Offshore Container Seminar

DNV 2.7-1 Design

Houston, October 10, 2011

What is an offshore container? Definition of Offshore Container:

A portable unit with a maximum gross mass not exceeding 25 000 kg, for repeated use in the transport of goods or equipment, handled in open seas, to, from or between fixed and/or floating installations and ships.

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What is an offshore container?

In addition to the definition are the following limitations to the design:
An offshore container is to have outer framework with Padeyes at or near the top. (waste skips may be constructed from flat steel plates forming the load bearing sections of the container) Sec.1.4.1. Protruding parts on the outside of the container frame that may catch or damage other containers or structures shall be avoided. (Padeyes and stacking guides may protrude above the top.) Sec. 4.1.3 Is to consist of a primary structure frame and (optionally) secondary structures (walls, roof, etc.)

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What is an offshore container?

Operational limitations for offshore containers: containers may be handled in maximum 6m significant wave height Design temperature -20 C (or colder) An offshore container shall be designed to withstand 30tilting in any direction without overturning. Payload is not to protrude above or beyond the container perimeter Lifting set is to be permanently attached to the container

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Strength
Strength is calculated for: Lifting by lifting set Lifting by fork lift truck Local impact loads on the frame in sides and bottom Special calculations for pad eyes Load on walls and floor Strength calculations are verified by prototype testing

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Strength
Design approval:
Strength is calculated: - Frame analyzes or simple manual calculations - Local strength, for instance padeyes, shear area in bottom fra,e or lifting sets Review of the design - Materials - Minimum thickness - Welds, details and special requirements Drawings are stamped and returned, with or without comments

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Strength
Frame analyzis is typically done for:
long containers heavy containers open baskets containers with complex frames

May not be necessary for

Smaller frames, for instance bottle racks Light containers Medium sized containers with strong frame Variants of well known designs
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Calculations and modelling

The Primary structure is identified from drawings What is the primary structure?
Load carrying and supporting frames and load carrying panels. Only the primary structure shall be considered in the design calculations.

Primary Structure

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10 October 2011

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Modelling/ calculations
Modelling of primary structure If the structure is symmetrical, it is only necessary to model

Add beam Mirror about properties XZ-plan YZ-plan

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10 October 2011

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Modelling/ calculations
Add lifting set
Use beam elements that do not transfer bending moments

Some programs may have special elements that only take tension loads

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10 October 2011

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Modelling/ calculations
Add boundary conditions
Top node is fixed

To achieve a valid solution, the model must be restricted from movement in horizontal direction.

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Modelling/ calculations
Lifting test
Add suitable loads Payload and tare are to be distributed as realistic as possible Evenly distributed in a general cargo container or node loads if there are fixed load points. Load factor is 2.5 when using 4point lifting and 1.5 using 2-point lifting.
Payload Tare mass

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Calculations and modelling

Analyse
1. Check the stresses. Note that allowable yield stress is:
4-point lifting: 0.85 x Re (for steel)

Pz = 2.5 x R x g

2. Check the deflection. Must not be greater than 1/300 of the span of the member.

3. Forces in the top node against the total design load. Must be equal to 2.5 x R x g

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Design
Detail requirements Pad eyes Minimum material thickness Fork lift pockets Protrusions Top protection Doors and door locks are to be secured for unwanted opening Is the container to be weather tight? Painting and corrosion protection

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Welding of padeyes

Not Acceptable

4.3.1: Main welds between the padeyes and the primary structure shall always be full penetration welds.

Good design: padeyes

To obtain full penetration welding with this design the base plate is slotted into the top frame. Padeye is being prepared and welded with full penetration. Base plate are to have Zquality.

Pad eyes
Poor weld quality observed on several containers in a series

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Pad eyes
One pad eye removed due to suspicion of unacceptable welding

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Pad eyes What we found

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Continuity

Connection between top rail and end structure is compromised

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Continuity

Not acceptable

Acceptable
Knee bracket

Good solution

Side walls are not included in primary structure

Fork lift pocket design

Corrosion inside fork pockets: May fall out Weakens pockets Problems reduced if pockets have bottom openings

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Fork lift pocket design

Fork lift pocket design

Old container, heavy corrosion, but no cracks

Fork pocket design

Old container: Cracks in bottom frame due to inufficient shear area above fork lift pockets

Fork pocket design

Reinforcement (increased shear area) above fork lift pockets.

Fork lift pocket design

Alternative reinforcements above fork lift pockets (wall plates are secondary structures and are not included in the shear area)

Fork lift pocket design

Paragraph 4.4.6 i DNV 2.7-1 states the following: Fork lift pockets shall be located such that the container is stable during handling with fork lift truck. Container length, height, width and rating shall be taken into account. Pockets shall be located as far apart as practical. Centre distance shall be at least 900 mm (where possible), but need not be more than 2050 mm.
This is supplemented by a Guidance Note with recommended distance between fork pockets related to length of container for loaded or empty lifting conditions

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Protrusions

Skid protrudes beyond container perimeter NOT APPROVED!

Protrusions
Protruding edge on padeye grinded down

Side protrusions
Door locking mechanism and hinges unprotected Other unacceptable protrusions Pork pockets have no shear area

Cargo protruding
Cylinders protrudes above frame Snagging hazard for slings in cylinder
ALSO: Padeyes not in line with slings Holes for shackle bolt too big Are the pad eye welds full penetration ? This Container is not approved to DNV 2.7-1

Container for stacking

This stacking guide may snag e.g. on deck rail on supply vessel. Alternative designs should be considered.

Container for stacking

Stacking guides

2006 edition, Sec. 4 Design

Top protection of open top containers: The top of all open frame containers and of all open top containers with permanent internal fittings, machinery or other installations where crane hooks or forerunners may snag, shall be protected with grating or plates. This may be fixed, hinged or removable. Top protection shall be capable of being secured.

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Plate top protection

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2006 edition, Sec. 4 Design (cont.)

Top protection of open frame container
Certified before protection requiremes introduced in 2006

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Net on skips and baskets

Protective nets are often used on open units like baskets and skips. Such nets are not required by DNV 2.7-1. Hooks for such nets should be placed in protected locations, not stick outside. Holes to attach hooks.must not be drilled in closed profiles

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2006 edition, Sec. 4 Design (cont.)

Top protection lids on cargo baskets (not mandatory)

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Protection of locking devices

Door locking bars are unprotected

Protection of locking devices Door protection accepted

Tank Containers

Tank Containers Tank containers are defined in Ch. 6.7 of the IMDG Code
The IMDG Code uses the term Portable Tank
- The term Tank container is only used for those portable tanks that comply with the definition of Container in the CSC Convention and for offshore tank containers

A special type is MEGC Multiple-Element Gas Containers

Tank Containers The IMDG Code Ch. 6.7:

Portable tanks for liquids, solids and gases Portable tanks are at least 450 litres
The term portable tank includes a shell fitted with service equipment and structural equipment necessary for the transport of dangerous substances. The portable tank shall be capable of being filled and discharged without the removal of its structural equipment. It shall possess stabilizing members external to the shell, and shall be capable of being lifted when full.

Portable tanks must be designed and fabricated according to a Recognized Pressure Vessel Code

Tank Containers 20 ISO tank container not suited for offshore use

Tank Containers

On offshore tank containers the tank is supported on 2 saddles and with a strong surrounding frame

Where are the various requirements?

THE IMDG CODE HAS REQUIREMENTS FOR: Design requirements for the tank The tank shell (minimum thickness) Valves and fittings The tank supports THE PRESSURE VESSEL CODE HAS REQUIREMENTS FOR: Tank shell and other pressurized parts The tank saddles DNV 2.7-1 HAS REQUIREMENTS FOR: The frame The lifting set Protection of the tank and fittings The tank supports

Tank Containers

Recognized pressure vessel codes:

USA: ASME VIII EN: Various EN standards for pressure vessels UK: alternatively PD 5500 Other standard may also be accepted by DNV after special consideration

Types of tank containers IMDG Chapter 6.7 PORTABLE TANKS

6.7.2 Tanks for liquids and solids 6.7.3 Tanks for non-refrigerated liquefied gases 6.7.4 Tank for refrigerated (cryogenic) gases 6.7.5 Multiple Element Gas Containers, MEGC
(for non-liquefied gases)

Marine transport of Dangerous Goods Selection of a tank container to carry a particluar dangerous cargo
Is the cargo classified? UN number? Danger class?
- Check the info. sheet for dangerous goods

What requriments apply for the tank container?

- Check entry for the UN number in part 3 of the IMDG - Check Tank Instruction, Special Provisions, etc.

Use the Tank Instruction number to find the particular requirements to the tank
- Part 4.2 of the IMDG

Select a tank container which fullfills these requirements, or design a new tank according to Part 6.7 in the IMDG Remember that the tank container must be certified!

What are the requirements to carry a special cargo in a tank container?

What are the requirements to carry a special cargo in a tank container? Tank Instructions:
From Tank Instructions in column 13 we find Tank Instruction T7 for Methanol NOTE: In older IMDG codes the tank instruction for Methanol, given in column 12, was T4. Column 12 was deleted on January 1st 2010 and only column 13 can be used for all tanks, new and old

What are the requirements to carry a special cargo in a tank container?

What are the requirements to carry a special cargo in a tank container?

EXAMPLE: Transport of methanol (UN No. 1230):

Tank instruction:

T7

Test pressure:4 bars Minimum thickness: 5 or 6 mm depending on tank diameter Safety valve: Normal, i.e. bursting disc not required Bottom closures: 3 closures in series:
- Internal valve - External valve - A bolted blank flange or screw cap

Marking:

Protection on tank containers

These valves need protection, e.g. by plate or beam (can be removable or hinged (This tank container was NOT certified by DNV)

Tank support
Tank is supported on doubling plates on the fork pockets.

(Tank Container not approved by DNV)

The result?

Tank support
It is cracking! It corrodes! It will soon be falling apart!

Offshore gas cylinder racks Bundles

Bottle racks:
A) with loose cylinders: the gas cylinders are certified at manufacturer, the container frame must be certified to DNV 2.7-1 B) If the gas cylinders are fixed and interconnected through a manifold with valves, the unit is defined in Ch. 6.2 of the IMDG Code as a gas cylinder bundle

Gas bottle racks

Bottle rack: frame with 16 gas bottles (Not connected by manifold therefore not a bundle)

Gas Bottle racks

Bottle rack: frame for 6 loose gas bottles

BUNDLES need to have the following certification:

- The IMDG Code Ch. 6.2 Receptacles for gases - The gas cylinders are certified to applicable standards at the manufacturer - For IMDG approval: ISO 10961 Gas Cylinders Cylinder bundles - (For ADR/RID approval: EN 13769 Transportable Gas Cylinders Cylinder Bundles) - USA: 49 CFR requirements? - DNV 2.7-1 Offshore containere
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Gas bottle racks bundles

This bottle rack is a BUNDLE according to the IMDG Code

Offshore gas cylinder racks Bundles vs. MEGCs

IMDG/ADR/RID Ch 6.2: Gas cylinder Bundles:
- Max volume 3000 litres - Offshore use not specifically mentioned in the code, but offshore containers must comply with MSC/Circ. 860 - DNV interpretation: Approval to Ch. 6.2 can be combined with DNV 2.7-1

IMDG/ADR/RID Ch. 6.7.5: Multiple Element Gas Cylinder Tanks MEGCs

- No lower volume limit - ISO 10961 or EN 13769 not applicable - Offshore container certification (i.e. DNV 2.7-1) also required by the IMDG Code

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