| Written by Mark Buzinkay
Safety protocols on FPSOs
Safety on Floating Production Storage and Offloading (FPSO) units is critical due to the complex operations, hazardous materials, and remote offshore locations involved. A robust set of safety protocols and procedures is implemented on board to protect personnel, the asset, and the environment. (1)
Access control and muster management are essential first steps. Controlled access zones ensure that only authorised personnel can enter hazardous areas such as the engine room or production deck. Digital e-mustering systems and Personnel-on-Board (POB) tracking allow real-time personnel monitoring, particularly vital during emergencies. New arrivals and visitors must undergo safety inductions and are provided with identification badges to regulate movement.
Fire and explosion prevention is another key focus. Continuous gas detection systems are installed to monitor for hydrocarbon leaks like methane or hydrogen sulfide. Fire detection and suppression systems, including CO₂, foam, deluge systems, and portable extinguishers, are strategically located throughout the FPSO. Hot work, such as welding or grinding, is strictly controlled through a formal permit system to minimise ignition risks.
All high-risk activities on board must be authorised through a Permit to Work (PTW) system. This process ensures that tasks like confined space entry or work at height are subject to thorough planning and safety checks. Each task begins with a Job Safety Analysis (JSA), which identifies hazards and outlines mitigation strategies.
Offshore emergency response procedures are in place to ensure quick, coordinated action during incidents. Regular drills—including fire, abandon ship, and man-overboard exercises—keep the crew prepared. The FPSO is equipped with lifeboats and life rafts that are routinely inspected. Emergency Shutdown (ESD) systems, both manual and automatic, are integrated into operations to isolate hazards and prevent escalation.
Due to the presence of explosive gases, hazardous area classification is critical. All equipment in such zones must meet ATEX or IECEx standards, ensuring they do not act as ignition sources. Adequate ventilation and gas dispersion systems prevent gas build-up, particularly in engine rooms and production areas. Heating, ventilation, and air conditioning (HVAC) systems are also configured to maintain safe atmospheres.
Personal protective equipment (PPE) is mandatory in designated areas. Crew members must wear flame-retardant clothing, helmets, safety boots, gloves, and lifejackets. Additional PPE is used for specialised tasks such as chemical handling or confined space operations.
The FPSO’s Health, Safety, and Environment (HSE) management system is typically based on ISO 45001 or OHSAS 18001 standards. It includes procedures for incident reporting, behaviour-based safety (BBS) programs, and continuous improvement initiatives that promote a proactive safety culture.
Marine operations and offloading procedures are tightly controlled. The mooring system, including the turret and anchor points, is continuously monitored. During crude oil offloading to shuttle tankers, dynamic positioning systems, emergency disconnects, and spill response tools are used to minimise risks. Real-time weather monitoring also ensures that operations can be safely halted during adverse conditions.
All personnel undergo continuous training to maintain safety competencies. This includes firefighting, first aid, helicopter safety, H2S awareness, and sea survival training, often certified through programs like BOSIET. Simulations and drills reinforce this knowledge and verify crew readiness.
Maintenance and integrity management systems are in place to ensure the safe operation of critical equipment. Preventive maintenance programs regularly check pumps, valves, and sensors, while non-destructive testing (NDT) is used to inspect pressure vessels and structural components. Corrosion protection measures, such as cathodic protection and coating inspections, are essential in the harsh marine environment.
Environmental protection protocols are also strictly enforced. Oil Spill Contingency Plans (OSCPs) are maintained, including the use of containment booms, skimmers, and dispersants. Produced water is treated before discharge to meet regulatory limits, and waste management systems responsibly handle hazardous and non-hazardous materials.
These comprehensive safety protocols form a multilayered defence system that reduces risks and ensures the smooth operation of FPSOs in one of the most challenging industrial environments.
POB Management
POB management, or Personnel-on-Board management, refers to continuously tracking and administering every individual present on an offshore asset, such as an FPSO (Floating Production Storage and Offloading unit). This system ensures that operators know exactly who is on board at any given time, where they are, and whether they are safe, especially in emergency situations.
The necessity of accurate POB management on FPSOs stems from the high-risk environment in which they operate. FPSOs are remote, self-contained industrial facilities at sea, often located far from shore and hosting dozens or even hundreds of personnel. These individuals may include crew members, contractors, engineers, and visitors who board via helicopter or vessel transfers. Knowing exactly how many people are on board—and who they are—is critical for operational planning and, more importantly, emergency preparedness and response (read more about emergency response solutions). In the event of an incident such as a fire, explosion, gas leak, or abandon-ship scenario, the ability to rapidly account for all personnel can mean the difference between life and death.
Regulatory authorities and class societies mandate that offshore installations like an offshore rig or FPSO must be able to produce a current and accurate POB list at all times. This requirement is rooted in safety legislation and emergency response obligations. In an emergency, rescue services or command centres onshore must be able to verify exactly who is on board, confirm their muster status, and coordinate search-and-rescue operations accordingly. A delay or error in POB information can severely compromise emergency efforts, potentially putting lives at greater risk.
POB systems must be designed for 24/7 accuracy, resilience, and automation to meet these critical requirements. Integrating multiple technologies and workflows is at the core of an effective system. First, every person boarding the FPSO should be registered and issued a unique identification—often via RFID badges, biometric verification, or smart cards. These IDs are logged at each access control point, whether at the heli-deck, gangway, or secured zones within the vessel. Real-time data capture is essential, with all entries and exits recorded automatically to a centralised database.
Additionally, modern systems often include electronic mustering features, which allow crews to swipe in at muster points during drills or real incidents, instantly updating the central POB system. Integration with crew transfer systems, vessel traffic monitoring, and work permits further enhances situational awareness. The system should be able to distinguish between active crew, visitors, those off-duty, and those currently off the vessel. Importantly, the data must be stored redundantly both on board and transmitted to onshore command centres in real time or at frequent intervals.
Human factors are also a key consideration. The interface must be intuitive for crew members and emergency teams, enabling fast access to names, roles, cabin numbers, muster stations, and any relevant medical or evacuation needs. Backup procedures, such as printed lists and manual check-in protocols, must be available in case of system failures, but reliance on paper-based methods should be minimised.
Ultimately, robust POB management is not just a compliance measure—it is a critical element of operational safety. It ensures accountability, enhances emergency responsiveness, supports logistical planning, and builds confidence among crew members that their presence and safety are always accounted for, day and night.
Why is e-POB state-of-the-art on FPSOs?
An electronic Personnel-on-Board (POB) system that works automatically and hands-free is an advanced solution designed to continuously and accurately track every individual aboard an offshore asset like an FPSO. A prime example of such a system is Crew Companion by Identec Solutions, which integrates location tracking, real-time monitoring, and emergency management into a single platform.
Crew Companion operates using RFID-based tags assigned to personnel. Once registered, each individual is associated with a unique tag that automatically transmits their location to the system without requiring manual check-ins. These tags are detected by fixed sensors installed in various zones throughout the FPSO, such as accommodation areas, muster points, engine rooms, and production decks. The system continuously updates each person’s position and displays this in real time within the application interface, including on a visual map of the vessel. The information is automatically refreshed and requires no manual user input to remain current.
One of the most significant advantages of such a hands-free POB system is its ability to deliver a 24/7 accurate count of all personnel on board, including their specific locations. This is especially crucial during emergencies, where time-sensitive information can determine the success of evacuation and rescue efforts. The system automatically identifies which individuals are present in hazardous zones, who have mustered at safe points, and who are still unaccounted for. In emergency mode, Crew Companion switches to a specialised interface that highlights real-time muster progress, missing personnel, and zone-specific threats. Emergency response teams can use this data to coordinate efforts with maximum efficiency.
Furthermore, Crew Companion eliminates the reliance on manual lists or voice roll calls, which are time-consuming and error-prone, especially in high-stress situations. It allows for instant generation of POB reports, filtered by categories such as mustered, missing, evacuated, or located in hazardous areas. These reports can be exported to PDF, Excel, or Word formats for documentation or transfer to command centres.
The system also supports advanced features like lone worker tracking, where individuals working in isolated zones are automatically flagged and monitored. If they fail to return within a predefined timeframe, the system triggers alerts. All of this is managed via a centralised software interface accessible both on board and remotely, with automated backups and failover modes to ensure continuous operation, even during technical disruptions.
In short, a hands-free, automated electronic POB system like Crew Companion brings significant operational and safety benefits to FPSO operators. It provides constant, accurate visibility over personnel movements, streamlines emergency responses, supports compliance with international safety regulations, and fosters a safer work environment without creating additional administrative burdens for the crew.
Registering users and tags with Crew Companion
Crew Companion registers users and assigns RFID tags through a structured and secure process using its Tag Registration Kit, which includes a dedicated software interface and a tag programming device. Here’s how the system handles user and tag pairing:
First, personnel are entered into the system via the registration screen in the Crew Companion application. This involves filling in personal details such as name, company, position, next-of-kin contacts, and any certification data. Required fields must be completed before the record can be saved.
Once the personnel data is entered, the user is assigned to a specific zone (e.g. accommodation or working area), and optionally, a firm or group for easier filtering and access control management.
The RFID tag itself is then paired using a tag programmer—a device that reads and writes tag information. The operator places a blank or reusable RFID tag on the tag programmer, which is connected to the Crew Companion system. When the “Save” or “Save and New” button is clicked, the tag is encoded and officially linked to the registered person in the database. This process takes only a few seconds and is confirmed within the software interface.
If a tag needs to be replaced or reissued (for example, due to loss or battery expiry), the system allows the existing personnel record to be quickly retrieved and reassigned with a new tag. A list of “Personnel without tags” helps streamline this process.
The system ensures that each individual’s RFID tag is uniquely identifiable, allowing real-time tracking, emergency mustering, and movement history to be accurately tied back to a known person at all times.
FAQ: Electronic Personnel-on-Board (e-POB) Systems
What is an e-POB system, and how does it work?
An electronic Personnel-on-Board (e-POB) system uses RFID or similar technologies to automatically track the presence and location of individuals on offshore installations like FPSOs. Each person carries a tagged device, and fixed readers installed throughout the asset detect their movements in real time. This allows for a constantly updated, accurate overview of who is on board, where they are, and whether they are safe, without manual check-ins.
Why are e-POB systems important on FPSOs?
E-POB systems are vital for safety, compliance, and operational efficiency. They provide instant personnel visibility during emergencies, reduce human error in mustering, and ensure regulatory requirements are met. By knowing exactly who is on board and their location, operators can quickly coordinate evacuation or rescue efforts and avoid delays that could put lives at risk.
Can e-POB systems function during power or network failures?
Yes, robust e-POB systems like Crew Companion are designed with built-in redundancies. They feature local data storage, battery backups, and failover modes to maintain tracking even if central systems go offline. Data can be automatically synced with onshore control once connectivity is restored, ensuring continuous and reliable personnel monitoring.
Takeaway
Effective safety management on FPSOs requires more than protocols—it demands real-time awareness of personnel and risks. As offshore environments grow more complex, electronic POB systems have become essential to ensure accountability, rapid emergency response, and regulatory compliance. Crew Companion stands out by offering a fully automated, hands-free solution that delivers accurate, round-the-clock tracking. Its intuitive interface, RFID-based technology, and emergency mode capabilities allow operators to manage personnel safely and efficiently, even under extreme conditions. This makes Crew Companion a critical asset for modern FPSO operations focused on safety, reliability, and operational readiness.
Delve into one of our core topics: Emergency Response Management
Glossary
An RFID badge is a wearable identification device embedded with a Radio Frequency Identification (RFID) chip and antenna, enabling automatic, wireless communication with readers. When worn by personnel, the badge transmits a unique identifier that allows real-time tracking of location and access status. In high-risk environments like FPSOs, RFID badges are essential for monitoring personnel movement, improving emergency response, and ensuring regulatory compliance. (2)
References:
(1) International Association of Oil & Gas Producers (OGP) https://cabmakassar.org/wp-content/uploads/2020/05/Guidline-for-FPSO.pdf
(2) Finkenzeller, K. (2010). RFID Handbook: Fundamentals and Applications in Contactless Smart Cards, Radio Frequency Identification and Near-Field Communication (3rd ed.). Wiley.
