OS-C501

Recommendations

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Offshore Standard DNV-OS-C501, November 2013 Sec.11 Fabrication – Page 172 recommended but not required by this standard. If a FAT test is not planned to be performed all parties of the project shall be informed about this decision and the system integrity test shall identify the same aspects as a FAT test. Guidance note: The factory acceptance test has the advantage that gross manufacturing errors are detected before the component leaves the factory. In some cases it is inconvenient or to perform a FAT test. The system integrity test will detect the same manufacturing mistakes as a FAT test, and the defect will be detected before operation starts. However, replacement or repair may be more complicated if a defect is detected as late as in a system integrity test. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e--- 5.2.4 The system integrity test is performed after final installation of all components and before the system goes into service. 5.2.5 The system integrity test shall be performed on all structures according to the requirements for pressure testing or other testing. 5.3 Pressure testing of vessels and pipes 5.3.1 All pressure vessels and pipes of safety class normal or high shall be pressure tested before going into service. 5.3.2 A test pressure of 1.3 x maximum service pressure shall be used unless such a pressure would introduce damage to the component that may reduce its lifetime. The maximum service pressure shall be the minimum test pressure. 5.3.3 A detailed test programme shall be defined. The following shall be stated as a minimum: — rates of pressure increase — holding times — time over which the pressure in the system shall not drop without actively applying pressure, i.e. a leakage test. 5.3.4 The test schedule shall be developed for each application. The testing should allow detecting as many possible defects in the structure as possible. As a general guidance the following schedules are recommended: — the minimum time over which the maximum test pressure in the system (from [5.3.2]) shall not drop without actively applying pressure should be at least 10 minutes for systems that do not creep — for systems that show creep the maximum test pressure should be kept for 1 hour applying active pressure. The pressure should be monitored for another hour without actively applying pressure. The pressure drop shall be predicted before the test and the test result should be within 10% of the prediction. 5.3.5 Pressure vessels of low safety class shall be tested up to their service pressure. Pressures shall be applied for at least 10 minutes. 5.3.6 Most authorities give general test requirements for pressure vessels. The requirements of the authorities that govern the location of the application shall be followed. 5.4 Other testing 5.4.1 It is recommended to test structures of safety class normal or high up to their main maximum service loads before going into service. 5.4.2 A test programme should be established based on the requirements of the application and the possibilities to test the structure before it goes into service. 5.4.3 An equivalent approach as the one described for pressure testing should be used. 5.5 Dimensions 5.5.1 The dimensions of the component shall be checked to be within the specified tolerances. DET NORSKE VERITAS AS
Offshore Standard DNV-OS-C501, November 2013 Sec.11 Fabrication – Page 173 6 Installation 6.1 6.1.1 The installation of composite structures shall be carefully planned. It shall be part of the design analysis. 6.1.2 Handling composite structures like metal structures may introduce severe damage. Any aspects of handling that deviates from typically practice with metal structures should be identified. Procedures should be in place to describe special handling requirements for composites. 6.1.3 Handling of composite structures requires special care. Handling instructions should follow each component. 6.1.4 Point loads and should be avoided. 6.1.5 Scraping, wear and tear should be avoided. 6.1.6 Bending the structure into place should be avoided. 6.1.7 Lifting shall only be done at specially indicated spots that were designed to take such loads. 6.1.8 All installation activities shall be verified independently for high safety class components. Whether the verification shall be done by the manufacturer himself, by the customer, or by a third party should be decided by the project. 7 Safety, health and environment 7.1 7.1.1 The fabrication of laminates may involve certain health risks. This standard does not address these issues. 7.1.2 All regulations with respect to safety, health and environment should be followed. 7.1.3 It is also recommended to perform a careful evaluation of all risks involved in producing composite structures. DET NORSKE VERITAS AS
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OS-C501

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