Delivering Precision and Reliability — Auxiliary Console Panel Solution for Samsung’s FPSO Project

Introduction — Supporting the Energy Industry at Sea

In the global drive for sustainable and efficient energy production, Floating Production Storage and Offloading (FPSO) vessels play a crucial role in offshore natural gas and oil extraction. These massive offshore facilities extract raw natural gas from deep-sea wells and process it onboard into usable forms for industrial and civilian applications.

Recently, Weimiao had the honor to participate in a major Samsung FPSO project, providing a tailor-made Auxiliary Console Panel solution for the vessel’s main control room. This FPSO operates 24 hours a day, 7 days a week, demanding uncompromising precision, ergonomic comfort, and continuous power stability to ensure safe and efficient production.

The offshore environment presents some of the harshest operational conditions in engineering — from constant vibration and humidity to the need for uninterrupted operation. For this reason, Weimiao’s engineering team designed every element of the console system—from the mechanical structure to electrical integration—with marine-grade durability and ergonomic excellence in mind.

Project Overview — FPSO Control Room Auxiliary Console Panel

Weimiao’s Scope of Work and System Design

For this project, Weimiao was responsible for the design, manufacturing, and electrical integration of a series of Auxiliary Console Panels and Ergonomic Control Desks dedicated to the FPSO’s main control and monitoring area.

The control room serves as the nerve center of the vessel, where operators continuously monitor and manage the entire gas extraction and production process. Recognizing the critical importance of this workspace, Weimiao’s design team developed a customized control console solution that meets stringent marine safety standards while enhancing operator comfort and long-term reliability.

Each auxiliary console includes:

• High-precision cable routing channels for organized cable flow.

• Integrated power modules for quick access and easy maintenance.

• Durable marine-grade materials to resist vibration and corrosion.

Because FPSO vessels experience continuous movement, all consoles were mechanically fastened with reinforced anchor bolts directly to the vessel’s deck structure. This ensured stability, safety, and long-term reliability even in rough sea conditions.

Integration of Advanced Electrical Components

To fulfill Samsung’s demanding operational requirements, Weimiao integrated several high-performance electrical systems and components to ensure reliability and redundancy.

Key Electrical Systems Integrated

• Schneider Electric Automatic Transfer Switch (ATS) Systems — Ensures smooth and automatic power transfer between multiple onboard generators.

• Zonit Z-ATS Power Transfer Units — Provides redundant power paths to critical control systems, preventing any operational downtime.

• Phoenix Contact Terminals and Connectors — Guarantees vibration-resistant and secure connections for long-term stability.

• Low-Smoke Zero-Halogen (LSZH) Cables — Enhances safety by minimizing toxic gas emissions during fire and maintaining low flame spread.

These systems collectively allow the FPSO’s control room to operate under a multi-generator redundant configuration, ensuring a continuous and stable power supply even during maintenance, power transitions, or generator failures.

Safety, Durability, and Cable Management

Marine engineering projects require a focus on robust design and long-term safety. The FPSO control room contains an extensive cable network connecting sensors, monitoring systems, and automation controls throughout the vessel.

To address this, Weimiao’s auxiliary console design integrates a comprehensive internal cable management system, keeping all electrical and communication cables securely organized. Internal raceways and labeling systems simplify troubleshooting and ensure maintenance efficiency.

Marine-Grade Compliance and Safety Features

• All structural and electrical components comply with IEC 60092 marine electrical standards and DNV-GL safety guidelines.

• Every console uses powder-coated steel, anti-corrosive hardware, and vibration-resistant brackets for maximum durability.

• Cable routing systems were designed to withstand ship vibration and dynamic stress, maintaining system integrity under all conditions.

Through these measures, Weimiao ensured that the FPSO control room system achieved the highest level of safety, efficiency, and maintainability, even under demanding offshore environments.

Human-Centered Ergonomic Design

In the demanding environment of an FPSO control room, operators must stay alert and focused throughout long shifts — often in 24-hour operations with rotating crews. Recognizing this challenge, Weimiao placed strong emphasis on ergonomic comfort and human-centered design principles when developing the control desks and auxiliary consoles for Samsung’s offshore project.

Sit-Stand Adjustable Workstations

Each control desk was equipped with a sit-stand adjustable tabletop system, allowing operators to seamlessly switch between seated and standing positions. This design supports continuous monitoring activities while reducing physical strain during extended hours of operation.

The height-adjustable console surfaces are controlled through an ergonomic electric lifting mechanism, offering smooth, quiet, and stable movement even when loaded with equipment and monitors. This ensures that operators can customize their workstation height for optimal visibility and reach — essential for precise control of critical systems.

Reducing Fatigue and Enhancing Focus

In high-stakes environments such as an FPSO control room, operator fatigue can lead to costly or dangerous errors. By providing ergonomic features such as adjustable desks, angled monitor mounts, and well-planned cable routing, Weimiao’s design helps maintain operator comfort, posture, and concentration levels throughout continuous shifts.

Ergonomically optimized furniture also promotes better air circulation, posture variation, and reduced musculoskeletal strain, all of which contribute to a more efficient and healthier working environment for crew members who are essential to the vessel’s safe operation.

Engineering for Stability and Safety

Designing control consoles for a marine environment requires more than precision — it requires resilience. Every movement of the vessel, from mild vibrations to heavy ocean swells, places stress on equipment and furniture. Weimiao’s engineering team accounted for these challenges through a combination of structural reinforcement, safety anchoring, and vibration resistance.

Structural Reinforcement and Anti-Vibration Design

All auxiliary consoles and control desks were designed using marine-grade steel framing and reinforced joints, providing long-term mechanical strength. Each unit was securely bolted to the vessel’s deck structure using industrial-grade anchors to prevent displacement or movement caused by ship vibration or rolling.

Anti-Vibration and Safety Features

• Anti-vibration brackets and fasteners were used to absorb dynamic forces from ship motion.

• Sealed wiring pathways and protected raceways prevent saltwater corrosion and electrical interference.

• Rounded edges and impact-resistant surfaces add a layer of safety in confined control room spaces.

These structural adaptations not only enhance equipment stability but also improve crew safety and operational reliability, even under turbulent offshore conditions.

Compliance with International Marine Standards

To ensure global compliance, Weimiao’s engineering and fabrication process followed several marine-grade and offshore safety standards, including:

• IEC 60092 – Electrical Installations in Ships

• DNV-GL Offshore Standards for Control and Safety Systems

• ABS Marine and Offshore Guidelines

Adhering to these standards guarantees that each product meets stringent quality, fire safety, and vibration resistance requirements demanded by the international marine and oil & gas industries.

Electrical System Integration

Electrical stability is the foundation of any FPSO control system. The Samsung FPSO operates with multiple onboard generator sources, providing continuous energy to critical systems, including the control room. To support this, Weimiao designed and integrated a fully redundant power management system within each auxiliary console panel.

Uninterrupted Power Supply (UPS Concept)

The control panels were designed to maintain uninterrupted operation even in the event of power fluctuation or generator switchover. This was achieved by adopting a UPS-like configuration using dual power sources routed through automatic transfer devices.

This ensures that control systems, monitoring screens, and communication equipment remain powered at all times — a crucial requirement for offshore production where downtime or electrical failure could disrupt critical gas processing operations.

Dual ATS Redundancy Design

Each console integrates dual Automatic Transfer Switch (ATS) systems, combining Schneider industrial ATS and Zonit Z-ATS units. This redundancy provides:

• Seamless switching between generator sources.

• No-break transition for mission-critical circuits.

• Load balancing and fault tolerance, even during maintenance.

With this architecture, operators can depend on constant electrical reliability and fail-safe performance, ensuring the FPSO continues its mission without interruption.

Fire Safety and Cabling Integrity

To enhance safety within enclosed marine control rooms, Weimiao utilized LSZH (Low Smoke Zero Halogen) cables throughout the installation.

Benefits of LSZH Cabling

• Minimal smoke emission during fire incidents.

• No release of toxic halogen gases, ensuring better crew safety.

• Superior flame resistance and long service life in high-humidity conditions.

Combined with structured cable trays and heat-resistant terminations, this approach ensures that the FPSO’s electrical systems remain safe, organized, and compliant with marine fire regulations.

Factory Acceptance Test (FAT) with Samsung Engineers

Before delivery, every project undertaken by Weimiao undergoes a comprehensive Factory Acceptance Test (FAT) to ensure full functionality, compliance, and customer satisfaction. For the Samsung FPSO auxiliary console panel project, this process was carried out with exceptional rigor and transparency.

On-Site Inspection at Weimiao’s Dongguan Factory

Samsung’s engineering and quality assurance team visited Weimiao’s Dongguan manufacturing facility to conduct a complete on-site inspection and validation. This collaboration demonstrated Weimiao’s open, professional, and quality-focused approach to international partnerships.

During their visit, the Samsung representatives performed detailed visual and technical evaluations on both the auxiliary console panels and ergonomic control desks, confirming that each system met marine-grade standards and the project’s design specifications.

FAT Procedures and Testing Scope

The Factory Acceptance Test involved multiple layers of verification to ensure system performance and long-term reliability under real-world conditions. The procedures included:

1. Functional Testing

• Verification of power input and output performance under simulated marine voltage conditions.

• Testing of switching logic, power redundancy, and ATS (Automatic Transfer Switch) operation to confirm seamless source transition.

2. Wiring Verification

• Comprehensive continuity checks, insulation resistance tests, and label verification to ensure all terminations matched the wiring schematic.

• Confirmation of proper grounding and shielding for marine electromagnetic compatibility (EMC).

3. Mechanical Fit and Assembly Check

• Validation of cabinet alignment, mounting tolerances, and panel interfaces to ensure precise mechanical integration on the FPSO deck.

• Inspection of anti-vibration supports and anchoring points for safety during offshore operations.

4. Safety and Compliance Validation

• Assessment against IEC 60092 and DNV-GL standards for marine electrical systems.

• Testing of emergency power recovery and system shutdown sequences.

After completing all FAT stages, Samsung’s engineers officially approved the system without any non-conformities. The auxiliary consoles and control desks were then carefully packaged, documented, and dispatched to the FPSO shipyard for final installation.

Project Outcome and Value Delivered

The successful completion of this project marks another milestone in Weimiao’s ongoing commitment to delivering high-quality, precision-engineered control solutions for the global energy industry.

Ensuring Operational Reliability and Crew Comfort

Through the combination of ergonomic design, robust marine engineering, and electrical integration excellence, Weimiao’s auxiliary console system provided the FPSO control room with:

• Uninterrupted operational performance, even under harsh offshore conditions.

• Improved operator comfort through sit-stand functionality and human-centered ergonomics.

• Enhanced safety with LSZH cabling, vibration-resistant structures, and redundant power control.

By prioritizing these elements, Weimiao ensured that the FPSO’s crew can monitor complex production processes around the clock with maximum safety, efficiency, and reliability.

Demonstrating Expertise in Offshore Industrial Projects

This collaboration with Samsung highlights Weimiao’s strong capability in handling offshore and marine-grade control system projects. From conceptual design to electrical integration and FAT certification, every phase was executed with precision and technical expertise.

The project also reaffirms Weimiao’s position as a trusted global supplier in sectors such as:

• Offshore oil & gas platforms

• Marine vessel automation systems

• Industrial control and monitoring infrastructure

With this FPSO project, Weimiao once again demonstrated its ability to meet international standards, deliver customized engineering solutions, and provide timely support to global clients.

Closing — Commitment to Excellence in Control Systems

Dedication to Innovation and Quality Assurance

At Weimiao, our success is built on a foundation of innovation, quality assurance, and continuous improvement. All projects are managed under the ISO 9001:2015 Quality Management System, ensuring strict process control from material sourcing to final delivery.

Our in-house design and engineering teams are constantly improving panel integration methods, ergonomic solutions, and marine safety compliance to meet evolving industrial requirements.

Global Customer Support and Partnership

With a manufacturing base in Dongguan, China, and offices in Hong Kong and Singapore, Weimiao provides responsive support and technical consultation to clients worldwide. Our mission is to deliver customized control panel systems, auxiliary console panels, and FF&E (Furniture, Fixtures & Equipment) solutions that empower industries to operate safely and efficiently.

Call to Action

Whether for offshore platforms, industrial control centers, or energy production facilities, Weimiao is your trusted partner for precision-engineered control solutions.

📞 Contact Weimiao today to discuss your next project and discover how our engineering expertise can enhance your operational performance.