Best Practices for Tank Boundary and Penetration Testing Final ... - NSRP

Best Practices for Tank Boundary and Penetration Testing

Final Report Revision "-"

Technology Investment Agreement #2005-333

National Steel and Shipbuilding Company Project Engineering / Machinery Systems Engineering

Issued: May 13, 2013 ? Revision (-) Category B Data ? Government Purpose Rights

Final Report with Unlimited Distribution

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Table of Contents

1. Executive Summary ...................................................................................................................5 2. Introduction & Project Overview...............................................................................................6

2.1. Participants (Organizations) ..................................................................................................6 2.2. Participants (Individuals).......................................................................................................7 3. Project Elements ........................................................................................................................8 3.1. Overview ...............................................................................................................................8 3.2. Identification of key measures for success of early testing .................................................10 3.3. Identifying complex geometry boundaries ..........................................................................21 3.4. Determination of impacts of owner/classification society requirements .............................23 3.5. Investigation of methods of management of the testing process .........................................26 3.6. Document opportunities for continuous improvement ........................................................31 3.7. Document coordination issues between steel and outfit planning processes .......................39 3.8. Application of automation tools for producing production and test information ................40 4. Conclusion ...............................................................................................................................44

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Abbreviations

ABS - American Bureau of Shipping AC ? Alternating Current B&P ? Blast and Paint BIW ? Bath Iron Works (General Dynamics) CAD ? Computer Aided Design DC ? Direct Current DSME - Daewoo Shipbuilding & Marine Engineering IMCO - Intergovernmental Maritime Consultative Organization LNG ? Liquid Natural Gas MIG ? Metal Inert Gas MPI ? Magnetic Particle Inspection NASSCO--National Steel and Shipbuilding Company (General Dynamics) NDT ? Non-Destructive Testing PI ? Production Information PC ? Product Carrier SOC ? Stage of Construction

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1. EXECUTIVE SUMMARY

The ability to test shipboard tank boundary and outfit penetration welds prior to completion of the tank that they make-up is an important enabler for painting blocks at an earlier stage of construction. Traditionally, tank testing required that painting and outfitting must be held back from boundary welds for a tested tank until the final tank pressure test had been completed satisfactorily. This significantly impairs the shipyard's ability to complete outfitting and painting at the earliest, and most efficient, stage of construction. Best practice would allow for early testing and sign-off of large segments of tank boundaries prior to the erection and testing of all hull blocks that constitute the complete tank. Once boundaries have been tested as tight, they can be painted at the block stage and outfitting can be installed in the areas adjacent to the boundary welds. Welded boundaries that are part of the erection joints can remain unpainted and tested and certified at the time of the final tank pressure test. This project estimates that there is 1 to 2.25 cost advantage in adopting this early testing methodology. This project investigates shipyard practices for the testing of tank boundaries together with the ability to test outfit penetration welds prior to completion of the tank that they make-up. Utilizing knowledge gained from process improvements instituted at NASSCO, along with best practices from other leading US and Asian shipyards, this study describes ways to identify and optimize those testing methods currently mandated by Classification Societies and Owner requirements. The project concludes with current and future research into automating the generation of Production Information of tank boundary tests as direct outputs from modern Computer Aided Design tools such as the Tribon M3, 3-D modeling system as used at NASSCO.

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