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INADEQUATE DESIGN or
OVERLOAD
Fracture
Ideal Repair:
ADHESIVE PATCH:
NO GOING OFF LOCATION
IN-SITU ON LOCATION
NO PRODUCTION STOP
NO HOT WORK
NO CUTTING/WELDING
MOST GEOMETRIES
COST EFFECTIVE
VERY!
QUICK
VERY!
LOW TECH
EQUIV. TO WELDING
RELIABLE
20 YEARS EXPERIENCE
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Repair Timescales
Extensive welded
repairs
Minor welded
repairs
Wait for
weatherwindow
Shut down
production
Transit to
yard
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Wait for
weatherwindow
Clean
damaged
area
Shut down
production
Docking +
repair
Transit to
field &
hook up
Patch repairs
Repair
Months
Start
production
Production
interruptions
avoided only
damaged area
is shut down
Repair &
cure
Weeks
No interruption
in production
MATRIX
+
REINFORCEMENT
ADHESIVE
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LAMINATE
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MATRIX POLYMERS:
Epoxy, Polyester, Vinylester, Urethane...
REINFORCEMENT:
Glass fibre, Carbon fibre, other high performance fibre
types.
Multi orientation (csm), Woven roving (0/90), Unidirectional, or Combination mats
ADHESIVES:
Structural adhesive: May be identical to the matrix or a
dedicated structural adhesive
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Loads
Material properties
Safety factors
calibrated to
ensure consistent
safety level
Structural
reliability
approach
Acceptance criteria
for patch repairs
are developed
based on:
DNV experience
with FPSO and ships
in general
Recently developed
acceptance criteria
for composite
materials
Qualified repair
DNV-OS-C101 Design of
offshore steel structures,
general
DNV-OS-C102 Structural
design of offshore ships
DNV-RP-A203
Qualification procedures
for new technology
DNV-RP-C203 Fatigue
strength of offshore steel
structures
DNV-OS-C501
Composite
Components
Qualification
procedure for
adhesive
patch repairs
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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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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Artificial crack
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Demonstrator Testing
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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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Acknowledgement
DNV would like to thank the following companies in Phase 1 of the
JIP Qualification of Adhesive Bonding in Structural Repairs of
FPSOs for the permission to present this paper:
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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.
PHASE 3(?):
MEGA-SCALE
TESTING
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