPSO and ships in general
• Recently developed acceptance criteria for composite materials
Safety factors calibrated to
ensure consistent safety level
Loads
Material properties
Structural reliability approach
Qualified repair
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Slide 21
Use of existing DNV documents
DNV-OS-C101 Design of offshore steel structures, general
DNV-OS-C102 Structural design of offshore ships
DNV-RP-C203 Fatigue strength of offshore steel structures
DNV Rules for ships provide background
Qualification procedure for
adhesive patch repairs
DNV-OS-C501 Composite ComponentsDNV-RP-A203
Qualification procedures for new technology
Specific information and technical background for patch repair design and qualification
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Slide 22
Demonstration Examples
Key objectives:• Demonstrate principles in patch design and
in qualification process • Provide information on failure modes and
general performance of generic patch repair designs
• Establish base cases to be used as reference when designing full scale patch repairs
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Slide 23
Demonstration Examples
Two demonstrators are chosen:“The corroded panel” – simulating corrosion damage and
leakage in tank or shell plating“The fractured stiffener” simulating a fatigue crack in a
beam (local or global stiffening member)
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Slide 24
Corroded Panel Demonstrator
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Slide 25
Panel Repair: Production Sequence
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Slide 26
Fractured Stiffener Demonstrator
Artificial crack
Composite repair by ”pre-preg” or prefab plates
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Slide 27
Demonstrator Testing
Corroded panel demonstrator Fractured stiffener demonstrator
Detail of notch with strain gauge – ready for testing
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Slide 28
Continued Work in a Phase 2
2004-2006:• Extension of test programme
(small scale testing – bond zone properties)• Updating the document with more test
results• Establishing more repair base cases• Performing a full scale field repair on an
FPSO in operation
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Slide 29
Conclusions
• Fire Adhesive patch repairs enable field repairs of FPSOs and other offshore structures without hot work.
• Hazards and shut-down requirements are minimised.
• A framework for quality assurance and procedures for qualification of patch repairs will help avoid basic design and production errors, which could potentially lead to repair failures.
• This JIP will result in an official DNV document providing such a framework.
• Successful full scale field demonstrations will pave the way for patch repairs as an accepted technology in the future.
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Slide 30
AcknowledgementDNV would like to thank the following companies in Phase 1 of the JIP “Qualification of Adhesive Bonding in Structural Repairs of FPSO’s” for the permission to present this paper:
• ConocoPhillips• Norsk Hydro• Petrobras (CENPES)• Petronas (PRSS)• Shell-Enterprise Oil• Statoil
DNV would also like to thank Devonport Royal Dockyard Ltd (DML) for their cooperation in the JIP and also for their contribution to this paper.
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Slide 31
PHASE 3(?):
MEGA-SCALE TESTING