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Case Study - Project Engineering for Refurbishment of the Internal Lining System of four Waste Heat Recovery Units (WHRU) installed on a fully operational Floating Production Storage and Offloading (F

Case Study - Project Engineering for Refurbishment of the Internal Lining System of four Waste Heat Recovery Units (WHRU) installed on a fully operational Floating Production Storage and Offloading (FPSO) Vessel

The WHRU units are installed in the exhaust system of 30 MW gas turbine power generation packages, designed to recover 15 MW of heat to facilitate oil production and offloading.  The internal lining system had to be replaced due to design and manufacturing defects, encountered shortly after the units became operational offshore.  A number of the lining studs’ casing attachment welds failed, jeopardising the integrity of both the lining system and the turbine below - as the exhaust is of a vertical design.

The major constraints of the project included confined space work, on-board HSE requirements and high ambient temperatures, all of which had to be considered in the repair design and procedures. 


Our engineering scope involved:

• Developing the Repair Strategy and Design
• Design Verification
• Development of Installation Procedures with a Third Party Contractor
• Review and Approval of Third Party Contractor Documentation and Drawings
• Technical Support during Onshore Fabrication Phase
• Technical Support for Third Party Contractor and Client during Offshore Implementation Phase
• Implementation of Lessons Learned on the First Unit into the Design and Fabrication Procedures for Subsequent Units
• Resolve on-going Technical Issues Encountered during the Implementation Phase Offshore