Delivering Comprehensive Asset Integrity Management for MISC Mero 3 FPSO with Metegrity Inc. and ABSC

Introduction

FPSO The Mero oil field, located in Brazil’s ultra-deepwater Santos Basin, is one of the world’s most significant pre-salt discoveries, holding approximately 3.3 billion barrels of oil equivalent. The field is managed by the Libra Consortium, comprising Petrobras, Shell, TotalEnergies, CNODC, CNOOC, and Pre-Sal Petróleo. Divided into four development areas—Mero 1, Mero 2, Mero 3, and Mero 4—each area presents unique technical challenges in production and integrity management.

This case study focuses on the Mero 3 FPSO, named Marechal Duque de Caxias, owned by MISC, which utilizes cutting-edge technologies, including Metegrity’s Vision Enterprise and ABS Digital Solutions, to ensure operational readiness and compliance with stringent regulatory requirements.

Mero 3 FPSO: An Overview

The Marechal Duque de Caxias FPSO is among the world’s largest ultra-deepwater FPSOs, designed to operate efficiently in the challenging conditions of the Santos Basin. Converted from the Bunga Kasturi Dua, a VLCC shuttle tanker, the FPSO integrates high-pressure separation (HISEP) technology to manage CO₂-rich gas streams—a global first. Key specifications include:

Production Capacity: 180,000 barrels of oil per day.
Storage Capacity: 1.4 million barrels of crude oil.
Gas Handling Capacity: 440 mmscfd.
Water Depth: Deployed at approximately 2,100 meters.

The FPSO achieved its first oil on October 30, 2024, and is chartered to Petrobras for 22.5 years.

Challenges in Integrity Management for Mero 3 FPSO

Given its size and operational scope, Mero 3 FPSO posed several challenges for integrity management:

Regulatory Compliance: Adherence to stringent Brazilian regulations and DNV classification requirements.
Operational Readiness and Assurance: Ensuring reliability without dry-docking for the duration of the charter.
Asset Integrity Management (AIM): Monitoring and maintaining critical components, including hull structures, mooring systems, topside equipment, and explosive-proof equipment.
Risk-Based Inspection (RBI): Developing robust inspection plans tailored to the FPSO’s unique operational profile.

Selecting the Right Solution

To address these challenges, MISC solicited proposals from leading solution providers. After an exhaustive evaluation, MISC selected ABS, supported by ABS Consulting and Metegrity, for a comprehensive AIM Digital Solution and RBI solution. The contract was divided into two phases:

Development Phase: Design and implement RBI and AIM strategies.
Annual Support Phase: Ongoing support to ensure long-term operational success.

Key Solutions and Technologies Deployed

1. Metegrity’s Vision Enterprise^®

Metegrity’s Vision Enterprise^® was central to managing the integrity of topside static equipment, piping systems, pressure safety valves (PSVs), pressure relief valves (PRVs), and pressure relief devices (PRDs). Its key contributions included:

Digital Integrity Management: A 3D-enabled platform for database population, visualization, inspection reporting, and KPI monitoring.
RBI Implementation: Grouping assets, reviewing damage mechanisms, and developing risk-based inspection strategies.
Asset Monitoring: Identifying anomalies through real-time inspection and monitoring.
Dashboards

2. ABS NS5 Enterprise

ABS deployed its NS5 Enterprise solution, which included:

Hull Monitoring (HM/HD3D): Focused on hull structures, mooring systems, and topside structures.
Compliance Tools: Ensuring adherence to classification society and regulatory requirements.

3. ABS Consulting RBI Services

ABS Consulting conducted RBI assessments for hull structures, mooring systems, and topside equipment. The process involved:

Conducting RBI workshops and assessments.
Developing equipment-specific inspection plans.
Populating databases with inspection data.
Submitting RBI plans for class approval.

Outcomes and Benefits for Mero 3 FPSO

The collaboration between MISC, ABS, and Metegrity delivered several measurable benefits:

Optimized RBI Strategies
Comprehensive risk assessments enabled targeted inspections, reducing unnecessary interventions and downtime.
Enhanced Compliance
Automated reporting ensured alignment with DNV classification and Brazilian regulatory standards.
Proactive Maintenance
Predictive analytics identified potential failures, supporting timely interventions to minimize risks.
Seamless Integration
The AIM digital solution interfaced with MISC’s Data Hub and CMMS, streamlining operations.
Extended Asset Lifespan
Real-time monitoring and advanced methodologies enhanced asset reliability and longevity.

Conclusion

The Mero 3 FPSO project exemplifies the importance of integrating advanced digital solutions in offshore integrity management. Metegrity’s Vision Enterprise^®, combined with ABS’s expertise, delivered a comprehensive AIM and RBI solution, enabling MISC to meet operational and regulatory demands while ensuring safety and efficiency.

As FPSOs continue to play a critical role in global energy production, such innovative approaches set a benchmark for the industry, demonstrating the value of collaboration and cutting-edge technology in addressing the complexities of offshore operations.