Hull & Structural Maintenance Repairs on Live FPSO

Challenge: Extending Life Without Interrupting Production

GRO executed critical hull and structural repairs on their FPSO as part of a strategic life-extension program. The mission: restore integrity and reliability without halting production. Operating on a live vessel posed significant safety and technical challenges, demanding precision, agility, and deep expertise in offshore hot work execution.

Solution: Engineering Precision Meets Rope Access Expertise

GRO’s multidisciplinary team began by analysing inspection data and conducted an on-site survey to identify additional deterioration. Leveraging this insight, we developed a bespoke engineering repair methodology aligned with ABS shipbuilding standards and client specifications.

Once approved, a team of multi-disciplined rope access-certified welders and fabricators was mobilised offshore. Using a combination of Shielded Metal Arc Welding (SMAW) and Flux-Cored Arc Welding (FCAW) techniques, the team executed high-quality hot work repairs—safely and efficiently, even in the demanding conditions of a live production environment.

Results: Zero Downtime, Maximum Impact

GRO successfully renewed and reinforced critical hull and structural components, ensuring the FPSO’s continue safe operation without a single interruption to production. The project not only extended the asset’s lifecycle but also reinforced GRO’s reputation for delivering high-stakes offshore solutions with precision and safety.