Section
5 Materials and construction
5.1 Materials
5.1.2
Materials forming the structure of the ship unit
- To determine the grade of plate and sections
used in the hull structure, a temperature calculation shall be performed for
all tank types when the cargo temperature is cooler than –10°C. The
following assumptions should be made in this calculation:
- The primary barrier of all tanks shall be assumed to be
at the cargo temperature.
- In addition to item (i), where a complete or partial
secondary barrier is required it shall be assumed to be at the cargo
temperature at atmospheric pressure for any one tank only.
- The ambient temperatures for air and
sea-water are to be based on those levels for which these
temperatures have a probability of exceedance of 99,6 per cent. The
ambient temperatures are to be rounded down to the nearest degree
Celsius.
- Still air and sea water conditions shall be assumed,
i.e. no adjustment for forced convection.
- Degradation of the thermal insulation
properties over the life of the ship unit due to factors such as
thermal and mechanical ageing, compaction, ship motions and tank
vibrations as defined in Pt 11, Ch 4, 5.1 Materials 5.1.4(g) and Pt 11, Ch 4, 5.1 Materials 5.1.4(h) shall be assumed.
- The cooling effect of the rising
boil-off vapour from the leaked cargo should be taken into account
where applicable.
- No credit shall be given for any means of heating,
except as described in Pt 11, Ch 4, 5.1 Materials 5.1.4(e) and provided the heating arrangements are in
compliance with Pt 11, Ch 4, 5.1 Materials 5.1.4.
- For members connecting inner and outer hulls, the mean
temperature may be taken for determining the steel grade.
- Consideration should be given to scenarios in the
lifecycle of the unit, other than on-site operation, where the cargo
containment system may be used, tested or operated e.g. exposure to
hotter or colder environmental temperatures.
- The data set used for the ambient temperatures
calculation should be sufficiently large to minimise uncertainties.
Where limited data is available sufficient margins shall be included
in the calculation to account for statistical uncertainties. It is
the responsibility of the Owner to determine and propose the final
ambient temperatures most suitable for a particular unit's
operational requirements.
- These site specific ambient temperatures are
supplementary to any other statutory requirements which may be
applicable to the unit. As such, this Section is not intended to
duplicate, alter, amend or supersede any requirements that may be
imposed by the National Authority or Administrations.
When heat transmission studies are carried out, the
heat balance method is acceptable to LR.
- The shell and deck plating of the ship unit
and all stiffeners attached thereto shall be in accordance with the
requirements of Pt 10 Ship Units and this Part. If the
calculated temperature of the material in the design condition is below –5°C
due to the influence of the cargo temperature and ambient sea and air
temperatures, the material shall be in accordance with Table 6.1.5 Plates and sections for
hull structures required by . The ambient sea and air temperatures are
to be determined as defined in (a)(iii).
- The materials of all other hull structures
for which the calculated temperature in the design condition is below 0°C,
due to the influence of cargo temperature and ambient sea and air
temperatures, and that do not form the secondary barrier, shall also be in
accordance with Table 6.1.5 Plates and sections for
hull structures required by . This includes hull structure supporting
the cargo tanks, inner bottom plating, longitudinal bulkhead plating,
transverse bulkhead plating, floors, webs, stringers and all attached
stiffening members. The ambient sea and air temperatures are to be
determined as defined in (a)(iii).
- The hull material forming the secondary barrier shall be in
accordance with Table 6.1.2 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below 0°C and down to –55°C,
maximum thickness 25 mm (see Note 2). Where the secondary barrier is formed by
the deck or side shell plating, the material grade required by Table 6.1.2 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below 0°C and down to –55°C,
maximum thickness 25 mm (see Note 2) shall be carried into the adjacent deck or
side shell plating, where applicable, to a suitable extent.
- Means of heating structural materials may be
used to ensure that the material temperature does not fall below the minimum
allowed for the grade of material specified in Table 6.1.5 Plates and sections for
hull structures required by . In the calculations required in (a),
credit for such heating may be taken in accordance with the following:
- for any transverse hull
structure;
- for longitudinal hull structure
referred to in (b) and (c) where colder ambient temperatures are
specified, provided the material remains suitable for the ambient
temperature conditions of +5°C for air and 0°C for sea-water with no
credit taken in the calculations for heating; and
- as an alternative to (ii), for longitudinal bulkhead
between cargo tanks, credit may be taken for heating provided the
material remains suitable for a minimum design temperature of –30°C,
or a temperature 30°C lower than that determined by Pt 11, Ch 4, 5.1 Materials 5.1.2 with the heating considered, whichever is less.
In this case, the longitudinal strength of the ship unit shall
comply with SOLAS Regulation Regulation 3-1 - Structural, mechanical and electrical requirements for ships for both when
those bulkhead(s) are considered effective and not.
- The means of heating referred to in Pt 11, Ch 4, 5.1 Materials 5.1.2.(e) shall comply with the
following requirements:
- the heating system shall be
arranged so that, in the case of a single failure of a mechanical or
electrical component in any part of the system, standby heating can
be maintained equal to not less than 100 per cent of the theoretical
heat requirement;
- the heating system shall be
considered as an essential auxiliary. Where the requirements
specified by Pt 11, Ch 4, 5.1 Materials 5.1.2.(f).(i) are met by
duplication of the system components, i.e. heaters, glycol
circulation pumps, electrical control panel, auxiliary boilers etc.,
all electrical components of at least one of the systems are to be
supplied from the emergency switchboard;
- where duplication of the primary source of heat, e.g.
oil-fired boiler, is not feasible, alternative proposals such as an
electric heater capable of providing 100 per cent of the theoretical
heat requirement is to be provided, which is to be supplied by an
independent circuit, arranged separately on the emergency
switchboard. Other solutions may be considered acceptable towards
satisfying the requirements specified in Pt 11, Ch 4, 5.1 Materials 5.1.2.(f).(i) provided that a
suitable risk assessment is conducted to the satisfaction of the
Administration. The requirement in paragraph Pt 11, Ch 4, 5.1 Materials 5.1.2.(f).(ii) continues to
apply to all other electrical components in the system; and
- the design and construction of the
heating system shall be included in the approval of the containment
system by LR.
Details of the proposed heating system are to be
submitted.
5.1.3
Materials of primary and secondary barriers
- Metallic materials used in the construction of primary and
secondary barriers not forming the hull, shall be suitable for the design
loads that they may be subjected to, and be in accordance with Table 6.1.1 Plates, pipes (seamless
and welded, see Notes 1 and 2), sections and forgings for cargo tanks
and process pressure vessels for cargo design temperatures not lower than
0°C, Table 6.1.2 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below 0°C and down to –55°C,
maximum thickness 25 mm (see Note 2) or Table 6.1.3 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below –55°C and down to
–165°C (see Note 2), maximum thickness 25 mm (see Notes 3 and
4).
- Materials, either non-metallic or metallic but not covered by
Table 6.1.1 Plates, pipes (seamless
and welded, see Notes 1 and 2), sections and forgings for cargo tanks
and process pressure vessels for cargo design temperatures not lower than
0°C, Table 6.1.2 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below 0°C and down to –55°C,
maximum thickness 25 mm (see Note 2) and Table 6.1.3 Plates, sections and
forgings (see Note 1) for cargo tanks, secondary barriers and process
pressure vessels for cargo design temperatures below –55°C and down to
–165°C (see Note 2), maximum thickness 25 mm (see Notes 3 and
4), used in the primary and
secondary barriers may be approved by LR considering the design loads that
they may be subjected to, their properties and their intended use.
- Where non-metallic materials, including composites, are used
for or incorporated in the primary or secondary barriers, they shall be
tested for the following properties, as applicable, to ensure that they are
adequate for the intended service:
- compatibility with the cargoes;
- solubility in cargo;
- absorption of cargo;
- ageing;
- density;
- mechanical properties;
- thermal expansion and contraction;
- abrasion;
- cohesion;
- resistance to vibrations;
- resistance to fire and flame spread;
- resistance to fatigue failure and crack
propagation;
- influence of water;
- resistance to cargo pressure.
- The above properties, where applicable, shall be tested for the
range between the expected maximum temperature in service and 5°C below the
minimum cargo design temperature, but not lower than –196°C.
- Where non-metallic materials, including composites, are used
for the primary and secondary barriers, the joining processes shall also be
tested as described above.
- Guidance on the use of non-metallic materials in the
construction of primary and secondary barriers is provided in
Appendix 1, 1,5.
- Consideration may be given to the use of materials in the
primary and secondary barrier, which are not resistant to fire and flame
spread, provided they are protected by a suitable system such as a permanent
inert gas environment, or are provided with a fire retardant barrier.
5.1.4
Thermal insulation and other materials used in cargo containment systems
- Load-bearing thermal insulation and other materials used in
cargo containment systems shall be suitable for the design loads.
- Thermal insulation and other materials used
in cargo containment systems shall have the following properties, as
applicable, to ensure that they are adequate for the intended service:
- compatibility with the cargoes;
- solubility in the cargo;
- absorption of the cargo;
- shrinkage;
- ageing;
- closed cell content;
- density;
- mechanical properties, to the extent that they are
subjected to cargo and other loading effects, thermal expansion and
contraction;
- abrasion;
- cohesion;
- thermal conductivity;
- resistance to vibrations;
- resistance to fire and flame spread;
- resistance to fatigue failure and crack
propagation.
- In addition to the requirements given in (b), fatigue and crack
propagation properties for insulation in membrane systems are also to be
submitted. Insulation materials are to be approved by LR. Where applicable,
these requirements also apply to any adhesive, sealers, vapour barriers,
coatings or similar products used in the insulation system, any material
used to give strength to the insulation system, components used to hold the
insulation in place and any non-metallic membrane materials. Such products
are to be compatible with the insulation.
- The above properties, where applicable, shall be tested for the
range between the expected maximum temperature in service and 5°C below the
minimum cargo design temperature, but not lower than –196°C.
- Due to location or environmental conditions, thermal insulation
materials shall have suitable properties of resistance to fire and flame
spread and shall be adequately protected against penetration of water vapour
and mechanical damage. Where the thermal insulation is located on or above
the exposed deck, and in way of tank cover penetrations, it shall have
suitable fire resistance properties in accordance with a recognised Standard
acceptable to LR or be covered with a material having low flame spread
characteristics and forming an efficient approved vapour seal.
- Thermal insulation that does not meet recognised Standards
acceptable to LR for fire resistance may be used in hold spaces that are not
kept permanently inerted, provided its surfaces are covered with material
with low flame spread characteristics and that forms an efficient approved
vapour seal.
- Testing for thermal conductivity of thermal
insulation shall be carried out on suitably aged samples.
- Where powder or granulated thermal insulation
is used, measures shall be taken to reduce compaction in service, for
example due to vibrations, and to maintain the required thermal conductivity
and also prevent any undue increase of pressure on the cargo containment
system.
- Particular attention is to be paid to the cleaning of the
steelwork prior to the application of the insulation. Where insulation is to
be foamed or sprayed in situ, the minimum steelwork temperature at
the time of application is to be indicated in the specification in addition
to environmental conditions.
5.2 Construction processes
5.2.1 A construction, testing and inspection (CTI) plan for the installation
of the containment system is to be submitted for approval. This plan is to list the
following sequentially for each stage of installation, testing and
inspection: (a) The method to be used. (b) The
acceptance criteria. (c) The form of record to be made.
(d) The involvement of the shipyard, containment system designer
where relevant, and LR Surveyor. The testing and inspection should
be commensurate with assumptions made in the design of the containment system,
see
Pt 11, Ch 4, 4.3 Design conditions 4.3.3.(f). Further detailed documents, which may be cross-referenced by
the CTI plan, are to be submitted for approval as applicable.
5.2.2 A detailed quality assurance/quality control (QA/QC) programme shall be
applied to ensure the continued conformity of materials in the containment system
during installation and service. The quality assurance/quality control programme
shall include the procedure for fabrication, storage, handling and preventive
actions to guard against exposure of a material to harmful effects. The proposed
procedure is to be submitted to LR for consideration. All materials in the
containment system are also to be considered and included in the procedure. See
also Appendix 1, 1.5.
5.2.3
Weld joint design
- All welded joints of the shells of independent tanks shall be of
the in-plane butt weld full penetration type. For dome-to-shell connections
only, tee welds of the full penetration type may be used depending on the
results of the tests carried out at the approval of the welding procedure.
Except for small penetrations on domes, nozzle welds are also to be designed
with full penetration.
Except for the dome-to-shell
connections, T-butt welds will not be accepted in the shell.
This
requirement is applicable to independent tanks of type A or type B,
primarily constructed of plane surfaces. This includes the tank corners
which are constructed using bent plating which is aligned with the tank
surfaces and connected with in-plane welds.
The applicability of
the expression ‘For dome-to-shell connections only’ is clarified as
follows:
- Welded corners (i.e. corners made of weld metal)
shall not be used in the main tank shell construction, i.e. corners
between the shell side (sloped plane surfaces parallel to hopper or
top side inclusive, if any) and bottom or top of the tank, and
between the tank end transverse bulkheads and the bottom, top or
shell sides (sloped plane surfaces inclusive, if any) of the tank.
Instead, tank corners which are constructed using bent plating
aligned with the tank surfaces and connected with in-plane welds,
are to be used.
- Tee welds can be accepted for other localised
constructions of the shell such as suction well, sump, dome, etc.
where tee welds of full penetration type shall also be used.
- Welding joint details for Type C independent tanks, and for the
liquid-tight primary barriers of Type B independent tanks primarily
constructed of curved surfaces, shall be as follows:
- All longitudinal and circumferential joints shall be of
butt welded, full penetration, double vee or single vee type. Full
penetration butt welds shall be obtained by double welding or by the
use of backing rings. If used, backing rings shall be removed except
from very small process pressure vessels. Other edge preparations
may be permitted, depending on the results of the tests carried out
at the approval of the welding procedure.
- The bevel preparation of the joints between the tank
body and domes and between domes and relevant fittings shall be
designed according to a standard acceptable to LR. All welds
connecting nozzles, domes or other penetrations of the vessel and
all welds connecting flanges to the vessel or nozzles shall be full
penetration welds.
See also
Pt 5, Ch 10, 14 Construction of the Rules for Ships.
The applicability of the expression “Other edge preparations” is
clarified as follows:
- Cruciform full penetration welded joints in
a bi-lobe tank with centreline bulkhead can be accepted for the
tank structure construction at tank centreline welds with bevel
preparation subject to the approval of LR, based on the results
of the tests carried out at the approval of the welding
procedure (see
Figure 4.5.1 Cruciform full penetration weld).
- Where applicable, all the construction processes and testing,
except that specified in Pt 11, Ch 4, 5.2 Construction processes 5.2.5 shall be done in accordance with the applicable
provisions of Pt 11, Ch 6 Materials of Construction and Quality Control .
Figure 4.5.1 Cruciform full penetration weld
5.2.4
Design for gluing and other joining processes
The design of the joint to be glued (or joined by some other process
except welding) shall take account of the strength characteristics of the joining
process.
5.2.5
Testing during construction
- All cargo tanks and process pressure vessels
shall be subjected to hydrostatic or hydro-pneumatic pressure testing in
accordance with Pt 11, Ch 4, 6.1 Type A independent tanks to Pt 11, Ch 4, 6.6 Semi-membrane tanks, as applicable for the tank type.
- All tanks shall be subject to a tightness test which may be
performed in combination with the pressure test referred to in (a).
- Requirements with respect to inspection of secondary barriers
shall be decided by LR in each case, taking into account the accessibility
of the barrier. See also
Pt 11, Ch 4, 2.4 Design of secondary barriers 2.4.2.
- The Administration may require that, for ship units fitted with
novel Type B independent tanks or tanks designed according to Pt 11, Ch 4, 8 Cargo containment systems of novel configuration, at least one prototype tank and its supporting
structures shall be instrumented with strain gauges or other suitable
equipment to confirm stress levels. Similar instrumentation may be required
for Type C independent tanks, depending on their configuration and on the
arrangement of their supports and attachments.
- The overall performance of the cargo containment system shall
be verified for compliance with the design parameters during entry into
service in accordance with the survey procedure. Records of the performance
of the components and equipment, essential to verify the design parameters,
shall be maintained and be available to the Administration.
- The overall performance of the cargo containment system is to
be verified for compliance with the design parameters during initial
acceptance cargo trials. The initial trials are to be witnessed by LR’s
Surveyors, and are to demonstrate that the system is capable of being
inerted, cooled, loaded and discharged in a satisfactory manner, and that
all safety devices function correctly.
The temperature at
which these tests are carried out is to be at or near the minimum cargo
temperature. Where a refrigeration plant is fitted, its operation is to
be demonstrated to the Surveyors. Records of the plant performance taken
during entry into service at minimum temperature are to be submitted.
Logs of plant performance are to be maintained for examination by the
Surveyors when requested.
- Heating arrangements, if fitted in accordance with Pt 11, Ch 4, 5.1 Materials 5.1.2.(e) and Pt 11, Ch 4, 5.1 Materials 5.1.2.(f), shall be tested for required heat output and heat
distribution.
- The cargo containment system shall be inspected for cold spots
during or immediately following entry into service. Inspection of the
integrity of thermal insulation surfaces that can not be visually checked
shall be carried out in accordance with recognised Standards.
- Repair Procedures shall define imperfection and defects and
their allowable limits, identification of failure type and subsequent repair
processes.
Repairs shall be of a quality standard as
defined in Pt 11, Ch 4, 5.2 Construction processes.
Records of the performance of
the repaired components and equipment, essential to verify the design
parameters, shall be maintained and be available.
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