Section
1 Non-Metallic Materials
1.1 General
1.1.1 The guidance given in this Appendix is in addition to the requirements of
Pt 11, Ch 4, 5.1 Materials where applicable to non-metallic materials.
The manufacture, testing, inspection and documentation of non-metallic
materials shall in general comply with recognised Standards, and with the specific
requirements of this Part as applicable.
When selecting a non-metallic material, the designer must ensure it has
properties appropriate to the analysis and specification of the system requirements.
A material can be selected to fulfil one or more requirements.A wide
range of non-metallic materials may be considered. Therefore the section below on
material selection criteria cannot cover every eventuality and must be considered as
guidance.
1.2 Material selection criteria
1.2.1 Non-metallic materials may be selected for use in various parts of
liquefied gas carrier cargo systems based on consideration of the following basic
properties:
- Insulation – the ability to limit heat flow
- Load bearing – the ability to contribute to the strength
of the containment system
- Tightness – the ability to provide liquid and vapour
tight barriers
- Joining – the ability to be joined (for example by
bonding, welding or fastening).
Additional considerations may apply, depending on the specific system
design.
1.3 Properties of materials
1.3.1 Flexibility of insulating material
The ability of an insulating material to be bent or shaped easily without
damage or breakage.
1.3.2 Loose fill material
A homogeneous solid, generally in the form of fine particles, such as a
powder or beads, normally used to fill the voids in an inaccessible space to provide
an effective insulation.
1.3.3 Nanomaterial
A material with properties derived from its specific microscopic
structure.
1.3.4 Cellular material
A material type containing cells that are either open, closed or both
and which are dispersed throughout its mass.
1.3.5 Adhesive material
A product that joins or bonds two adjacent surfaces together by an
adhesive process.
1.3.6 Other materials
Materials that are not characterised in this section of the Part shall
be identified and listed. The relevant tests used to evaluate the suitability of
material for use in the cargo system shall be identified and documented.
1.4 Material selection and testing
requirements
1.4.1
Material specification
When the initial selection of a material has been made, tests are to be
conducted to validate the suitability of this material for the use intended.
The material used shall clearly be identified and the relevant tests
shall be fully documented.
Materials shall be selected according to their intended use. They shall:
- be compatible with all the products that may be carried
- not be contaminated by any cargo nor react with it
- not have any characteristics or properties affected by the
cargo and
- be capable to withstand thermal shocks within the operating
temperature range.
1.4.2
Material testing
The tests required for a particular material depend on the design
analysis, specification and intended duty. The list of tests below is for
illustration. Any additional tests required, for example in respect of sliding,
damping and galvanic insulation, shall be identified clearly and documented.
Materials selected according to Pt 11, Ch 21, 1.4 Material selection and testing requirements 1.4.1 of this Appendix shall be tested further according to Table 21.1.1 Material testing.
Thermal shock testing should submit the material and/or assembly to the
most extreme thermal gradient it will experience when in service.
Material testing
Table 21.1.1 Material testing
Mechanical tests
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X
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X
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Tightness
tests
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X
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Thermal
tests
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X
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Physical
tests (see 6.9.2.5)
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-
Inherent properties of materials
Tests shall be carried out to ensure that the inherent properties
of the material selected will not have any negative impact in respect of the
use intended.
For all selected materials, the following
properties shall be evaluated:
- Density; example Standard ISO 845
- Linear coefficient of thermal expansion (LCTE); example
Standard ISO 11359 across the widest specified operating temperature
range. However, for loose fill material, the volumetric coefficient
of thermal expansion (VCTE) shall be evaluated as this is more
relevant.
Irrespective of their inherent properties and
intended duty, all materials selected shall be tested for the design service
temperature range down to 5°C below the minimum cargo design temperature,
but not lower than –196°C.
Each property evaluation test
shall be performed in accordance with recognised Standards. Where there are
no such standards, the test procedure proposed shall be fully detailed and
submitted to the Administration for acceptance. Sampling shall be sufficient
to ensure a true representation of the properties of the material
selected.
- Mechanical tests
The mechanical tests shall
be performed in accordance with Table 21.1.2 Mechanical
tests.
Table 21.1.2 Mechanical
tests
Mechanical tests
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Load
bearing structural
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Tensile
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ISO 527
ISO 1421
ISO 3346
ISO 1926
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Shearing
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ISO 4587
ISO 3347
ISO 1922
ISO 6237
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Compressive
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ISO 604
ISO 844
ISO 3132
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Bending
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ISO 3133
ISO 14679
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Creep
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ISO
7850
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If the chosen function for a material relies on
particular properties such as tensile, compressive and shear strength, yield
stress, modulus or elongation, these properties shall be tested to a
recognised Standard. If the properties required are assessed by numerical
simulation according to a high order behaviour law, the testing shall be
performed to the satisfaction of the Administration.
Creep may be caused by sustained loads, for example cargo pressure or
structural loads. Creep testing shall be conducted based on the loads
expected to be encountered during the design life of the containment
system.
- Tightness tests
The tightness requirement for the material shall relate to its
operational functionality.
Tightness tests shall be
conducted to give a measurement of the material’s permeability in the
configuration corresponding to the application envisaged (e.g. thickness and
stress conditions) using the fluid to be retained (e.g. cargo, water vapour
or trace gas).
The tightness tests shall be based on the
tests indicated as examples in Table 21.1.3 Tightness
tests.
Table 21.1.3 Tightness
tests
Tightness tests
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Tightness
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Porosity/Permeability
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ISO 15106
ISO 2528
ISO 2782
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- Thermal conductivity tests
Thermal
conductivity tests shall be representative of the lifecycle of the
insulation material so its properties over the design life of the cargo
system can be assessed. If these properties are likely to deteriorate over
time, the material shall be aged as best as possible in an environment
corresponding to its lifecycle, for example, operating temperature, light,
vapour and installation (e.g. packaging, bags, boxes, etc).
Requirements for the absolute value and acceptable range of
thermal conductivity and heat capacity shall be chosen taking into account
the effect on the operational efficiency of the cargo containment system.
Particular attention should also be paid to the sizing of the associated
cargo handling system and components such as safety relief valves plus
vapour return and handling equipment.
Thermal tests shall
be based on the tests indicated as examples in Table 21.1.4 Thermal
conductivity tests or their equivalents.
Table 21.1.4 Thermal
conductivity tests
Thermal tests
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Insulting
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Thermal
conductivity
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ISO 8301
ISO 8302
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Heat
capacity
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x
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- Physical tests
In addition to the
requirements of Pt 11, Ch 4, 5.1 Materials 5.1.3 (c) and Pt 11, Ch 4, 5.1 Materials 5.1.4 (b), Table 21.1.5 Physical
tests provides guidance and information on some
of the additional physical tests that may be considered.
Table 21.1.5 Physical
tests
Physical tests
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Flexible insulating
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Loose fill
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Nanomaterial
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Cellular
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Adhesive
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Particle size
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x
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Closed cells content
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ISO
4590
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Absorption/desorption
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ISO
12571
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x
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ISO
2896
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Absorption/desorption
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x
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Viscosity
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ISO 2555
ISO 2431
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Open time
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ISO
10364
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Thixotropic properties
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x
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Hardness
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ISO
868
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Requirements for loose fill material segregation
shall be chosen considering its potential adverse effect on the material
properties (density, thermal conductivity) when subjected to environmental
variations such as thermal cycling and vibration. Requirements for a
materials with closed cell structures shall be based on its eventual impact
on gas flow and buffering capacity during transient thermal phases.
Similarly, adsorption and absorption requirements shall take
into account the potential adverse effect an uncontrolled buffering of
liquid or gas may have on the system.
1.5 Quality control and quality assurance
(QA/QC)
1.5.1
General
Once a material has been selected, after testing as outlined in Pt 11, Ch 21, 1.4 Material selection and testing requirements of this Appendix, a detailed quality assurance/quality control
(QA/QC) programme shall be applied to ensure the continued conformity of the
material during installation and service. This programme shall consider the material
starting from the manufacturer’s quality manual (QM) and then follow it throughout
the construction of the cargo system.
The QA/QC programme shall include the procedure for fabrication, storage,
handling and preventive actions to guard against exposure of a material to harmful
effects. These may include, for example, the effect of sunlight on some insulation
materials or the contamination of material surfaces by contact with personal
products such as hand creams.
The proposed procedure is to be submitted to LR for consideration. All
other materials in the containment system are also to be considered and included in
the aforementioned procedure.
The sampling methods and the frequency of testing in the QA/QC programme
shall be specified to ensure the continued conformity of the material selected
throughout its production and installation.
Where powder or granulated insulation is produced, arrangements should be
made to prevent compacting of the material due to vibrations.
1.5.2
QA/QC during component manufacture
The QA/QC program in respect of component manufacture must include, as a
minimum but not limited to, the following items:
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Component identification
For each material, the manufacturer shall implement a
marking system to clearly identify the production batch. The marking
system shall not interfere in any way with the properties of the
product.
This marking system shall ensure complete
traceability of the component and shall include:
- Date of production and potential expiration
date
- Manufacturer’s references
- Reference specification
- Reference order
- When necessary, any potential environmental
parameters to be maintained during transportation and
storage.
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Production sampling and audit method
Regular sampling is required during production to ensure the
quality level and continued conformity of a selected material. The
frequency, the method and the tests to be performed shall be defined in
QA/QC program; for example, these tests will usually cover, inter
alia, raw materials, process parameters and component checks.
Process parameters and results of the production QC
tests shall be in strict accordance with those detailed in the QM for
the material selected.
The objective of the audit
method as described in the QM is to control the repeatability of the
process and the efficacy of the QA/QC program.
During
auditing, Auditors shall be provided with free access to all production
and QC areas. Audit results must be in accordance with the values and
tolerances as stated in the relevant QM.
1.6 Bonding and joining process requirement
and testing
1.6.1
Bonding procedure qualification
The Bonding Procedure Specification and Qualification Test should be
defined in accordance with an appropriate recognised Standard.
The bonding procedures shall be fully documented before work commences to
ensure the properties of the bond are acceptable.
The following parameters are to be considered when developing a
specification:
- surface preparation
- materials storage and handling prior to installation
- covering time
- open time
- mixing ratio, deposited quantity
- environmental parameters (temperature, humidity)
- curing pressure, temperature and time.
Additional requirements are to be included if necessary to ensure
acceptable results.
The bonding procedures specification shall be validated by an appropriate
procedure qualification testing programme.
1.6.2
Personnel qualifications
Personnel involved in bonding processes shall be trained and qualified to
recognised Standards. Regular tests shall be made to ensure the continued
performance of people carrying out bonding operations to ensure a consistent quality
of bonding.
1.7 Production bonding tests and
controls
1.7.1
Destructive testing
During production, representative samples shall be taken and tested to
check they correspond to the required level of strength as required for the design.
1.7.2
Non-destructive testing
During production, tests which are not detrimental to bond integrity
shall be performed using an appropriate technique such as:
- visual examination
- internal defects detection (for example acoustic, ultrasonic or
shear test
- local tightness testing.
If the bonds have to provide tightness as part of their design function,
a global tightness test of the cargo containment system shall be completed after the
end of the erection in accordance with the designer’s and QA/QC programme.
The QA/QC standards shall include acceptance standards for the tightness
of the bonded components when built and during the lifecycle of the containment
system.
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