Bunkering Reels

Amanda Johnson

Pioneering Bunkering Solutions: INCITIAS’ Innovative Approach on FPSO and FSO Projects. 

In the competitive field of marine engineering, delivering original equipment solutions tailored to the unique needs of floating production, storage, and offloading (FPSO) and floating storage and offloading (FSO) vessels is paramount. INCITIAS recently showcased its capability to innovate under pressure in the design and installation of bunkering reels, essential for the efficient delivery of various fluids such as diesel, methanol, wax inhibitor, fresh water, and settled water. 

Optimizing Bunkering Reels for FPSO and FSO

Customized Engineering Design

INCITIAS was put to the test in the creation of five specialized bunkering reels for an FPSO, each designed to handle a different fluid. This engineering effort extended to an FSO, which required a tailored solution for its unique operational context. The design process had to consider the technical and safety requirements and the specific aesthetic and structural specifications, such as paint colours for structural steel and accessways.

Achieving Design Efficiency and Approval

While striving to maintain design uniformity to enhance manufacturing efficiency, INCITIAS navigated complex regulatory landscapes to secure necessary DNV type approvals for critical components like hoses, swivels, and marine breakaway couplings. This effort underscores INCITIAS’ commitment to compliance and safety in all its engineering solutions.

Innovative Solutions in Project Management

Meeting Tight Timelines through Strategic Sourcing

Faced with a firm timeline, INCITIAS demonstrated exceptional problem-solving skills. The procurement challenge for specialized hoses, which faced extended manufacturing times, was adeptly managed by partnering with a third-party vendor. This strategic decision ensured the availability of the hoses and their customization in a Lloyd’s Register approved facility, thereby adhering to the highest standards of quality and safety.

Overcoming Added Requirements

The project scope evolved to include the need for classification society approvals during project execution. This requirement posed challenges to meet the project’s tight schedule. However, the INCITIAS team navigated these hurdles by identifying alternative procurement options and accelerating the approval processes, showcasing our   ability to adapt and innovate under pressure.

Team Collaboration and Onsite Support

The project’s success was further facilitated by seamless collaboration among two client-side project teams, ensuring each sides requests were meticulously accommodated. INCITIAS’ team member, Charles Holding, provided critical onsite support in Dubai, enhancing the installation process, facilitating swift, clear exchange with the Melbourne based INCITIAS team and offering technical support vital for the timely completion of the project.

The successful delivery of bunkering solutions for both FPSO and FSO vessels exemplifies INCITIAS’ commitment as a leader in providing original equipment, designed and built efficient engineering solutions for Marine and Offshore operations.

 

You can find out more about our involvement in this project here or check out these updates on LinkedIn. 

What are bunkering reels and why are they important for FPSO and FSO vessels?

Bunkering reels are mechanical equipment used to manage and store hoses which transfer fluids like diesel, fresh water, and chemicals to and from vessels. They are crucial for FPSO (Floating Production, Storage and Offloading) and FSO (Floating Storage and Offloading) vessels as they ensure the safe, efficient, and orderly handling of various fluids necessary for daily operations and emergency procedures. Their design allows for the extreme conditions at sea, contributing to operational efficiency and safety.

How does INCITIAS ensure compliance with international standards in their projects?

INCITIAS adheres strictly to international standards by incorporating comprehensive regulatory compliance checks throughout the project lifecycle. This includes securing necessary type approvals from recognized IACS bodies such as Lloyd’s Register, DNV and Bureau Veritas, conducting rigorous quality assurance testing, and ensuring all engineering designs and materials meet global safety and environmental standards. Our team works closely with project managers and engineers to update and advise them on the latest standards and regulations relevant to each project. 

What were the specific challenges faced in the FPSO and FSO projects, and how were they addressed?

The FPSO and FSO project presented several challenges, including stringent timelines, the need for custom design solutions, and navigating regulatory approvals. INCITIAS tackled these issues by:

  • Customizing designs to meet specific vessel requirements while maintaining manufacturing efficiency.
  • Accelerating procurement processes by collaborating with third-party vendors to source pre-approved hoses, thus bypassing long manufacturing lead times.
  • Securing rapid type approvals by supporting our vendors and liaising effectively with certification bodies, ensuring no delays in project timelines.

How does INCITIAS handle tight project deadlines?

INCITIAS employs several strategies to manage tight deadlines effectively:

  • Advanced project planning that includes buffer periods and risk assessments to anticipate and mitigate potential delays.
  • Responsive project management techniques to allow for flexibility in task prioritization and resource allocation.
  • Strategic partnerships with suppliers and subcontractors to ensure quick turnarounds and high-quality inputs.

Can you explain the role of third-party collaborations in INCITIAS projects?

Third-party collaborations are integral to INCITIAS’ approach to project management and execution. By partnering with specialized vendors and subcontractors, INCITIAS can leverage external expertise and resources, particularly for specific components or when facing unusual challenges. These collaborations enable us to extend our capabilities, access innovative technologies, and meet specific project demands more efficiently. For example, in sourcing hoses with a quick turnaround, we collaborated with a third-party who had the needed inventory and could meet our specifications, including the fitting of end couplings in a certified workshop.

For more information please contact the Project Team: Bastiaan Scheepers

Engineering Services

INCITIAS Services and Original Products are supported by in-house team of engineers and designers:

  • Naval architects
  • Process engineers
  • Mechanical and Marine engineers
  • Safety and risk engineers
  • Structural and civil engineers
  • Electrical and instrumentation engineers
  • Subsea engineers
  • Construction supervisors
 

Naval Architecture services:

  • Hydrodynamic analysis
  • Hydrostatic analysis
  • Offshore and nearshore mooring systems design 
  • Design in accordance with IMO and class requirements

Process Engineering services:

  • Cryogenic system engineering for LNG, ethane, LPG, and hydrogen
  • Chemical engineering for olefins, biodiesel, and chemical bulk handling
  • Natural gas networks
  • Fuel systems
  • Jetty topsides for conventional oil and LNG
  • FPSO topsides design
  • Process system commissioning
 

Mechanical and Marine Engineering services:

  • Original equipment and machinery design
  • Hydraulic and pneumatic system design
  • Cryogenic pressure vessel design
  • Piping systems design
  • Package engineering
  • Marine systems integrations
  • Cargo and ballast systems, HVAC, and cooling propulsion solutions
 

Safety and Risk Engineering services:

  • Explosion studies
  • Gas dispersion studies
  • Cooling water dispersion studies
  • QRA, HAZOP and HAZID coordination
 

Structural Engineering services:

  • Marine and offshore structure design
  • Structure life extension
  • Fatigue studies
  • Asset integrity
 

Electrical and Instrumentation Engineering services:

  • Load lists
  • Shore-to-ship power connections
  • Power system design
  • LV and MV engineering
  • Subsea electrical systems engineering
  • Process and machinery instrumentation design
 

Subsea Engineering services:

  • ROV operations engineering
  • Subsea intervention engineering
  • Subsea pipeline system design
  • Flexible flowline and umbilical design

FPSO External Riser turret mooring

Mooring Handling LIFTING BEAM GENERAL ASSEMBLY Original Equipment

Hose Reel 3D hybrid render

FPSO Bow Extension 3D modelling

FPSO Decommissioning

Our clients find our experience invaluable during FPSO decommissioning planning and execution, using the INCITIAS teams’ ability to assess the most suitable strategy, based on the project and local authority’s requirements. Our team has extensive experience in the design and installation of FPSO mooring systems, risers and umbilicals.

 

We can support the client decommissioning plan with the following services:

 

  • Decommissioning option selection study and recommendation
  • Cost estimate and assessment of cost escalation
  • Contracting strategy options selection and recommendation
  • Integrated owner engineering team
  • Original equipment to unlock value in the decommissioning plan
  • Project management of decommissioning team and sub-contractor

 

Examples of typical deliverables for FPSO Decommissioning are:

 

  • Execution plan and cost estimation
  • Riser, umbilical and mooring disconnection analysis
  • Vessel spread selection and market enquiry
  • Decommissioning story board, tools and resource lists 
  • Design and build of original equipment 
  • ROV campaign support
  • Decommissioning schedule and procedure
  • Request for quotation, bid assessment and recommendation 
  • HAZID and HAZOP

Single Point Mooring system

Turret Mooring

Independent Verification Design

Working together with INCITIAS, clients can obtain objective evidence of asset compliance with project requirements.

With our independent verification design process, INCITIAS applies an efficient risk-based assessment method to prioritise critical elements of the asset.

 

An INCITIAS comprehensive review can include:

 

  • Desktop review of design documents
  • Review of HAZID, EIA and QRA findings
  • Risk ranking of asset elements
  • Preparation of review plan
  • Client approval of review plan
  • Execute review plan, including on-site performance verification
  • Issue of certification certificate
 

We work together with our clients to ensure the appropriate level of review is carried out.

Operations & Maintenance Support

INCITIAS combines our Engineering expertise with real world Operations and Maintenance experience.  We support our clients with O&M development and management activities including:

 

  • Enterprise management system development
  • Organisation structure development and evaluation
  • Systems and procedures development and review, including detailed procedures, permits and work systems
  • Emergency response systems
  • Defining specific port operations requirements
  • Operation and maintenance training and competency assessment
  • Commissioning activities

Integrated Owner’s Engineering Services

We support Owners with engineering, technical, and project management expertise across LNG, marine, and vessel conversion projects. Our clients can minimise risk and maximise opportunities earlier in project execution, with INCITIAS Owner’s engineering services. 

 

INCITIAS can provide integrated owner’s engineering services for onshore and offshore projects from a client office, site location or remotely from our offices in Melbourne. 

 

Typical services are:

 

  • Design and construction management
  • Customised risk management solutions
  • Specialist LNG process and marine engineering
  • Budget implementation, scheduling, and cost control
  • Non-permanent on-site dedicated offices for project

 

 

Indicative deliverables are:

 

  • Technical document reviews
  • Project bankability documents 
  • Basis of design
  • Functional performance specification
  • Resource plan and project schedule
  • Request for quotation and technical bid evaluation
  • Participation in HAZID, HAZOP, QRA, design reviews
  • FAT (Factory Acceptance Tests) certification
  • Work packs for installation contractor
 

We can be as involved as you require. From specialist resources who consultant on specific aspects of your project, to the provision of a fully integrated Owners team. 

At INCITIAS we develop tailor-made delivery solutions to match your project’s execution strategy and risk profile. Offering a full range of alternative delivery methods enables us to deliver the most effective project outcomes for you.

CLP Jetty Installation during the daytime

Advisory Services

INCITIAS offers integrated technical and commercial advisory services to assist clients advance their projects and provide support for their decision-making process. Clients can reduce risk and maximise opportunities by accessing our team of advisory specialists’ wealth of experience.

 

Typical advisory services are:

 

  • Technology assessment and selection. 
  • Commercial risk assessment.
  • Pre-feasibility, feasibility, and pre-FEED and FEED studies.
  • Contract review against the project technical performance.
  • Independent review of project execution plan.
 

INCITIAS techno-commercial advisory services aligns commercial drivers with feasible and proven technical solutions. Our team’s experience includes facility selection, financial assessment, contracting strategies, construction management and project operations. Assisting clients meet their business objectives using our capabilities to provide insights and solutions. 

 

Indicative deliverables are:

 

  • Site selection study
  • Environmental pre-assessment 
  • Technology options, recommendations and definition
  • Review of contract commitment against the facility performance
  • CAPEX and OPEX estimates
  • Financial models, NPV calculation, tolling model, and sensitivity assessment 
  • Project bankability document pack
  • Probabilistic models combining queueing and Monte Carlo assessment for logistic studies
  • HAZID, HAZOP, QRA and project risk assessment 
  • Operations and training requirements definition