Custom Projects: FPSOs and Enhancing Asset Integrity
Structural monitoring on Floating Production Storage and Offloading units (FPSOs) is critical due to the challenging environments they operate in, which subject these vessels to continuous stress, leading to fatigue and potential failure. An example of this was highlighted in 2022 when an FPSO off Australia experienced an oil spill due to a hole in its tank, emphasizing the limitations of time-based maintenance and underscoring the need for advanced maintenance strategies beyond traditional methods.
FPSOs, whether newly built or converted tankers, face significant challenges in maintaining structural integrity. The constant exposure to marine environments results in cyclic stresses that can induce metal fatigue, particularly at welded joints. Corrosion exacerbates these effects, increasing the risk of cracks and structural failure. Traditional time-based maintenance, which schedules repairs at fixed intervals, often falls short as it does not account for the actual condition of the asset. This can lead to unexpected failures, as was the case with the Australian FPSO, which leaked just before its scheduled maintenance.
Sensors & solutions for FPSOs
The SENSFIB system by Light Structures addresses these issues through real-time structural health monitoring. Unlike periodic inspections, SENSFIB continuously measures stress and fatigue, providing accurate data that is essential for both condition-based and predictive maintenance strategies. SENSFIB utilizes fiber optic sensors to capture real-time stress measurements. This continuous monitoring is far superior to periodic inspections, offering a more precise understanding of the vessel’s structural health. The system incorporates algorithms that analyze stress data to predict fatigue life, allowing operators to schedule maintenance based on actual wear and tear, rather than predetermined schedules.
SENSFIB sensors can be installed without welding, using epoxy, which is particularly advantageous for submerged areas like ballast tanks or difficult to access locations around the moon pool. These sensors are also immune to electromagnetic interference and do not require recalibration, making them highly reliable. The SENSFIB system can integrate with digital twins, providing valuable data for digital twins and enhancing predictive maintenance capabilities.
Integration with digital twins
Digital twins are dynamic virtual models that simulate the real-world behavior of physical assets. For FPSOs, digital twins offer several advantages, enhancing predictive maintenance, optimizing operational parameters, and providing comprehensive asset management. By integrating SENSFIB data, digital twins can better simulate the structural effect of different operational scenarios, helping predict when and where structural issues might arise. This proactive maintenance approach reduces downtime and prevents failures.
Additionally, digital twins optimize load distributions and operational parameters, enhancing overall asset performance and extending the operational life of the FPSO. The continuous data flow from SENSFIB enables digital twins to provide a holistic view of the vessel’s condition, facilitating informed decision-making and efficient resource allocation. Advanced structural monitoring systems like SENSFIB and digital twin technology enables transitioning from time-based to condition-based and predictive maintenance strategies, ultimately helping to enhance asset integrity, prevent catastrophic failures, and optimize operational efficiency.
This blog is part of our Custom Projects series, which looks at the structural monitoring challenges and solutions of diverse maritime assets.