The first step in retrofitting an older FPSO's new technologies involves assessing the vessel's existing systems and infrastructure. Those aged vessels typically feature a mix of antilog and early digital technologies, including basic personnel tracking methods such as muster rolls, electronic t-card, swipe-card systems, or radio-based check-ins. These systems, while functional in their time, lack the real-time data integration and automation that modern solutions provide. The assessment must catalogue all hardware, software, and communication networks currently in use, paying close attention to power supplies, cabling, control rooms, and sensor placements. Engineers need to determine whether these components can support the new system or if they require upgrades. Crew Companion relies on a network of transponders, receivers, and a central software platform to track personnel via RFID (Radio Frequency Identification) tags, which demands a reliable power source and robust data transmission capabilities. On an older FPSO, the electrical grid may be insufficiently distributed or prone to outages, necessitating upgrades to transformers, wiring, or backup generators to ensure uninterrupted operation.
Beyond the electrical infrastructure, the physical layout of the FPSO must be thoroughly mapped. Systems like Crew Companion operate by dividing the vessel into zones such as mustering areas, lifeboat stations, hazardous zones, and accommodation blocks, each monitored by strategically placed receivers that detect personnel tags. Older vessels, designed without such technology in mind, may not have the structural provisions for mounting these devices. Decks cluttered with equipment, narrow passageways, or areas with heavy steel shielding could interfere with signal transmission, requiring creative solutions like elevated mounting platforms or additional repeaters to extend coverage. Engineers must collaborate with naval architects to ensure that any modifications comply with the vessel's stability and safety certifications, such as those mandated by the International Maritime Organization (IMO) or classification societies like DNV or ABS. This mapping process also involves identifying critical areas where real-time monitoring is most essential, such as engine rooms or topside processing units, where personnel safety risks are heightened due to the presence of flammable materials or high-pressure systems (see also: Crew Companion Heliport App).
Once the assessment and mapping are complete, the next phase focuses on integrating hardware with the FPSO's physical and operational environment. Crew Companion by Identec Solutions includes components like personnel tags, zone readers, and a central server that processes location data in real time. The transponders, lightweight RFID tags worn by crew members, are intrinsically safe and ATEX-certified, meaning they pose no ignition risk in explosive atmospheres—a critical feature for a vessel handling hydrocarbons. Installing these tags is straightforward, as they require no modification to the vessel itself; crew members simply wear them on lanyards, wristbands, or clipped to a helmet. However, deploying the readers presents a greater challenge. These devices must be positioned to provide comprehensive coverage without gaps, which may involve drilling into bulkheads or welding brackets onto steel surfaces. On an older FPSO, corrosion or wear could complicate this process, requiring surface preparation or reinforcement to ensure secure mounting. Additionally, the receivers must be connected to a power source and a data network, which may not be readily available in all areas of the vessel.
To address this, engineers may need to retrofit the FPSO with a modern wired or wireless communication network. Older vessels often rely on fragmented systems—perhaps a mix of coaxial cables for CCTV and VHF radios for communication—that are ill-suited to the high-speed data demands of a new RTLS System. A wired solution, such as Ethernet cabling, offers reliability but requires extensive installation work, including running cables through existing conduits or drilling new pathways, all while adhering to hazardous area classifications (e.g., Zone 1 or Zone 2). Alternatively, a wireless network using industrial-grade Wi-Fi or LoRaWAN could minimize physical alterations, leveraging the FPSO's steel structure to bounce signals between access points. However, wireless systems must contend with interference from the vessel's metal framework and machinery, necessitating careful frequency planning and signal testing. In practice, a hybrid approach often proves most effective, combining wired connections in critical areas like the control room with wireless coverage in open deck spaces. This network must link the receivers to the central server, typically housed in the FPSO's control room or IT hub, where real-time data is visualized on a dashboard for operators.
Powering this infrastructure is another key consideration. Systems' receivers and the server require a stable, low-voltage supply, typically 24V DC, which may not align with the FPSO's existing power distribution, often designed for higher voltages or AC systems. Retrofitting may involve installing step-down transformers or DC power supplies at strategic locations, ensuring redundancy with uninterruptible power supplies (UPS) to maintain functionality during blackouts—an all-too-common occurrence on ageing vessels. Solar panels or small wind turbines, common on modern FPSOs for auxiliary power, could supplement this setup, though their feasibility depends on the vessel's deck space and exposure to weather conditions. Engineers must also ensure that all electrical modifications comply with ATEX and IECEx standards for explosive environments, a non-negotiable requirement given the FPSO's operational context.
With the hardware in place, the focus shifts to software integration. Crew Companion's software platform is designed to interface with existing personnel management systems, such as Vantage, DaWinci, or Helipass, which handle crew logistics like flight manifests and Personnel On Board (POB) tracking. However, older FPSOs may lack such digital systems, relying instead on paper logs or standalone databases with limited connectivity. To bridge this gap, engineers must digitize the vessel's POB records, potentially by scanning historical data into a compatible format like SQL or CSV, and then configure system to sync with this database. This process requires custom middleware or APIs (Application Programming Interfaces) to translate legacy data into a format the system can process, a task that may involve collaboration with Identec Solutions' technical support team. The software must also be tailored to the FPSO's specific zoning scheme, with each receiver assigned to a designated area and tagged personnel linked to their roles (e.g., engineer, deckhand) for accurate tracking during drills or emergencies.
Testing and commissioning represent the critical next step. Before the system can be fully operational, engineers must validate every component under real-world conditions. This begins with a dry run, where crew members wear transponders and move through the vessel while operators monitor their locations on the dashboard. Signal strength, latency, and data accuracy are scrutinized, with adjustments made to receiver placement or network settings as needed. Simulated emergencies, such as a muster drill or evacuation to lifeboats, test the system's ability to provide real-time headcounts and identify missing personnel—a feature that can reduce muster times by up to 70%. These tests must account for the FPSO's unique challenges, such as signal interference from rotating machinery or temporary network disruptions during storms. Any failures, such as a receiver dropping offline or a transponder failing to register, require immediate troubleshooting, potentially involving firmware updates or hardware replacement. Once the system passes these trials, it undergoes a formal handover to the vessel's crew, accompanied by training on its use and maintenance.
Maintaining Crew Companion on an older FPSO demands ongoing attention, given the vessel's age-related vulnerabilities. The harsh offshore environment, saltwater corrosion, extreme temperatures, and vibration can degrade hardware over time, necessitating regular inspections of receivers, cables, and power supplies. Spare parts, such as replacement personal tags, should be stockpiled onboard to minimize downtime, even if the battery can last years. The software, too, requires periodic updates to address bugs, enhance features, or ensure compatibility with evolving industry standards. Identec Solutions offers remote monitoring and support via the Identec Support Portal, allowing technicians to diagnose issues from shore via satellite links, a boon for FPSOs operating far from the port. However, the crew must be equipped to handle basic repairs, such as resetting a receiver or swapping a faulty tag, to avoid reliance on external intervention during critical operations.
The benefits of such FPSO project extend far beyond compliance with modern safety regulations. By providing real-time visibility of personnel, Crew Companion transforms how an older FPSO manages emergencies, reducing the chaos of manual mustering and enabling rapid response to incidents like fires or gas leaks. Access control features restrict entry to hazardous areas, enhancing security, while data analytics from the system offer insights into crew movements, allowing operators to optimize workflows and reduce downtime. For an ageing vessel, this modernization can extend its operational life, making it competitive with newer FPSOs while improving its safety record—a key factor in securing contracts and maintaining a reputation as a reliable operator.
How challenging is it to retrofit an older FPSO with a modern real-time monitoring system?
Retrofitting an older FPSO with a real-time monitoring solution, such as Crew Companion, is challenging but entirely feasible with careful planning and technical expertise. One of the primary challenges is integrating new technologies with legacy systems that were not designed for real-time tracking, automated mustering, or access control. Older vessels often have outdated power supplies, cabling, and communication networks that may require upgrades to handle modern RFID-based tracking solutions. Another challenge lies in the physical layout of the FPSO—tight spaces, thick steel bulkheads, and complex structures can interfere with signal transmission, necessitating strategic placement of receivers or the use of additional repeaters. However, despite these challenges, the benefits of retrofitting are significant. It enhances safety by providing real-time personnel visibility, accelerates emergency response, and ensures compliance with modern safety regulations. Additionally, real-time monitoring improves operational efficiency, reducing muster times and optimizing workflows. A structured approach—starting with an infrastructure assessment, followed by phased installation and testing—can make the integration process smooth and effective.
Can an older FPSO's existing power and communication infrastructure support modern safety solutions?
In many cases, the existing power and communication infrastructure on older FPSOs is insufficient to fully support modern safety solutions without modifications. Older vessels often rely on legacy systems, such as analogue muster rolls or radio-based check-ins, which lack real-time data transmission capabilities. The electrical grid on these vessels may not be evenly distributed, and voltage levels may not be suitable for low-power RFID receivers and servers used in real-time monitoring. Upgrades may be necessary, including adding step-down transformers, uninterruptible power supplies (UPS), or even alternative energy sources like solar panels to ensure stable operation. On the communication side, older FPSOs typically have fragmented systems—such as coaxial cables for CCTV and VHF radios for communication—which are not optimized for real-time tracking. To integrate a system like Crew Companion, vessels may require a hybrid wired and wireless network solution. While Ethernet cabling offers reliability, it may require significant installation work. Wireless alternatives like industrial-grade Wi-Fi or LoRaWAN can reduce physical alterations but must be carefully planned to avoid interference from the vessel's metal structures. Retrofitting the right infrastructure ensures seamless data transmission, making real-time monitoring of ageing FPSOs both practical and effective.
Integrating Crew Companion into an older FPSO is a technical improvement that blends legacy infrastructure with modern innovation. From assessing the vessel's starting point to installing hardware, configuring software, and ensuring long-term reliability, each step requires precision and adaptability. The process not only upgrades the FPSO's capabilities but also aligns it with the industry's shift toward automation and real-time data. For operators willing to invest in this transformation, the payoff is a safer, more efficient vessel ready to meet the challenges of the 21st-century offshore environment.
Delve deeper into one of our core topics: Personnel on board
LoRaWAN (Long Range Wide Area Network) - is a low-power, long-range wireless communication protocol designed for Internet of Things (IoT) applications. Operating on unlicensed radio frequency bands, it enables battery-powered devices to transmit small amounts of data over long distances, up to several kilometres in urban areas and even farther in rural environments. LoRaWAN follows a star topology, where end devices communicate with gateways that forward data to a central network server. It supports bidirectional communication, device geolocation, and adaptive data rates, optimizing energy consumption and network efficiency.
LoRaWAN is well-suited for applications such as smart agriculture, industrial monitoring, smart cities, and asset tracking due to its low power consumption, scalability, and cost-effectiveness. It is governed by the LoRa Alliance, which ensures interoperability and standardization. Unlike cellular networks, LoRaWAN does not require costly infrastructure, making it ideal for large-scale deployments of IoT devices requiring long battery life and wide coverage.
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(1) https://www.thethingsnetwork.org/docs/lorawan/what-is-lorawan/