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JOINT INDUSTRY PROJECT UPDATE


A New Approach to
Repair of FPSOs Without Hot Work
A. T. Echtermeyer, M. J. Larsen & K. P. Fischer
DNV, Hvik, Norway
presented by
Johan Grdin
Mobile Offshore Units / FPSO, DNV SEA & ANZ, Singapore
Telephone +65 67791266
johan.gardin@dnv.com

www.dnv.com
Slide 2

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)
Slide 3

(Source OLF, Norway: data for 4 FPSO)

FPSO In-Service Inspection:


Ballast tank surface area 100,000 200,000 m2

The inspectability of most FPSOs and tankers is a nightmare.


Design for inspectability rarely enters the design engineers mind
until he has to participate in the inspection himself. (R. G. Bea)
Slide 4

FPSO In-Service Failures:


INADEQUATE PROTECTION

Slide 5

Local or General Corrosion

INADEQUATE DESIGN or
OVERLOAD

Fracture

Ideal Repair:
ADHESIVE PATCH:
NO GOING OFF LOCATION

IN-SITU ON LOCATION

NO PRODUCTION STOP

ONLY REPAIR AREA

NO HOT WORK

NO CUTTING/WELDING

ADAPTABLE TO ANY CASE

MOST GEOMETRIES

COST EFFECTIVE

VERY!

QUICK

VERY!

LOW TECH

EQUIV. TO WELDING

RELIABLE

20 YEARS EXPERIENCE

Slide 6

Repair Timescales
Extensive welded
repairs

Minor welded
repairs
Wait for
weatherwindow

Shut down
production

Transit to
yard

Slide 7

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

What Is Adhesive Patch Repair?


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
Slide 8

What Is an Adhesive Patch?

MATRIX

+
REINFORCEMENT
ADHESIVE

Slide 9

LAMINATE

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)

Slide 10

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), Unidirectional, or Combination mats
ADHESIVES:
Structural adhesive: May be identical to the matrix or a
dedicated structural adhesive
Slide 11

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 METHOD
must suit material choice and design of patch
repair
Skilled WORKMANSHIP, good PROCEDURES
and QUALITY ASSURANCE during design and
production / installation is paramount!
Slide 12

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

Slide 13

Opportunities with Patch Repair

Smart materials for performance


monitoring
Tailor-made directional properties
Lightweight easy handling

Slide 14

Current Applications of Patch Repairs


Currently 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
Slide 15

Application Examples, DML


Deck repairs on naval
ships
Repair carried out during
scheduled maintenance
docking:
Avoids time-consuming
removal / protection of
mechanical / electrical outfitting
prior to welding
All photos courtesy of DML Composites

Slide 16

Application Examples, DML


Rehabilitation of
pipelines
Repair can be permanent
or temporary
Repair can often be
carried out without
shutdown of production:
Avoids expensive downtime
All photos courtesy of DML
Composites
Slide 17

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
Slide 18

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
Slide 19

Use of DNVs Reliability Experience


The basic
functional
requirements for a
patch are simple:
The required strength
and stiffness must be
restored

Loads
Material properties
Safety factors
calibrated to
ensure consistent
safety level

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
Slide 20

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

Use of existing DNV documents

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 Rules for ships


provide background
Slide 21

Specific information and


technical background for
patch repair design and
qualification

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
Slide 22

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)

Slide 23

Corroded Panel Demonstrator

Slide 24

Panel Repair: Production Sequence

Slide 25

Fractured Stiffener Demonstrator


Composite repair by pre-preg or
prefab plates

Artificial crack

Slide 26

Demonstrator Testing

Corroded panel demonstrator

Detail of notch with strain


gauge ready for testing
Slide 27

Fractured stiffener demonstrator

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

Slide 28

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.
Slide 29

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:

Slide 30

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

Slide 31

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