After sixteen months of intense construction, COSCO Dalian Shipyard has completed its conversion of the VLCC “SUNRISE IV” to an FPSO for MODEC Offshore.

The new FPSO was renamed “FPSO CIDADE DE ANGRA DOS REIS MV22”, and will be deployed in the pre-salt Tupi Field of the Santos Basin, offshore Brazil, for exploring the ultra deep-water oil below the salt bed.

It’s the first FPSO to be put into long-term pilot production in the Tupi Area, and also the fifth FPSO Modec has engaged COSCO Dalian Shipyard to convert.

The main work scope involved the fabrication and installation of the living quarters, installation of 29 modules, renewal of 1600 tonnes of outer bottom plating, laying of 400,000 meters of cable and the installation of a new mooring system, module base,flame tower, helideck, as well as piping system installation tests and tank coating.

The vessel is the first to adopt many world leading technologies, such as the reinjection of CO2 separated from the associated gas, and broke the record for the maximum operating water depth.

This converted FPSO also created three world records in the installation of the Sandwich Plate System (SPS) Overlay, Steel Catenary Riser (SCR), and CO2 Processing Module.

The three key parts of the conversion were complex and difficult and had never before been faced by COSCO Dalian Shipyard; In particular, the high precision requirements on the suction inlet in the middle of the SCR had to be carefully considered.

However, all of these difficult problems were eventually solved through the joint efforts of the yard and the owner.

This conversion project, which is worth up to 100 million dollars, was the largest contract for a single vessel in China in 2009. Compared with previous FPSOs built by COSCO Dalian Shipyard, the production control became stricter, more careful, and more scientific, whilst the quality was also improved.

More information could be found here!

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