Optimizing FPSO Inspection Processes

FPSOs (Floating Production Storage and Offloading units) demand meticulous inspection due to exposure to harsh marine environments, including waves, currents, and saltwater corrosion. Additionally, given the nature of the asset, corrosion monitoring in hull tanks and oil storage is critical. Advanced inspection and monitoring can help prevent catastrophic events. Ultrasonic Testing (UT) and Visual Testing (VT) are imperative methods employed to ensure the structural integrity of these vessels. These inspections identify corrosion, erosion, or damage that may compromise their strength, allowing for timely repairs and maintenance to prevent costly downtime or accidents caused by tank failures.

Assessing assets such as FPSO tanks presents numerous challenges, including high temperatures and limited access through conventional methods like scaffolding or rope access in confined spaces. However, the industry is evolving by embracing innovative technologies like Unmanned Aerial Vehicles (UAVs). While UAVs can operate autonomously, they are typically controlled remotely by a human pilot. Additionally, specialized equipment tailored for high-temperature environments is being integrated to enhance inspection efficiency and effectiveness.

Elevated temperatures within the FPSO pose significant challenges.

Recently, Avestec achieved a successful milestone by conducting a comprehensive inspection of an FPSO tank, employing the cutting-edge technology of SKYRON. The mission was meticulously designed to conduct both UT and VT inspections within the confined spaces of the FPSO tank. Leveraging SKYRON's advanced capabilities, the VT inspection meticulously captured General Visual Inspection (GVI) and Close Visual Inspection (CVI) HD images, while UT readings were diligently collected from the tank’s surfaces. Despite facing scorching ambient temperatures reaching up to 46°C, SKYRON's performance remained unparalleled, thanks to its integrated proprietary cooling system, ensuring peak efficiency even in the most challenging conditions. SKYRON is also equipped with two long-range video systems optimized for operation in metallic confined spaces. One link transmits HD video for inspection, and the other transmits low-latency FPV (First Person View) video for navigation. The FPV allows inspectors to stay in a safe place and have a view of the areas being inspected.

First Person ViewFor the inspection within confined spaces, SKYRON's capabilities shone brightly. Equipped with a robotic arm for UT and a gimbal-mounted camera for VT, SKYRON navigated narrow spaces with remarkable ease, efficiently capturing crucial data. SKYRON UT utilizes a robotic arm on the front of the flying platform, allowing the UT transducer to take measurements at 25 points within a 2" x 2" square grid. Additionally, the robotic arm seamlessly attaches to surfaces of various angles and curvatures, including narrow horizontal and vertical stiffener flanges, enhancing the quality of contact-based UT readings. On the other hand, SKYRON VT utilizes a gimbal mounted on the front of the flying platform, enabling a full ±90o pitch for a floor-to-ceiling view. The gimbal is equipped with a Sony camera, featuring a full-frame lens mirrorless camera with a motorized lens for remote zooming, a laser pointer, lidar, and a lighting system for operation in dark environments.

SKYRON's tether cableMoreover, SKYRON's tethered design eliminates the need for batteries, ensuring uninterrupted operation and longer flight times in hot environments. The smart tether system is developed to supply power to the flying robot at lengths of up to 100m. It also incorporates a server that runs a proprietary inspection, robotic control, temperature monitoring, and reporting software application. This system is complemented by our software Avesoft, which permits real-time data transmission and report generation.

All GVI (General Visual Inspection), CVI (Close Visual Inspection), and UT (Ultrasonic Testing) measurements were captured using SKYRON, with ABS surveyor approval. This serves as a significant step toward method approval, as SKYRON can be considered a new approach for FPSO inspections, eliminating the need for humans to work at height using ropes or scaffolding.

In conclusion, SKYRON proves to be a game-changer in FPSO inspections, offering enhanced safety for inspectors, faster assessment processes, and reduced costs. Its ability to operate in challenging environments, coupled with its advanced capabilities, positions SKYRON as a reliable solution for ensuring the integrity of FPSOs worldwide.