FPSO Cidade de Itajai – Repair using SPS

 

Project Type

Bottom Plate Reinstatement/Cold Work

Location

Campos Basin, Rio de Janeiro, Brazil

Date

2024

Team

Metalock

© Altera Infrastructure

The FPSO Cidade de Itajai, situated in the Campos Basin off the Rio de Janeiro coast, underwent a structural repair using SPS Cold Work repairs to address corrosion in its cargo tank, which has an explosive atmosphere. As one of the largest independent private oil and natural gas producers in Latin America, the vessel owner required a solution that was safe and efficient and wouldn’t disrupt production.

In collaboration with our Network Partners, Metalock, for Altera & Ocyan, we provided a long-term, Class-approved repair using just 1.03 m² of Sandwich Plate System.

This FPSO repair was completed via our innovative Cold Work method. By applying SPS, the cargo tank’s bottom plates, which were corroded beyond class allowable limits, were safely restored via our on-site construction process implemented inside the tank – no hot work here!

This  cost-effective repair will keep the asset in good working order and personnel safe. SPS eliminated the requirement of expensive tasks like adjacent tanks gas free, diver and underwater cofferdam that required by conventional method. The work was completed within just few days with interruption to the asset’s production schedule and approved by DNV.

FPSO Repairs with SPS

SPS was the ideal choice for this FPSO repair project due to its unique benefits:

  • The COLD WORK repair was carried out without the need for welding or hot work, which ensured safety for personnel working within the cargo tank’s explosive atmosphere.
  • The repairs using SPS were completed within just a few days, minimising downtime and allowing operations to continue.
  • SPS provides a long-term repair solution that establishes the corroded hull plates’ strength, extending the FPSO asset’s lifespan.
  • SPS allows for on-site application so the repairs were carried out inside the cargo tank.