FPSO Pipeline Protection in Brazil’s Pre-Salt Fields
We were contracted to supply flexible pipeline protection solutions for a major FPSO project in Brazil’s pre-salt oil fields—one of the world’s most demanding ultra-deepwater environments (2.000+ meters). The project required reliable protection for umbilicals, subsea power cables, and flexible risers at all critical interfaces, including J-tube exits, subsea tree connections, and FPSO deck terminations.
Challenge
The client faced strict regulatory compliance (DNV, NORSOK) mandating maximum bend radius (MBR) control to prevent armor wire fatigue, insulation failure, and costly downtime. Additionally, the project demanded corrosion-resistant, modular solutions that could be installed efficiently to reduce vessel time—critical for minimizing operational expenses in deepwater operations.
Solution
The firm deployed a combination of polyurethane (PU) spine-type bend restrictors and dynamic bend stiffeners, tailored to South America’s offshore conditions:
J-Tube Exits & FPSO Decks: Spine-type bend restrictors were installed to lock the bend radius at ≥20x the pipeline outer diameter, eliminating overbending risks at static interfaces. These modular PU units were paired with cable hang-off clamps to create a fully sealed, load-bearing system.
Subsea Tree & Manifold Interfaces: Dynamic bend stiffeners with graded stiffness were integrated to absorb wave-induced vibrations and vortex-induced vibrations (VIV), protecting flexible risers and umbilicals in high-dynamic-load zones.
Material Selection: All components were manufactured from marine-grade PU, offering superior corrosion resistance against saltwater and hydrogen sulfide (H₂S)—a common hazard in Brazil’s pre-salt fields.
Results
Compliance & Risk Mitigation: The solution met all regulatory MBR requirements, preventing potential pipeline failures that could result in daily downtime losses of over $1 million.
Installation Efficiency: Modular PU designs reduced on-site installation time by 40% compared to traditional steel solutions, saving hundreds of vessel hours.
Scalability: For the full FPSO project, over 300 units of bend restrictors and stiffeners were deployed—aligning with South America’s trend of large-scale, ultra-deepwater developments.
Long-Term Reliability: The PU components required no cathodic protection, reducing lifecycle maintenance costs by 30% and supporting the project’s 25+ year operational lifespan.
Market Impact
This case demonstrates the critical role of bend restrictors and stiffeners as mandatory standard components in South America’s offshore energy sector. With Brazil leading 70% of regional demand, and Guyana and Suriname emerging as key growth markets, modular PU-based bend protection solutions are now the industry standard for ultra-deepwater oil & gas and floating wind projects across the continent.
