Dalian COSCO Shipyard's conversion of China's largest FPSO sets sail

2016-12-20 09:00

December 17, Dalian Cosco Shipyard completed the modification of a floating production, storage, and offloading vessel (FPSO) for MODEC, a global giant in offshore equipment The vessel The "Stade" FPSO, is ready for departure and will soon be transported to Brazilian waters for operation by Petrobras. The contract exceeded US$100 million. This is the largest FPSO modified by a Chinese shipyard, and the only ultra-large FPSO modification project delivered in 2016. As Dalian Cosco Shipyard's 11th FPSO modification project, its successful delivery further expands the shipyard's leading advantage as "China's No. 1 FPSO Modification Factory."
The "Stade", originally a VLCC-class ultra-large crude carrier, measures 335 meters in length, 58 meters in width, and 31 meters in depth, with a deck area approximately the size of three standard football fields.
During the modification, Dalian Cosco Shipyard added numerous production modules to the "Stade", including oil-gas separation, compressed air, and power generation systems—modules with high technical content and significant construction difficulty. They overcame challenges in piping welding super duplex stainless steel welding, long-distance transportation of oversized modules, and the installation of inclined vent stacks, among other new processes and technologies. The project involved 12,000 tons of steel structure work, painting of 300,000 square meters, 2,000 tons of piping work, cable laying of 700,000 meters. The total engineering volume far exceeded that of ordinary merchant ships, and the overall difficulty was much higher than that of typical new shipbuilding projects. After commissioning, the facility can process 24,000 cubic meters of crude oil per day, store 1.6 million barrels of oil, and process 3.5 million standard cubic meters of natural gas daily—enough to supply a city of 100,000 people for half a year. It is essentially a giant offshore oil processing plant, and the shipowner calls it a "world-class FPSO."
In Dalian Cosco Shipyard's previous FPSO modification projects, the work mainly focused on hull modification and the integration of core production function modules. However, the modification of the "Stade" included not only all hull modifications and production function module integration but also many production function module construction projects previously handled by specialized manufacturers. With the successful delivery of the "Stade", Dalian Cosco Shipyard's FPSO production module construction capabilities will undoubtedly gain more recognition from shipowners, laying a solid foundation for the company to further develop the module construction market.

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