That’s a “wrap”

Our team recently completed a crucial maintenance task on one of customers offshore FLNG facilities involving installing a composite wrap over a pressure vessel. Offshore Delivery Coordinator Matt Lovell gave us some insights into the project. 

This was project necessary after cracks were discovered during routine inspections, posing a risk to the vessel's structural integrity. 

The facility relies on the vessel for its continuous production operations, especially for the crucial cooling water system. The cracks, which penetrated the entire 20mm thickness of the steel on the top and were approaching critical levels on the bottom, required immediate intervention to prevent potential leaks that could disrupt operations. 

Composite wraps, similar to large external bandages, were carefully applied to strengthen the vessel, providing an additional barrier to retain pressure. This solution protected the vessel and reduced the risks associated with its compromised state. 

The project began in late 2022 and was overseen by Monadelphous. It progressed through rigorous phases over the following months, starting with extensive site preparation and meticulous layering of composite materials. By May 2024, the final layers were completed, ensuring the vessel's resilience to designed pressures and potential ruptures. 

The scale of the operation is highlighted by the fact that over 3000 hours were contributed offshore by subcontractor wrap applicators, along with substantial support from the planning team and various engineering disciplines. The logistical challenges were compounded by the offshore location, requiring meticulous planning for temporary power, scaffold erection, and fabric maintenance in tropical conditions. 

The installation of the 4-meter diameter, 2.5-meter-wide composite wrap, comprising 13 layers and weighing over 10 tonnes of materials, represented a significant achievement for Monadelphous. Accessing the vessel atop the facility required navigating 112 stairs followed by a 10-meter ladder climb, emphasising the project's complexity and logistical demands. 

Completing this project represents a critical interim solution, ensuring the vessel's operational safety until permanent remediation can be undertaken during the next scheduled shutdown, anticipated between 2026 and 2030. The successful execution averted potential operational disruptions and demonstrated Monadelphous' capability to manage intricate offshore projects under challenging conditions.