Fugro N.V., a global leader in geotechnical and offshore survey services, commissioned the construction of two state-of-the-art Geo-Technical Research Vessels (GTRVs) at TEBMA Shipyards, Mangalore. These vessels, Fugro Voyager and Fugro Scout, were among the first dedicated geotechnical research vessels to be built in India and were designed to support sophisticated offshore drilling, survey, and seabed investigation operations.

Due to the highly specialized nature of the onboard equipment—including drilling machinery, winches, cranes, pipe handlers, and hydraulic handling systems—the vessels demanded exceptional standards of reliability, cleanliness, and hydraulic system performance.

Cenergy Offshore, in partnership with Tube-Mac Industries (TMI), was selected to execute the complete hydraulic and high-pressure piping systems for the project under a demanding delivery schedule.

Project Scope

The project involved end-to-end implementation of hydraulic and high-pressure piping systems throughout the vessels, including:

1. Detailed engineering and piping design.
2. Hydraulic system planning and execution.
3. On-site pipe fabrication and installation.
4. Integration of non-welded piping technologies.
5. System flushing, pressure testing, and commissioning.

The installation covered critical vessel equipment including: High-capacity winches, Offshore cranes, Drilling systems. Iron rough neck equipment, Pipe handling systems, Auxiliary hydraulic machinery.

The project required a dedicated team of experienced hydraulic technicians and engineers working closely with the vessel owner and shipyard throughout the execution phase.

Engineering Challenges

The project presented several unique challenges:

1. Complex Routing in Restricted Areas : A significant portion of the hydraulic piping had to be routed through confined spaces, tanks, machinery rooms, and difficult-to-access vessel compartments while maintaining serviceability and compliance with design requirements.

2. Precision Fabrication: As-built vessel conditions required most piping to be fabricated directly on-site. Hydraulic piping tolerances were extremely tight, with minimal allowance for adjustment once installed.

3. Strict Cleanliness Requirements: The sophisticated drilling and hydraulic systems demanded exceptionally clean hydraulic circuits to ensure reliable operation and long service life.

4. Compressed Project Schedule: The entire engineering, fabrication, installation, flushing, testing, and commissioning scope had to be completed within a limited project timeframe.

Solution Delivered

1. Detailed Engineering : Cenergy Offshore engineers conducted vessel surveys and developed routing solutions based on hydraulic schematics while coordinating closely with Fugro and the shipyard to resolve technical and installation challenges.

2. On-Site Pipe Fabrication : Given the complexity of the installation, piping was fabricated directly at site using:a) Pipe flaring machinesb) Pipe grooving equipmentc) Pyplok® installation toolingd) Hydraulic pipe bending equipmentPipe bends up to 4" were completed on-site, while larger diameter and specialized bends were produced through TMI's manufacturing facilities. Complex routing through tanks and machinery spaces required highly accurate fabrication and fit-up.

3. Non-Welded Piping Technologies : The project incorporated multiple TMI non-welded piping solutions, including:a) 37° Flare Flange Systemsb) Retain Ring Flange Systemsc) Pyplok® Mechanically Attached FittingsThe use of non-welded technology reduced hot work requirements while improving installation efficiency and maintainability.

Flushing and Pressure Testing

Hydraulic flushing was executed through carefully planned looping arrangements to achieve the cleanliness levels required by the hydraulic equipment manufacturers.

Due to the mechanically cleaned and protected piping supplied within the TMI system, flushing operations were completed efficiently, achieving cleanliness levels exceeding project requirements. The final NAS cleanliness values were acknowledged and approved by the client.

All pressure lines were subsequently proof-tested up to 4,000 PSI using established hydraulic pressure testing procedures and safety protocols. The testing program was completed successfully without leakage or system failures.

Commissioning and Results

Following successful flushing and pressure testing, all hydraulic machinery and equipment were commissioned.

The systems were brought online without hydraulic leaks, resulting in a smooth and efficient commissioning process. The successful completion of the Fugro Voyager project led directly to the award of the second vessel, Fugro Scout, to the same project team. Both vessels were delivered successfully and within schedule requirements.

Project Highlights

1. Complete hydraulic and high-pressure piping implementation.
2. First Geo-Technical Research Vessels built in India.
3. Extensive use of non-welded piping technologies.
4. Successful flushing and pressure testing up to 4,000 PSI.
5. Leak-free commissioning.Repeat project award following successful delivery.
6. Positive client and shipyard feedback regarding workmanship, cleanliness, and system reliability.

Conclusion

The Fugro Voyager and Fugro Scout projects demonstrate Cenergy Offshore's capability to deliver complex hydraulic piping systems for specialized marine and offshore applications. Through detailed engineering, precision fabrication, advanced non-welded piping technologies, and rigorous commissioning procedures, the project was completed successfully while meeting the demanding performance and reliability requirements of modern geotechnical research vessels.