Multiple complex interacting systems
Modern FPSOs operate in complex, high-risk environments where weather, vessel behaviour, process systems and human decisions all interact. 'We had previously deployed several training simulators for the offshore sector but this was our biggest challenge' said Director Ray Allen. 'We needed to build a realistic FPSO model which would prepare crews for the multiple challenges they face - it needed to provide a realistic, controllable and repeatable environment for practising both day-to-day operations and responding to major emergencies'
'Although we could see demand for a product it was a big step - we were creating something that didn't really exist in the marketplace, a highly configurable system which would balance realism with ease of setup and customisation. We're very happy with the way the finished product has been adopted by major training providers'.
The system provides a highly realistic training experience across core FPSO systems and scenarios including :
Environmental Conditions
Users can adjust:
- wind strength and direction
- current profiles
- wave height and period
- full storm conditions, up to and beyond 100-year events
- heading changes and water-density effects (saltwater/freshwater/aerated water)
The system calculates realistic vessel motions, including roll, pitch, heave and drift-off, giving operators a clear picture of how conditions affect stability and operations.
Marine Systems and Station Keeping
The simulator represents:
- mooring lines and their pre-tension
- anchor drag events
- riser tension changes due to weather or vessel movement
- the effect of mooring failure on vessel attitude and operational safety
This allows trainees to practise maintaining control during significant metocean events or equipment problems.
Process & Utility Systems
The major FPSO systems are included, such as:
- cargo pumps (with efficiency changes and cavitation)
- ballast and bilge systems
- firefighting and deluge systems
- inert gas system (IGS)
- valves and sea-chest operations
- power distribution and emergency generation
- alarm systems and process overviews
Operators can perform normal routines as well as high-pressure troubleshooting.
Stability & Structural Behaviour
The simulator calculates vessel stability and loading effects in real time, including:
- shear forces and bending moments
- inclining angles and heel
- flooding in tanks, voids, pump rooms and machinery spaces
- unexpected displacement changes
- incorrect loading that exceeds allowable structural limits
Users see how poor loading decisions or damage scenarios affect overall safety.
Realistic Failure Simulation
One of the system’s strongest features is the ability to combine multiple failures at once. Instructors can introduce issues at any point, such as:
Mechanical and System Failures
- pump breakdowns
- valve faults (stuck, failed, or left in the wrong position)
- pipeline or sea-chest problems
- IGS subsystem failures
- manual and automatic valve malfunctions
Instrumentation Problems
- inaccurate tank levels
- pressure/temperature/O₂-content faults
- incorrect or missing draft readings
- control-panel lights and indicators showing wrong status
- faulty valve-position feedback
Electrical Failures
- full or partial blackout
- emergency generator failure
- degraded power distribution
Marine Emergencies
- mooring-line failure
- riser-tension excursions
- anchor drag
- progressive flooding
Failures can be layered to create realistic, high-pressure emergency sequences—for example:
blackout → pump failure → incorrect tank readings → rising heel angle → mooring-line failure
Training Scenarios Supported
The simulator supports a wide range of training types:
Routine Operations
- cargo loading/offloading
- ballast adjustments
- bilge operations
- tank cleaning
- firefighting system checks
- wellhead and water-injection operations
Abnormal or Complex Situations
- heavy-weather operations
- stability issues caused by incorrect loading
- unexpected mass transfers or displacement changes
- vacuum/overpressure problems in cargo tanks
Emergency & High-Risk Situations
- combined system failures
- progressive flooding
- mooring or riser incidents during severe weather
- blackout in the middle of offload operations
Teams experience the consequences of compound failures and learn to coordinate responses under pressure.
How the system is typically used by Engineers, Operators & Supervisors
Marine Teams
Practise station keeping, understand vessel motion under different sea states, and respond to mooring or riser events.
Cargo & Process Engineers
Operate pumps, valves and control systems under realistic conditions—including alarms, faults and abnormal readings.
Stability Officers
Analyse loading plans, identify unsafe configurations and respond to damage/flooding scenarios.
Control Room Teams
Handle alarms, maintain situational awareness, interpret faulty instrumentation and follow emergency procedures.
Emergency Response Personnel
Experience high-stress multi-system failures that mirror real offshore incidents.
Instructor & Debrief Tools
The simulator gives instructors:
- real-time control of events
- the ability to pause, accelerate, or rewind
- timeline and alarm/event logs
- replay tools for detailed debrief sessions
This allows structured training and clear performance evaluation.
Deployment Options
The simulator can be deployed as:
- a single-laptop training system
- a multi-console control-room replica
- a full immersive-motion environment
- a remote/online system for distributed teams
This makes it suitable for both training centres and remote operations support.
Summary of Benefits
- Realistic modelling of FPSO behaviour under combined environmental, mechanical and process conditions
- Safe reproduction of high-risk events that cannot be performed offshore
- Better decision-making through exposure to multi-layered failures
- Consistent, repeatable training for regulatory and competency requirements
- Ability to tailor the model to specific vessels or operational realities
