HOW TO FIT A SAFETY SOLUTION ON AN OLDER FPSO VESSEL?
Incorporating an ageing FPSO vessel with a real-time monitoring solution is challenging but not impossible. It needs careful planning, technical know-how, and an in-depth knowledge of both: the ship's legacy systems and the potential of the new technologies. FPSOs are built to last many years, typically decades, in severe marine conditions. A few older ships, launched in the 1980s or 1990s, are based on legacy systems and manual processes for people tracking, safety management, and emergency response. Retrofitting an existing ship that offers real-time visibility into people, automated mustering, access control, and enhanced safety capabilities—presents special challenges but also considerable opportunities to enhance operational efficiency and safety. This article explores the technical considerations, processes, and strategies involved in successfully integrating an older FPSO with such a solution, offering a detailed roadmap for engineers and operators on how to start modernization with Crew Companion.
WHERE TO START SUCH PROJECT?
The first step in retrofitting an older FPSO with new technologies involves assessing the vessel’s existing systems and infrastructure. Those aged vessels typically feature a mix of antilog and early digital technologies, including basic personnel tracking methods such as muster rolls, swipe-card systems, or radio-based check-ins. While functional in their time, these systems lack the real-time data integration and automation that modern solutions provide. The assessment must catalogue all hardware, software, and communication networks currently in use, paying close attention to power supplies, cabling, control rooms, and sensor placements. Engineers need to determine whether these components can support the new system or if they require upgrades. On an older FPSO, the electrical grid may be insufficiently distributed or prone to outages, necessitating upgrades to transformers, wiring, or backup generators to ensure uninterrupted operation.
Beyond the electrical infrastructure, the physical layout of the FPSO must be thoroughly mapped. E-mustering systems operate by dividing the vessel into zones such as mustering areas, lifeboat stations, hazardous zones, and accommodation blocks, each monitored by strategically placed receivers that detect personnel tags. Older vessels, designed without such technology in mind, may not have the structural provisions for mounting these devices. Decks cluttered with equipment, narrow passageways, or areas with heavy steel shielding could interfere with signal transmission, requiring creative solutions like elevated mounting platforms or additional repeaters to extend coverage. Engineers must collaborate with naval architects to ensure that any modifications comply with the vessel’s stability and safety certifications, such as those mandated by the International Maritime Organization (IMO) or classification societies like DNV or ABS. This mapping process also involves identifying critical areas where real-time monitoring is most essential, such as engine rooms or topside processing units, where personnel safety risks are heightened due to the presence of flammable materials or high-pressure systems.
HARDWARE INSTALLATION
Once the assessment and mapping are complete, the next phase focuses on integrating hardware with the FPSO’s physical and operational environment. Crew Companion, an e-Mustering system by Identec Solutions, includes personnel tags, zone readers, and a central server that processes location data in real-time. The transponders, lightweight RFID tags worn by crew members, are intrinsically safe and ATEX-certified, meaning they pose no ignition risk in explosive atmospheres—a critical feature for an FPSO handling hydrocarbon. Installing these tags is straightforward, as they require no modification to the vessel itself; crew members simply wear them on lanyards, wristbands, or clipped to a helmet. However, deploying the readers presents a greater challenge. These devices must be positioned in a way that provides comprehensive coverage without gaps, which may involve drilling into bulkheads or welding brackets onto steel surfaces. On an older FPSO, corrosion or wear could complicate this process, requiring surface preparation or reinforcement to ensure secure mounting. Additionally, the receivers must be connected to a power source and a data network, which may not be readily available in all areas of the vessel.
To address this, engineers may need to retrofit the FPSO with a modern wired or wireless communication network. Older vessels often rely on fragmented systems—perhaps a mix of coaxial cables for CCTV and VHF radios for communication—that are ill-suited to the high-speed data demands of the new RTLS System. A wired solution, such as Ethernet cabling, offers reliability but requires extensive installation work, including running cables through existing conduits or drilling new pathways, all while adhering to hazardous area classifications (e.g., Zone 1 or Zone 2). Alternatively, a wireless network using industrial-grade Wi-Fi or LoRaWAN could minimize physical alterations, leveraging the FPSO’s steel structure to bounce signals between access points. However, wireless systems must contend with interference from the vessel’s metal framework and machinery, necessitating careful frequency planning and signal testing. In practice, a hybrid approach often proves most effective, combining wired connections in critical areas like the control room with wireless coverage in open deck spaces. This network must link the receivers to the central server, typically housed in the FPSO’s control room or IT hub, where real-time data is visualized on a dashboard for operators.
Powering this infrastructure is another key consideration. Systems’ receivers and the server require a stable, low-voltage supply, typically 24V DC, which may not align with the FPSO’s existing power distribution, often designed for higher voltages or AC systems. Retrofitting may involve installing step-down transformers or DC power supplies at strategic locations, ensuring redundancy with uninterruptible power supplies (UPS) to maintain functionality during blackouts—an all-too-common occurrence on ageing vessels. Solar panels or small wind turbines, common on modern FPSOs for auxiliary power, could supplement this setup, though their feasibility depends on the vessel’s deck space and exposure to weather conditions. Engineers must also ensure that all electrical modifications comply with ATEX and IECEx standards for explosive environments, a non-negotiable requirement given the FPSO’s operational context.
HOW TO INTEGRATE SOFTWARE?
With the hardware in place, the focus shifts to software integration. Crew Companion’s software platform is designed to interface with existing personnel management systems, such as Vantage, DaWinci, or Helipass, which handle crew logistics like flight manifests and Personnel On Board (POB) tracking. However, older FPSOs may lack such digital systems, relying instead on paper logs or standalone databases with limited connectivity. To bridge this gap, engineers must digitize the vessel’s POB records, potentially by scanning historical data into a compatible format like SQL or CSV, and then configure the system to sync with this database. This process requires custom middleware or APIs (Application Programming Interfaces) to translate legacy data into a format the system can process, a task that may involve collaboration with Identec Solutions’ technical support team. The software must also be tailored to the FPSO’s specific zoning scheme, with each receiver assigned to a designated area and tagged personnel linked to their roles (e.g., engineer, deckhand) for accurate tracking during drills or emergencies.
TESTING AND COMMISSIONING
Testing and commissioning represent the critical next step. Before the system can be fully operational, engineers must validate every component under real-world conditions. This begins with a dry run, where crew members wear transponders and move through the vessel while operators monitor their locations on the dashboard. Signal strength, latency, and data accuracy are scrutinized, with adjustments made to receiver placement or network settings as needed. Simulated emergencies, such as a muster drill or evacuation to lifeboats, test the system’s ability to provide real-time headcounts and identify missing personnel—a feature that can reduce muster times by up to 70%. These tests must account for the FPSO’s unique challenges, such as signal interference from rotating machinery or temporary network disruptions during storms. Any failures, such as a receiver dropping offline or a transponder failing to register, require immediate troubleshooting, potentially involving firmware updates or hardware replacement. Once the system passes these trials, it undergoes a formal handover to the vessel’s crew, accompanied by training on its use and maintenance.
MAINTENANCE AND SUPPORT
An e-mustering system on vessels needs maintenance given the harsh offshore environment: saltwater corrosion, extreme temperatures, and vibration can degrade hardware over time, necessitating regular inspections of receivers, cables, and power supplies. Spare parts, such as replacement personal tags, should be stockpiled onboard to minimize downtime, even the battery can last years. The software, too, requires periodic updates to address bugs, enhance features, or ensure compatibility with evolving industry standards. Identec Solutions offers remote monitoring and support via the Identec Support Portal, allowing technicians to diagnose issues from shore via satellite links, a boon for FPSOs operating far from the port. However, the crew must be equipped to handle basic repairs, such as resetting a receiver or swapping a faulty tag, to avoid reliance on external intervention during critical operations.
WHAT ARE THE BENEFITS OF A RETROFIT?
The benefits of this retrofit extend far beyond compliance with modern safety regulations. By providing real-time visibility of personnel, e-mustering transforms how an older FPSO manages emergencies, reducing the chaos of manual mustering and enabling rapid response to incidents like fires or gas leaks. Access control features restrict entry to hazardous areas, enhancing security, while data analytics from the system offer insights into crew movements, allowing operators to optimize workflows and reduce downtime. For an ageing vessel, this modernization can extend its operational life, making it competitive with newer FPSOs while improving its safety record—a key factor in securing contracts and maintaining a reputation as a reliable operator.
TAKEAWAY
In conclusion, integrating an e-mustering system like Crew Companion into an older FPSO is a technical improvement that blends legacy infrastructure with modern innovation. From assessing the vessel’s starting point to installing hardware, configuring software, and ensuring long-term reliability, each step requires precision and adaptability. The process not only upgrades the FPSO’s capabilities but also aligns it with the industry’s shift toward automation and real-time data. For operators willing to invest in this transformation, the payoff is a safer, more efficient vessel ready to meet the challenges of the 21st-century offshore environment.
