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Aarlborg Industries

Aarlborg FPSO: Boiler Module Packaging, Singapore

Under a Co-operation Agreement with Aarlborg, ICON performed structural and mechanical engineering and drafting to package proprietary boiler units into modules suitable for lifting onto FPSO decks during fit-out. The comprehensive workscope included 3D CAD modelling of structural framing and mechanical piping and process services.

The detailing of access walkways and stairways had to provide safe and ergonomically acceptable access to all key valves and mechanical components.

Aalborg boiler modules for Cidade de Sao Mateus FPSO.jpg

Aarlborg boiler modules for Cidade de Sao Mateus FPSO


A total of six boiler modules for Prosafe were fabricated in Singapore and two each installed on the Azurite FDPSO, Ningaloo Vision FPSO and Cidade de Sao Mateus FPSO respectively. The other two boiler modules for Talisman were also fabricated in Singapore and installed on the Orkid FSO in Malaysia.

The boiler module design was simple in appearance but robust and catered to the client requirements for providing access to all major valves, fittings and openings on the boiler.

Mono-rail beams and lifting padeyes were also designed and fitted below different platform levels for handling of heavy mechanical equipment such as the forced draft fans, valves and fittings. ICON also designed the boiler pipework and generated stress analysis reports for the steam line and feed water lines that run from the boiler to the tie-in points on the pipe racks of the various FPSO units. A connecting bridge was designed to provide personnel and material access from the starboard to port side boiler module on the FDPSO and FPSO.

Staad Pro and Tekla software were used extensively for structural design and drafting while Caesar II and AutoPlant software were used for piping design and drafting. The boiler modules were designed in strict compliance with API, AISC and Noble Denton codes and certified by ABS, DNV, Lloyd’s Register and BV marine class.

The key deliverables for the detailed engineering of boiler modules included:

  • A comprehensive Basis of Design
  • Detailed design report including; analysis for in-place, transit, damage, fatigue and lift conditions, pipe stress reports for the boiler pipe work and lux calculations,
  • Detailed engineering and design drawings for the modules including; general arrangements, isometrics, junction box layouts and single line diagrams for the lighting system
  • Fabrication shop detail drawings
Tekla model of Cidade de Sao Mateus FPSO boiler module.jpg
A model of the Cidade de Sao Mateus FPSO boiler module

 Aalborg boiler module installed on Azurite FDPSO.jpg

A boiler module on the Azurite FDPSO
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