DNVGL-RP-C301 Design, Fabrication, Operation And Qualification Of .
RECOMMENDED PRACTICEDNVGL-RP-C301Edition July 2015Design, fabrication, operation andqualification of bonded repair of steelstructuresThe electronic pdf version of this document found through http://www.dnvgl.com is the officially binding version.The documents are available free of charge in PDF format.DNV GL AS
FOREWORDDNV GL recommended practices contain sound engineering practice and guidance. DNV GL AS July 2015Any comments may be sent by e-mail to rules@dnvgl.comThis service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of thisdocument by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use ofthis document.
GeneralThis document supersedes DNV-RP-C301, April 2012.Text affected by the main changes in this edition is highlighted in red colour. However, if the changesinvolve a whole chapter, section or sub-section, normally only the title will be in red colour.On 12 September 2013, DNV and GL merged to form DNV GL Group. On 25 November 2013 Det NorskeVeritas AS became the 100% shareholder of Germanischer Lloyd SE, the parent company of the GL Group,and on 27 November 2013 Det Norske Veritas AS, company registration number 945 748 931, changed itsname to DNV GL AS. For further information, see www.dnvgl.com. Any reference in this document to “DetNorske Veritas AS”, “Det Norske Veritas”, “DNV”, “GL”, “Germanischer Lloyd SE”, “GL Group” or any otherlegal entity name or trading name presently owned by the DNV GL Group shall therefore also be considereda reference to “DNV GL AS”.Main changes July 2015 GeneralThe revision of this document is part of the DNV GL merger, updating the previous DNV recommendedpractice into a DNV GL format including updated nomenclature and document reference numbering, e.g.:— DNV replaced by DNV GL.— DNV-RP-C301 to DNVGL-RP-C301 etc.A complete listing with updated reference numbers can be found on DNV GL's homepage on internet.To complete your understanding, observe that the entire DNV GL update process will be implementedsequentially. Hence, for some of the references, still the legacy DNV documents apply and are explicitlyindicated as such, e.g.: Rules for Ships has become DNV Rules for Ships.Editorial correctionsIn addition to the above stated main changes, editorial corrections may have been made.AcknowledgementThis recommended practice is based upon a project guideline developed within the Joint Industry Project“Qualification of adhesive bonding in structural repairs of FPSO's”. The following companies sponsored thisJIP:— ConocoPhillips— Norsk Hydro— Petrobras (CENPES)— PETRONAS Research and Scientific Services— Shell (Enterprise Oil)— StatoilDNV GL is grateful for valuable discussions and the fruitful co-operations with these companies. Thecompany individuals are hereby acknowledged for their contribution.In addition DML, Devonport Royal Dockyard Ltd., and Umoe Mandal AS have provided services to the JIP.The contributions provided by the Advisory Committee and by DML and by Umoe Mandal are gratefullyacknowledged.Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 3Changes – currentCHANGES – CURRENT
CHANGES – CURRENT . 3Sec.1Sec.2Sec.3Sec.4Introduction . 81.1Objective and scope .81.2Document structure .91.3Relationship to other codes .91.4Requirements to documentation .91.5Definitions.101.6Abbreviations .101.7Symbols .101.8Normative references .111.8.1 Revisions . 111.8.2 DNV GL/DNV offshore standards . 121.8.3 DNV GL recommended practices . 121.8.4 DNV classification notes . 121.8.5 DNV GL rules. 121.8.6 International Organization for Standardization and ASTM Internationalstandards . 121.9Informative references.13Requirements. 142.1Criticality assessment and repair decision making .142.2Examples.16Repair philosophy and design format . 173.1Introduction .173.1.1 General . 173.1.2 Background . 173.2Definitions.173.2.1 Repair classes . 173.2.2 Function of repair . 183.2.3 Scope. 183.3Design format .183.3.1 Target reliability . 183.3.2 General principles . 19Design basis . 204.1Purpose .204.2General .204.2.1 Outline . 204.2.2 Phases . 204.2.3 Design lifetime . 204.2.4 Functional requirements . 204.2.5 Geometry of damaged structural element and repair. 214.2.6 Failure modes and failure mechanisms. 214.2.7 Inspection strategy for the installed repair. 214.3Loads4.3.14.3.24.3.34.3.4and boundary conditions .22Variable functional loads . 22Permanent loads . 22Environmental loads . 22Accidental loads. 23Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 4ContentsCONTENTS
Sec.5Sec.6Sec.7Environments (chemicals, temperature) .234.4.1 General . 234.4.2 Exposure from surroundings . 234.4.3 Temperature ranges . 234.4.4 Chemical environment . 234.4.5 Electrical conductivity . 244.5Special considerations for repair preparation .244.5.1 General . 244.5.2 Safety of personnel . 244.5.3 Application of the bonded repair. 244.5.4 Influence of vessel condition (trim) of floating structures on stressesin repair areas . 24Failure mechanisms and design criteria . 265.1General.265.1.1 Objective and scope . 265.1.2 Approach . 265.1.3 Loads and load effects . 265.1.4 Environmental effects . 265.2Failure modes and failure mechanisms.275.3Design criteria.285.3.1 General . 285.3.2 Class 0 repairs. 295.3.3 Class I repairs . 295.3.4 Class II repairs . 295.3.5 Class III repairs (informative). 295.4Safety factors .305.4.1 Load effect factors . 305.4.2 Material factors. 30Analysis methodology . 316.1General.316.1.1 On modelling of fracture and debonding of bonded repairs(informative). 316.1.2 Application . dels of bonded repair failure mechanisms.336.3.1 Fatigue debonding growth . 336.3.2 Static bondline capacity . 346.3.3 Bondline stress rupture. 356.3.4 Patch fracture. 356.3.5 Initial and long term repair efficiency . 35and load effects.31General . 31Wave load effects established from global analysis . 31Load effects estimated from damage assessment and local analysis . 32Simple upper bound for load effects . 32Local thermal loads . 32Deformation loads. 32Boundary conditions . 33Materials . 367.1General.367.2Substrate .367.2.1 General notes on substrate . 36Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 5Contents4.4
Sec.8Sec.9Substrate material grades and minimum strength properties . 36Fatigue and fracture mechanical properties. 367.3Adhesives .367.3.1 General notes on adhesives . 367.3.2 Shear strength and fracture toughness . 377.3.3 Long term properties . 377.4Composite materials.377.4.1 General notes on composite materials. 377.4.2 Relevant material properties. 377.4.3 Fibre materials . 377.4.4 Resins . 37Qualification Testing . 388.1General.388.1.1 Approach . 388.1.2 Test environment. 388.1.3 Specimen preparation. 388.2Characterisation of bondline properties – general .388.3Characterisation of laminates and metals.398.4Component testing .398.4.1 General . 398.4.2 Design qualification based on component testing only . 408.4.3 Design qualification based on a combination of an analytical andexperimental models . 408.4.4 Testing for capability to stop crack growth. 40Fabrication procedures and quality assurance . 419.1General.419.2Substrate – surface preparation dhesive bonding .449.4.1 General . 449.4.2 Overview of process parameters . 459.4.3 Control of bondline thickness . 459.4.4 Control of alignment. 459.4.5 Control of cure parameters. 459.5Personnel .46fabrication .41General . 41Fabrication of pre-formed patch elements . 42Direct lamination . 43Handling and preparation of constituent materials . 43Lay-up of laminate . 44Control of wet-out. 44Control of cure parameters. 44Sec.10 In-service inspection. 4710.1 General.4710.2 Inspection strategy .4710.2.1 Inspection schedule. 4710.2.2 Critical crack length. 4810.3 Inspection of the metal substrate .4810.3.1 Monitoring of damage development . 4810.3.2 Technology and methods for inspection of substrate . 48Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 6Contents7.2.27.2.3
10.5 Inspection of patch laminate .49App. A Survey procedures . 50App. B Criticality assessment of the damage . 51App. C Checklist for repair and criticality assessment . 52App. D List of required documents for approval ofbonded patch repairs . 53App. E Determination of formula for debond length due to fatigue . 55App. F(Informative) Screening tests . 56App. G Crack-patched beam shear fracture test . 58App. H Patched beam edge fracture test. 62App. IDouble strap shear fracture test. 64App. JDouble strap edge fracture test. 67App. K Blister fracture resistance test . 69App. LIdealised fracture toughness tests . 70Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 7Contents10.4 Inspection of bondline.4910.4.1 Monitoring of damage development . 4910.4.2 Technology and methods for inspection of bondline . 49
SECTION 1 INTRODUCTION1.1 Objective and scopeThe main objectives of this recommended practice (RP) are to:— provide an accepted industry practice for using bonded repair— serve as a technical reference document in contractual matters.This RP provides:— An assessment and decision making process on whether to proceed with a bonded patch repair.— A design and qualification process to design and fabricate bonded patches.The scope of this RP covers design, materials, structural analysis, fabrication, testing, in-service inspectionand maintenance of bonded repairs. Aspects relating to documentation, verification and quality control arealso addressed.Guidance note:A repair might be rehabilitation of fatigue cracks in a structural element or bridging of cracks in corroded (structural or non-structural)tank plating.Furthermore, this technology could be used for modification or upgrading by reinforcing structural elements to provided o-t-e---The repair procedures covered by this RP utilizes patches of composite material, steel or other structuralmaterials that are bonded to an existing steel structure.The principle of a bonded repair is shown in Figure 1-1. The original structure was designed for certain loads.A fatigue or corrosion damage reduces its capability and the structure needs repair. Instead of welding, apatch will be applied to restore the integrity of the structure.Figure 1-1 Concept of the composite repair for cracks and corrosion thinning11“Reprinted from Composites Part A: Applied Science and Manufacturing, 40, MCGEORGE, D., ECHTERMEYER, A. T., LEONG, K. H., MELVE,B., ROBINSON, M. & FISCHER, K. P, Repair of floating offshore units using bonded fibre composite materials. 17 pages, Copyright (2009),with permission from Elsevier”Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 8
1.2 Document structureThe individual phases in the repair design are covered by the various sections as shown below:Part 1 – Decision making— Sec.1 contains general information, references and definitions.— Sec.2 provides guidance on deciding whether to perform bonded repairs.Part 2 – Technical provision— Sec.3 describes the safety and design philosophy.— Sec.4 describes the required contents of the design basis.— Sec.5 describes criteria for evaluation of failure mechanisms and capacity checks of the repairedstructure.— Sec.6 provides guidance on modelling and analysis of the bonded repair.— Sec.7 describes materials and bonding agents and points out special considerations for bonding ofpatches onto steel substrates.— Sec.8 provides recommendations for screening testing to aid material selection and patching processimprovements, material characterisation testing to obtain input data to theoretical models andcomponent testing to directly demonstrate the performance of bonded repairs.— Sec.9 describes fabrication procedures and quality assurance including condition assessment andsurface preparation of the substrate.— Sec.10 gives guidance on in-service inspection and maintenance of the installed bonded repair.1.3 Relationship to other codesThis RP should be used in combination with the standards for design of steel offshore structures, denotedDNVGL-OS-C101 and DNVGL-OS-C102 or other applicable object standard (e.g. ship classification rules),as well as the standard for design of composite components, denoted DNV-OS-C501. This RP shall not beused as a stand-alone document. Where reference is made to codes other than DNV GL documents, thevalid revision shall be taken as the revision that was current at the date of issue of this RP, unless otherwisenoted, see [1.8.6].1.4 Requirements to documentationThe documentation provided prior to installation of the repair shall include:— A survey report of the damage providing information as specified in App.C.— A design report covering the design basis (see Sec.4 for requirements) and the results of all design andqualification activities in the bonded repair development shall be prepared. The design report forms thebasis for acceptance of the bonded repair by owner, operator and / or relevant authorities. The designreport shall document that all relevant information has been collected and all identified issues have beenaddressed in the design input, analysis, fabrication and qualification phases of the bonded repairprocess.— An installation report shall be prepared by the repair contractor.— An in service inspection programme deemed appropriate for maintaining the integrity of the repair shallbe prepared.Guidelines for the preparation of these reports can be found in App.D.Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 9
1.5 DefinitionsTable 1-1 DefinitionTermDefinitionadherendgeneric term used to denote a body or component attached to another by means of an adhesivebondlinethe term bondline is used to designate the adhesive layer between the adherends as well as theinterfaces between the adhesive and the adherend surfaces including surface preparation andprimer layers if anycrackherein, crack is used to denote a crack in the steel substrate that is to be repaired with bondedpatches, see also debondFor bonded repairs both the patch and steel substrate are adherends.Sometimes the term substrate crack is used for clarity.critical elementsdebondelements considered for repair in critical structural areas, i.e. areas that have been identifiedfrom calculations to require monitoring or from the service history of the subject vessel or unitor from similar or sister vessel or units to be sensitive to cracking, buckling or corrosion whichwould impair the structural integrity of the vessel or unitdebond crack between the patch and the substrateThe term crack is not used with this meaning to avoid confusion with cracks in the substrate(those that are to be patch-repaired).non-critical elementsstructural elements that are not criticalpatchthe adherend bonded to the steel substrate in order to repair itsubstratethe steel adherend onto which the patch is bonded in a bonded repairHence the term substrate is used in a narrower sense than the term adherend.this RPrefers to this document, i.e. RP on recommended practice for Design, fabrication, operation andqualification of bonded composite repair of steel structures1.6 AbbreviationsTable 1-2 AbbreviationAbbreviationDescriptionASTMAmerican Society for Testing and MaterialsFEAfinite element analysisFEMfinite element methodFOUfloating offshore unitFRPfibre-reinforced plasticsFPSOfloating production storage and offloading unit.ISOInternational Organization for StandardizationLRFDload and resistance factor designNDInon-destructive inspectionRPrecommended practiceSRAstructural reliability Analysis1.7 SymbolsThe Latin symbols in Table 1-4 and Greek symbols in Table 1-5 are used throughout this RP in combinationwith the indices in Table 1-3. These symbols are not always explained where they are used. Symbols notlisted in these tables are explained whenever they are used.Table 1-3 Indicesc- central, i.e. referring to the position at the center of a patch bridging a crack or hole - characteristicd- designe- edgep- patch - plastics- substrateRecommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 10
Table 1-4 Latin symbolsa- length of debond or crack (for internal cracks with two tips, the total length is by convention 2a)A- area, e.g. of a cross section- proportionality constant in Paris’ law (substrate crack)C- proportionality constant in modified Paris’ law (debonding)D- beam flexural stiffness; equals E IE- Young’s modulus- expected value of random variablef- axial force per unit width (F/w)F- axial force- cumulative probability distributionG- shear modulush- beam height- Weibull shape parameterI- second moment of areaJ- fracture loading (energy release rate)k- axial stiffness, equals E Al- overlap lengthL- length; e.g. of beamm- slope parameter in Paris’ law (substrate crack)N- number of cyclesP- applied loadq- shear force per unit width (Q/w)- Weibull scale parameterQ- shear forceR- fracture resistanceS- load effect (generic term for e.g. stress, strain, cross sectional force)t- thicknessT- timeU- elastic energyw- width; e.g. of patchW- work; e.g. by external forces or inelastic deformationsTable 1-5 Greek symbolsεdirect strainγengineering shear strainμslope parameter in modified Paris’ law (debonding)σdirect stressτshear stress1.8 Normative references1.8.1 RevisionsThe latest revisions of the referenced DNV GL and DNV documents apply.Guidance note:The latest revision of the DNV GL documents may be found in the publication list at the DNV GL -e---n-o-t-e---Recommended practice, DNVGL-RP-C301 – Edition July 2015DNV GL ASPage 11
1.8.2 DNV GL/DNV offshore standardsTable 1-6 DNV GL/DNV offshore standardsDocument codeTitleDNVGL-OS-C101Design of offshore steel structures, general - LRFD methodDNVGL-OS-C102Structural design of offshore shipsDNV-OS-C501Composite Components1.8.3 DNV GL recommended practicesTable 1-7 DNV GL recommended practicesDocument codeTitleDNVGL-RP-C203Fatigue strength analysis of offshore steel structuresDNV-RP-C205Environmental Conditions and Environmental Loads1.8.4 DNV classification notesTable 1-8 DNV classification notesDocument codeTitleDNV Classification Note 30.1Buckling Strength AnalysisDNV Classification Note 30.6Structural Reliability Analysis of Ship StructuresDNV Classification Note 30.7Fatigue Assessment of Marine StructuresDNV Classification Note 31.3Strength Analysis of Hull Structures in Tankers1.8.5 DNV GL rulesTable 1-9 DNV GL rules for classification - offshore unitsReferenceTitleDNVGL-RU-OU-0101Offshore drilling and support unitsDNVGL-RU-OU-0102Floating production, storage and loading unitsDNVGL-RU-OU-0103Floating LNG/LPG production, storage and loading unitsDNVGL-RU-OU-0104Self elevating units1.8.6 International Organization for Standardization and ASTMInternational standardsNote:The references are to the specific issues of the standards indicated.---e-n-
Recommended practice, DNVGL-RP-C301 - Edition July 2015 Page 3 DNV GL AS CHANGES - CURRENT Changes - current General This document supersedes DNV-RP-C301, April 2012.
DNVGL-RP-F113 Pipeline subsea repair DNVGL-RP-F203 Riser interference DNVGL-RP-F204 Riser fatigue DNVGL-RP-F205 Global performance analysis of deepwater floating structures DNVGL-RP-N101 Risk management in
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For generic qualification procedures for new technology and service specifications, see DNVGL-RP-A203 and DNVGL-DSS-401.These guidelines provides a specific qualification procedure for how to utilize DNVGL-RP-A203 for qualification of AM technologies. See App.C. 1.6 Definitions and abbreviations Table 1 Definitions Term Definition
DNV GL offshore standards contain technical requirements, principles and acceptance criteria related to classification of offshore units. . DNVGL-RP-B401 Cathodic protection design DNVGL-RP-C201 Buckling strength of plated structures D
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