Packaging of FPSO compressor systems for sea transport

We are carrying out a complex project to package FPSO compressor systems for MAN ENERGY SOLUTIONS, manufactured by Rockfin. This unique project involves securing nine massive systems intended for use on offshore platforms.

Scope of service provided:

System specifications:

Description of the implementation of the order:

At the outset of the implementation, we reviewed the full scope of the client’s requirements and the specifications of the systems that would ultimately operate on the vessel in the vicinity of the oil platforms. The priority was to minimise the risk of damage during sea transport, while not increasing the dimensions of the cargo excessively. To this end, we proceeded with detailed planning of the support structure on each of the systems.

The first step was to prepare the wooden frame, which we mounted directly onto the unit. We opted for tried-and-tested solutions in order to create a stable base for the subsequent protective layers – foils and tarpaulin. Our aim was not only to protect the massive components, but also to adequately insulate installation components and critical points such as platforms, cable trays and any openings. In this way, we avoided unwanted external factors getting into the systems.

A key moment was the installation of the underlay beams with a section of 450×300 mm. The choice of this size and the limitation to four beams for each system made it possible to significantly reduce the dimensions of the structure. At the same time, we had to be sure that the beams in this configuration could carry loads of up to 130 tonnes. Therefore, each element was made from a single piece of high-strength timber and was carefully tested before assembly.

Once the support structure was ready, we moved on to the next protective steps. We focused on carefully protecting the space underneath the unit, filling and sealing any gaps to prevent water or dirt from entering. We placed anti-corrosion capsules and moisture absorbers in sensitive areas to provide long-lasting protection during the multi-week sea voyage. We coated selected components with a layer of Tectyl preservative, which further protects them from the effects of sea salt and moisture.

The next step was a build-up of plywood panel, to which we then applied a VCI corrosion protection film. This layer has a double function: it provides a mechanical shield and prevents corrosion reactions. To provide an even higher level of protection, we applied shrink film, which we carefully shrunk over the entire surface. Only then were we able to move on to laying out the tarpaulin and safety net. We labelled all the items in accordance with transport standards, paying attention to the legibility and durability of the markings.

The next step was a build-up of plywood panel, to which we then applied a VCI corrosion protection film. This layer has a double function: it provides a mechanical shield and prevents corrosion reactions. To provide an even higher level of protection, we applied shrink film, which we carefully shrunk over the entire surface. Only then were we able to move on to laying out the tarpaulin and safety net. We labelled all items in accordance with transport standards, paying attention to the legibility and durability of the markings.

Throughout the process, close collaboration with project managers, packaging coordinators and other departments enabled us to adapt the assumptions to current needs. Every modification or additional requirement was consulted during regular production meetings. This ensured that the final solution met the expectations of both our client and the other participants in the logistics chain.

In addition to the main packed units, we also prepared around 35 crates of bulk parts. In this case, some components, such as shafts and shaft parts, needed to be coated with VCI anti-corrosion fluid. When packing these smaller components, we were also guided by the principle of maximum protection against weather and mechanical damage. As a result, we created transport-ready kits that can withstand the hardships of the sea journey.

The whole job was a major logistical and production challenge, but thanks to precise coordination and years of experience in packing such dimensions, we completed it as planned. We are confident that our comprehensive approach will ensure a safe and trouble-free journey for all the prepared systems, all the way to their final installation.