FPSO Operations: The Complete Guide to Activities Onboard a Floating Production Storage and Offloading Vessel

FPSO Operations: The Complete Guide

Floating Production Storage and Offloading (FPSO) vessels are complex offshore facilities designed to receive hydrocarbons from subsea wells, process oil and gas, store crude oil, and safely offload it to export tankers. An FPSO integrates production, marine, utility, maintenance, safety, and accommodation systems into a single operating asset.

This page serves as a comprehensive FPSO operations hub, covering all activities carried out onboard an FPSO, with direct links to detailed articles, procedures, safety guides, and training resources related to offshore operations.

FPSO Overview and Fundamentals

FPSOs are designed to operate continuously in harsh offshore environments while maintaining safe, efficient, and compliant production.

Key topics covered under this section include:

What an FPSO is and how it works
Differences between FPSO, FSO, TLP, and semi-submersible facilities
Typical FPSO layout and zoning
FPSO life cycle from design to decommissioning
FPSO organizational structure and onboard roles

Production Operations and Process Systems

Production operations form the core function of an FPSO, ensuring hydrocarbons are safely processed to export specifications.

Major production activities include:

Well fluid reception and production manifolds
First, second, and third stage separation
Crude oil stabilization and storage
Gas compression and gas export systems
Produced water treatment and discharge
Metering and custody transfer systems

Marine Operations and Crude Offloading

Marine operations ensure the FPSO maintains position and safely transfers crude oil to shuttle tankers.

This section covers:

Mooring systems (internal and external turret systems)
Station keeping and heading control
Tandem and side-by-side offloading operations
Hose handling and cargo transfer procedures
Marine communications and navigation safety
SIMOPS during offloading activities

Utility and Support Systems

Utility systems provide essential services that support production, safety, and habitability onboard the FPSO.

Typical FPSO utility systems include:

Power generation and electrical distribution
Instrument air and utility air systems
Fuel gas and diesel supply systems
Fresh water generation (RO and evaporators)
Sewage treatment and waste water systems

Maintenance and Asset Integrity Management

Maintenance and asset integrity activities ensure equipment reliability, regulatory compliance, and safe operation throughout the FPSO life cycle.

Key maintenance activities include:

Planned preventive maintenance (PPM)
Corrective and breakdown maintenance
Rotating and static equipment maintenance
Corrosion control and inspection programs
Structural integrity monitoring and repairs

Health, Safety, Security, and Environment (HSSE)

HSSE management is fundamental to FPSO operations due to the presence of major accident hazards.

This section addresses:

HSSE leadership and safety culture
Permit to Work (PTW) systems
Job Hazard Analysis (JHA) and risk assessments
Toolbox talks and safety communication
Life-saving rules and behavioral safety programs

Emergency Response and Crisis Management

FPSOs maintain robust emergency response systems to protect personnel, assets, and the environment.

Emergency scenarios covered include:

Fire and explosion response
Gas release and toxic exposure
Man overboard incidents
Vessel collision and offloading emergencies
Helicopter ditching and aviation incidents
Medical emergencies and evacuation

Simultaneous Operations (SIMOPS)

SIMOPS occur when multiple activities are performed at the same time, increasing operational risk.

Common FPSO SIMOPS include:

Production during crude offloading
Lifting operations near live process areas
Hot work during maintenance campaigns
Marine operations alongside deck activities

Lifting, Rigging, and Deck Operations

Deck operations are among the highest-risk activities onboard an FPSO and require strict controls.

This section includes:

Offshore crane operations
Lifting gear inspection and certification
Deck cargo handling and storage
Container management and securing
Dropped object prevention measures

Process Safety and Major Accident Hazard Control

Process safety focuses on preventing catastrophic incidents involving hydrocarbons and energy release.

Key process safety topics include:

Process Safety Management (PSM)
Hazard identification and risk studies (HAZID/HAZOP)
Bow-tie and barrier management
Safety-critical elements and performance standards

Environmental Management and Regulatory Compliance

FPSOs operate under strict environmental regulations to protect the marine environment.

Environmental management activities include:

Produced water discharge control
Flaring and emissions management
Chemical storage and usage control
Waste segregation and disposal
Oil spill prevention and response planning

Accommodation, Welfare, and Human Factors

Crew welfare directly impacts safety and operational performance onboard FPSOs.

Topics covered include:

Living quarters safety and comfort
Fatigue management and shift work
Food safety and hygiene offshore
Mental health and wellbeing
Human factors and ergonomics

Training, Competency, and Offshore Careers

Competent personnel are essential for safe FPSO operations.

This section focuses on:

Offshore induction and onboarding
Competency assurance systems
Role-based training and certification
FPSO career pathways and progression

Control Room and Digital Systems

Modern FPSOs rely heavily on automation and digital monitoring systems.

Key systems include:

Distributed Control Systems (DCS)
Emergency Shutdown (ESD) systems
Fire and Gas detection systems
Condition monitoring and alarms

FPSO Life Extension and Decommissioning

FPSO operations include planning for asset longevity and end-of-life activities.