FPSO Inspection, Maintenance, and Repair (IMR)

Target Audience:

  • Offshore inspection and maintenance engineers
  • FPSO operations and asset integrity personnel
  • Marine superintendents, class coordinators, and offshore supervisors
  • Engineers and planners involved in reliability, safety, and compliance

Course Objectives:

By the end of the course, participants will be able to:

  • Understand class and statutory requirements for FPSO inspection and compliance
  • Identify and manage critical topside and hull components requiring IMR
  • Plan and execute underwater inspections (UWILD) and risk-based inspection (RBI) programs
  • Apply preventive maintenance (PM) and asset integrity strategies tailored for FPSOs
  • Apply CFD to real-world engineering problems

Module Highlight

Module 1

  • FPSO configuration: hull, turret, mooring, topsides, and subsea interfaces
  • Differences between ship-shaped FPSOs and fixed platforms
  • Importance of IMR in asset life extension and safety
  • Classification of FPSO systems by criticality (Safety-Critical Elements)
  • Overview of maintenance strategies: reactive, preventive, predictive, and risk-based

Module 2

  • Role of classification societies (ABS, DNV, Lloyd’s, BV)
  • Class notations and special survey cycles for FPSOs
  • UWILD vs dry-docking requirements and exemptions
  • Statutory inspections under flag state and IMO (SOLAS, MARPOL, ISM)
  • Inspection documentation and audit readiness

Module 3

  • Pressure vessels, piping, flare systems, and separators
  • PSV testing, piping wall thickness checks, corrosion under insulation (CUI)
  • Pumps, compressors, and rotating machinery maintenance
  • Electrical and instrumentation systems
  • Safety systems: ESD valves, fire & gas detection, deluge systems
  • Thermal imaging, ultrasonic testing, vibration analysis

Module 4

  • Structural zones: deck, side shell, bottom, internal tanks
  • Corrosion monitoring and coating inspection
  • UT gauging and visual inspection techniques
  • Ballast and cargo tank inspections
  • Steel renewal and coating reapplication
  • Class reporting format and corrosion allowance criteria

Module 5

  • Overview of UWILD program and planning
  • ROV and diver inspection techniques
  • Hull, mooring, and thruster inspections
  • Sea chest, bilge keel, and anode condition assessment
  • Class requirements for video capture and reporting
  • Coordination between marine, class, and ROV teams

Module 6

  • Principles of RBI and API 580/581 guidelines
  • Criticality ranking and risk matrix development
  • Damage mechanisms and failure modes (corrosion, fatigue, erosion)
  • Probability vs consequence modeling
  • Integration with CMMS and digital twin systems
  • RBI reporting and reassessment triggers

Module 7

  • PM schedules and intervals based on OEM and class requirements
  • Use of CMMS (SAP, Maximo, IFS, etc.) in work planning
  • Job plans, spare parts tracking, and failure history logging
  • Permit to Work (PTW) system interface with maintenance
  • Managing deferred maintenance and backlog reporting

Module 8

  • Asset Integrity Management System (AIMS) framework
  • Integrating topsides, hull, mooring, turret, and subsea IMR
  • Key performance indicators (KPIs) and dashboards
  • Aging asset strategies and life extension planning
  • Audits, inspections, and intervention triggers
  • Communication between discipline leads, operations, and asset teams

Module 9

  • Emergency repair planning and isolation strategies
  • Use of temporary clamps, composite wraps, and habitat welding
  • Case studies on failures: hull breach, turret issues, fire, corrosion
  • Lessons from industry failures and best practices in IMR
Enroll Now
X