FPSO Xikomba : Dubai Drydocks, UAE

Dubai Drydocks, Dubai, United Arab Emirates

Conversion of the VLCC Mosocean into FPSO Xikomba

ShipConstructor Modules:
Pipe, Structure, ManualNest, AutomaticNest, NC-Pyros, BuildStrategy

FPSO Xikomba after conversion

Project Highlights:

Dubai Drydocks successfully used Albacore Research Ltd's (ARL) ShipConstructor software for the conversion of the VLCC Mosocean into the FPSO Xikomba for Single Buoy Moorings of Monaco. The FPSO Xikomba is the first complete FPSO conversion carried out at Dubai Drydocks.

3D Approach Increases Quality and Saves Time - Before Dubai Drydocks started using ShipConstructor, structure and pipes were drawn in 2D with several sectional views and details. Many areas of the ship would be drawn multiple times, resulting in extensive manual checking for accuracy and consistency for each drawing. The pipe lines would then be broken down into convenient spools. Each spool and isometric drawing was manually detailed to allow for pipe spool fabrication and subsequent installation. This methodology left room for errors and took up a valuable amount of time in terms of manual calculations of interferences between pipes and pipe and structure, which would inevitably lead to rework. Even the most experienced professionals found it challenging to picture the 3D ‘world' from 2D drawings. Frequent visits to the assembly area to assist in the visualization of the complex layout contributed to slowdowns and misunderstandings, resulting in time-consuming and costly rework.

The 3D approach saved Dubai Drydocks a great deal of time during the conversion. The average time required to produce an error-free ISO drawing was about one minute per ISO, in quantities of 10 spools or more – a vast improvement over the 1-2 hours to produce each fabrication drawing under the conventional 2D approach.

The VLCC Moscean before conversion

Automatic Generation and Updating Reduces Errors -

Dubai Drydocks left 2D techniques behind with ShipConstructor's 3D product model, which consists of intelligent drawing objects connected to an integrated SQL server database. The project database, giving combined quantities, weight and CG while allowing for planning of pre-outfitting and assembly, formed the backbone of the conversion project. Errors have been greatly reduced at Dubai Drydocks because the ISO spool pipe drawings are linked directly to the structural model and are generated and updated automatically, including bill of materials which list accessory items such as required bolts and gaskets. Minimal checking is required because ShipConstructor ensures that they will be consistent with the 3D model.

Catalogs and specifications which are a subset of one or more company specific catalogs, are also part of the 3D product model database. Therefore, if an item in a reference catalogue is changed, then the same item is automatically updated in the specification. Dubai Drydocks customized the built-in and user-defined materials library database and transferred it to the project database to ensure further consistency.

ShipConstructor Helps Streamline Processes -

The 3D product model approach with integration of functions for the generation of pipe arrangement, isometric equipment, foundation, and unit assembly drawings provided Dubai Drydocks with the best possible working environment.  Pipe and structural penetrations were computed early, defined in the 3D model and precut in the steel, eliminating the need for labor intensive cutting in the assembly area. This greatly reduced congestion and produced a less cluttered workplace.

Aerial view of the FPSO Xikomba following conversion

Pipe Creation Made Easy -

Dubai Drydocks highlighted ShipConstructor's Pipe module as particularly valuable. Building upon the intuitive menu and toolbars for elbows, tees, flanges, valves, and pipes, the team at Dubai Drydocks was especially impressed with the easy-to-use PORT/STBD/AFT/FWD orientation icons on spool drawings for installing pipe, outfitting and equipment items, and the bent pipes and saddle tee commands. With the Pipe module integrated with all other disciplines, Dubai Drydocks had the facility to convert 2D piping drawings into a 3D structural model and vice versa, and to automatically check and create bulkhead pipe penetration openings and penetration spool pieces. Errors were eliminated with Pipe's automatic interference checking of pipes and structure and checking of misalignment and incorrect gaps on their piping drawings.

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