Japanese duo’s FPSO and FSO repair method becomes ABS-certified

Japan’s MODEC and Toray Industries have received what they say is the first of its type approval from the American Bureau of Shipping (ABS) for their process for in-situ ship repairs of floating production, storage, and offloading (FPSO) and floating storage and offloading (FSO) systems.

According to the pair, this enables certified vessels to employ their vacuum-assisted resin transfer molding (VaRTM) process, reducing the time needed for engineering reviews and verifications for ship repairs. This method entails applying carbon fiber reinforced plastic (CFRP), a technique approved by ABS last year, to corroded areas with reduced thicknesses of FPSO and FSO vessels.

In 2020, Toray and MODEC co-developed the VaRTM repair process, which consists of applying Toray’s TORAYCA carbon fiber woven fabric, which is said to be strong and elastic, to the surfaces of existing steel structures. Next, the fabric is covered with a film and vacuum-sealed, followed by an injection of epoxy resin that cures to complete repairs by bonding the CFRP to the steel structures.

Since FPSO and FSO maintenance is usually done offshore using steel materials, oil and gas production is stopped during welding, also known as hot work. The Japanese-developed procedure does not involve hot work, thus reducing the repairs’ impact on production. Furthermore, the partners say this in-situ VaRTM process makes transporting materials and equipment to locations easier than with regular steel-based techniques, and repairs can be performed faster, saving staff and time needed. 

Toray intends to continue working on its in-situ VaRTM process for various industrial applications while developing repair and reinforcement technologies for FPSOs and FSOs to meet market needs.

Last month, MODEC revealed that its decarbonization plan as part of the path to net zero by 2050 includes tackling power generation issues, which it identified as the main culprit for greenhouse gas (GHG) emissions, accounting for 65% of its carbon footprint.

Mitsui O.S.K. Lines (MOL) recently increased its stake in MODEC to 15%. This is seen as a way to build stronger ties between partners and enhance the competitiveness of their offshore businesses.