Robots will be integrated into the Asset Integrity Management System, which will consolidate the work results of various robots operating inside the tank.
The aim is to minimize human intervention in the cleaning, inspection, and painting stages, reducing the risks of exposure to contaminated environments.

ouronova, a Brazilian deep tech company operating in the energy sector, has partnered with Equinor, an international energy company with over two decades of presence in Brazil, to develop robotic systems for Integrity, Maintenance, and Repair (IM&R) tasks in FPSO (Floating Production, Storage and Offloading) tanks. These mandatory and periodic tasks, as required by regulations, expose workers to high risks due to unhealthy (confined and height-related) and hazardous (explosive atmosphere) environments. The open innovation model project will be funded through the R&D&I clause of concession contracts regulated by the Brazilian National Agency of Petroleum, Natural Gas and Biofuels (ANP).

The project’s main goal is to improve the efficiency and quality of cleaning, inspection, and painting operations by reducing the need for personnel entry into FPSO tanks (high-risk areas). The robots, equipped with advanced and precise technologies, will enhance human safety and asset integrity.
“Brazil has one of the world’s largest fleets of operational FPSOs, and there is growing demand for these stationary production units (SPUs), which are crucial for enabling oil and gas exploration in deep waters. The complexity and scale of these operations, along with the need to ensure proper offshore system integrity, make regular tank maintenance an essential task to guarantee operational continuity and safety,” says Eduardo Costa, CEO of ouronova.

According to ABS guidelines – Enhancing Safety on FPSOs: Practical Considerations for Operations and Maintenance – FPSO cargo tanks must be cleaned every five years to allow for integrity inspections and potential repairs.
The partnership between ouronova and Equinor, a global leader in offshore oil and gas exploration and production, aims to enable the development of technological tools to make the inspection and maintenance of ballast and cargo tanks (which store the extracted oil until transport or export) safer and more efficient, enhancing operational safety and extending the service life of these units.

Traditional cleaning methods, both manual and mechanized, require operators to enter the tank, exposing them to elevated risks. The implementation of robotic systems will benefit operations by reducing the need for a human presence inside the tanks – a confined and potentially dangerous space due to its unhealthy conditions – thus minimizing accident risks and lowering POB (People On Board) during task execution.

THE TANKBOTICS PROJECT

The project initially involves developing robotic systems with embedded inspection devices that will enable surface integrity checks before painting and/or after cleaning.

A modular robotic platform will be designed to clean residues accumulated at the bottom of the tank, including the removal of crude oil, debris, and potentially naturally occurring radioactive materials (NORM), in an optimized, efficient, and safe manner – reducing or potentially eliminating the need for human presence inside the tank.

“After the cleaning phase, the same system will inspect the tank bottom using industry-standard sensing technology to identify possible damage, corrosion, or other irregularities that could compromise the tank’s integrity,” explains the executive. The modular robotic platform allows for tool changes according to the activity to be performed and the functionalities required for that task.

Another robotic system, equipped with advanced sensors to detect signs of wear, corrosion, and other structural damage that may affect asset integrity, will be developed to inspect the tank’s columns and inner walls. In addition to inspection, this system will paint the internal surfaces by treating the surface and applying protective coatings that prevent corrosion and extend the structure’s lifespan, ensuring uniform coverage following current regulations and best practices.

DIGITAL TWIN

These robotic systems, which will be integrated into the Asset Integrity Management System, will enhance the accuracy of inspections and enable more reliable diagnostics and more effective interventions.

“The inspection results will be integrated into a Digital Twin of the tank, which is also part of the project, allowing asset integrity teams to monitor the evolution of critical points in real-time. The Digital Twin will also be integrated with the robots’ HMI (Human-Machine Interface), supporting navigation and georeferencing of collected data and performed activities. It may also be used in simulations for concept validation in the early phases of the project and for planning and training related to future service execution,” the executive adds.

The R&D&I project between ouronova and Equinor paves the way for similar technologies to be applied in other areas of FPSOs and various assets across the industry, further expanding the positive impact of these solutions on offshore operations. The system could also be adapted for cleaning, inspection, and painting of hulls and other topside structures.

“This represents a significant leap in automating and modernizing FPSO operations, aligning with the oil and gas industry’s need to operate more safely, efficiently, and sustainably. It also enables the development of a national solution to address this complex challenge,” concludes Eduardo Costa, CEO of ouronova.

About ouronova
ouronova is a deep-tech company rooted in research, development, and innovation. It contributes intellectual and operational resources to build new businesses through partnerships that combine capabilities, aiming to provide innovative solutions for the oil and gas industry while increasingly supporting energy diversification. Learn more at www.ouronova.com

About Equinor
Equinor is an international energy company committed to creating long-term value in a low-carbon future. In Brazil – a strategic international area for the company – its growing portfolio includes oil and gas (O&G) and renewable energy assets. In O&G, the company has development projects such as Raia and Bacalhau, and producing assets like Peregrino and Roncador. In renewables, Equinor operates the Apodi and Mendubim solar plants and, in 2023, acquired Rio Energy, a leading onshore renewable energy company in Brazil