We helped an FPSO operator reduce the cost and duration of their FPSO Water Ballast Tank Class Special Survey inspections by tailoring the generic Class scope to their specific asset. By applying engineering expertise and engaging with Class, we reduced unnecessary inspection work. This both enabled coating repairs to arrest corrosion and saved over 30% in cost and schedule compared to the standard approach.
The challenge
Class inspection requirements are typically generic and interpreted fairly rigidly by inspection contractors. They rely on traditional inspection methods with manned tank entry and for example the requirement for inspectors be within arm’s length of any CVI (Close Visual Inspection) points. This often leads to an inefficient scope, unnecessary offshore work, and increased cost and risk. Our client needed a way to optimise the inspection scope for their specific asset and operating conditions.
Key challenges included:
- Generic Class Special Survey rules not tailored to the asset and assume closeup manned inspection, not RIT (Remote Inspection Technologies).
- Inspection contractors not incentivised for scope efficiency.
- Lack of technical understanding to justify scope refinement and reductions.
- Offshore inspections are costly and expose personnel to risk.
Our solution
We applied engineering judgement and engaged directly with Class to justify an optimised inspection scope and methodology. Even without a formal RBI framework, we demonstrated that certain inspections could be modified or omitted based on asset-specific evidence.
Our activities included:
- Reviewing Class requirements and identifying areas of flexibility.
- Assessing asset condition and degradation mechanisms.
- Presenting engineering evidence to Class to support scope changes.
- Introducing CVI using a remote ‘camera on a pole’ to reduce rope access requirements (i.e. the need for the inspector to be physically an arm’s length from the point of interest).
- Coordinating with inspection teams to implement the optimised scope and methods.
The outcome
The optimised inspection scope delivered significant efficiency improvements achieving over 30% reduction in inspection cost and schedule. Our approach demonstrated value of engineering-lead inspection planning delivered the following significant benefits:
- Reduced offshore inspection time minimising impact on bed space and operations.
- Reduced personnel exposure to offshore risks (less time in tanks and less work at heights).
- Improved planning confidence and inspection efficiency.
- The time saved enabled coating repairs to corroded areas to be carried out at the same time – stopping corrosion and directly reducing integrity risk