Visual Flame Detection Technology for FPSO False Alarm Prevention
False alarms are a costly and disruptive challenge for offshore oil and gas operations, particularly on Floating Production Storage and Offloading units (FPSOs). Traditional infrared flame detection systems often trigger unnecessary shutdowns when exposed to heat reflections, vibrating machinery, or changing environmental conditions. As a result, many operators are now turning to visual flame detection technology supported by advanced 3D modelling to ensure accurate, reliable flame detection and improved operational continuity.
One of the most recent examples is the Haewene Brim FPSO, which adopted a combination of 3D flame-detection modelling and intelligent visual flame detectors to significantly reduce false alarms and prevent production stoppages.
The Limitations of Traditional Triple-IR Flame Detection
Many offshore facilities rely on triple-IR (IR3) detectors, which compare three infrared wavelength bands to identify flame signatures. While effective in controlled environments, they become less reliable when exposed to radiative transfer—reflected electromagnetic energy caused by:
- Sunlight bouncing off the sea surface
- Heat shimmering from gas turbines
- Vibration from diesel generators
- Hot exhaust pipes near processing equipment
In these conditions, IR3 detectors can become desensitised or, worse, trigger unwanted alarms. For FPSOs—which often have large flare stacks and wide reflective surfaces—these false alarms can lead to costly shutdowns and safety-critical interruptions.
Why Visual Flame Detection Technology Is Transforming Offshore Safety
Visual flame detectors work differently. Instead of relying solely on infrared analysis, they use live video images and advanced flame-recognition algorithms to visually confirm the presence of fire. This makes them immune to radiative transfer effects and significantly more reliable on offshore units.
Key advantages of visual flame detection technology
- Immune to reflections and heat distortions
- High accuracy in complex offshore environments
- Reduced false alarms, leading to fewer stoppages
- Ability to operate effectively near flare stacks
- Supports advanced fire mapping and analysis
This technology is becoming increasingly popular in the offshore sector, especially for FPSOs operating in reflective and high-heat regions.
Aoka Mizu FPSO: The First Phase of the Upgrade
Bluewater Energy Services, a global designer and operator of FPSOs, initially approached Micropack to address a persistent false alarm problem on the Aoka Mizu FPSO. Despite using triple-IR detection configurations, the vessel continued to experience nuisance alarms triggered by radiative effects.
3D Modelling and Fire Mapping with Haz Map 3D
Micropack used its Haz Map 3D modelling software to design a precise flame-detection layout around the Aoka Mizu’s processing areas. The modelling included:
- Flame-detector positioning
- Voting configuration assessments
- Coverage evaluation around complex equipment
- Sensitivity analysis for each detector type
Voting configurations determine how alarms are escalated—for example, one detector may trigger a manual investigation, while two detectors may activate an automatic response such as agent release or process shutdown.
The modelling revealed the optimal mix of detector numbers, types, and placement to maximise coverage while reducing cost.
A Successful Transformation
Twenty-six IR3 detectors on the Aoka Mizu were replaced with Micropack’s FDS301 intelligent visual flame detectors, dramatically reducing false alarms. The success of this project led Bluewater to implement a similar upgrade on the Haewene Brim FPSO.
Haewene Brim FPSO: Eliminating False Alarms and Preventing Shutdowns
Following repeated false alarm incidents on the Haewene Brim’s IR3 detectors—each leading to costly interruptions during its operation in the Pierce Field—Bluewater again partnered with Micropack.
Using the same modelling and analysis approach, Micropack recommended replacing sections of the vessel’s existing IR3 network with FDS301 detectors. Installation was completed in just 10 days, resulting in noticeably improved performance and far fewer process interruptions.
Inside the Micropack FDS301 Visual Flame Detector
The FDS301, now widely recognised as one of the most advanced visual flame detectors available, represents over twenty years of algorithm development.
Core Features of the FDS301
- Dual-camera system:
- One camera provides a live colour video feed
- The second uses near-infrared technology to visually identify flames
- 22-year refined flame-recognition algorithm capable of operating in extreme environments
- Black box–style recording: The unit stores footage from 8.5 seconds before and after each alarm event
- High false-alarm immunity, even in complex heat-reflection environments
- Ideal for FPSOs, where flare stacks frequently interfere with IR-based detection systems
This combination of real-time video and sophisticated software makes the FDS301 ideal for offshore installations requiring high reliability and precise flame discrimination.
Expanding Adoption Across the Offshore Sector
Building on its success in the North Sea, Micropack has recently secured another major contract involving the installation of more than 200 visual flame detectors for a large offshore project in the Gulf of Mexico. As operators continue searching for ways to eliminate false alarms, visual flame detection technology is becoming a preferred choice for complex marine and offshore environments.
