The multi-criteria evaluation in the decision support tool plays a critical role by systematically comparing the three modularisation concepts (large, medium, and small modules) against key criteria. It is structured around the concepts' insensitivity to seven frequent project changes, analyzing both the FPSO design and integration process impacts. This structured approach ensures that all conceptual alternatives are judiciously evaluated for their practical viability and adaptability, enabling optimal modularisation decisions .

The characteristics of the integration yard influence the FPSO project integration process by determining the feasibility and efficiency of installation methods used. Common challenges include dealing with inadequate yard facilities, which may not support advanced installation techniques or accommodate large module sizes. This insufficiency can lead to project delays and additional costs due to required modifications in the installation process or selection of alternative yards, thus impacting the overall integration efficiency and timeline .

Modularisation of FPSO topsides influences the project's overall success by offering adaptability and resilience to late-stage design changes, which are common in such complex projects. By using modular components, the project can adjust individual modules without large-scale redesigns, thus minimizing delays, cost overruns, and integration risks. Effective modularisation enhances the project’s ability to cope with changes in design, process, and environmental conditions, ensuring smoother project execution and completion .

Changes in environmental and installation loads can significantly affect the FPSO project’s integration process by imposing additional stresses or requirements on the hull and topside structures. These alterations might necessitate redesigns or reinforcements of module foundations and the topside deck to withstand changed load conditions. Such adaptations can cause delays and increase costs due to additional engineering work and potential modification of integration or transportation sequences .

The decision support tool enhances designers' understanding of modularisation concepts by depicting the advantages, disadvantages, and bottlenecks of each concept. Through its multi-criteria evaluation, the tool demonstrates the behavior of different modularisation concepts under common change scenarios. This comprehensive evaluation helps designers comprehend the practical implications of each modularisation approach, thereby facilitating informed decision-making and optimization of the topside integration process .

The primary categories of changes in FPSO projects during the integration phase include changes in the FPSO design, the integration process, and the surrounding environment. Design changes involve alterations in weight, sizes, or fitting of the topside elements and modules. Integration process changes are related to modifications in the installation method and inadequacy of the integration yard's characteristics. Surrounding changes are imposed externally, such as delivery specification adjustments and variations in environmental and installation loads due to hull motions. These changes can cause severe delays and added costs by affecting various FPSO elements like the module foundation, topside deck, installation equipment, and project schedules .

The research recommended that ABB Lummus Global focus on adopting smaller module sizes to enhance the sensitivity of the integration process to project changes. This recommendation is crucial as it addresses the significant delays and added costs associated with frequent design and process changes typical in FPSO projects. By optimizing for smaller, more manageable modules, the project can adapt more efficiently to unforeseen changes while still delivering on time and within budget .

Topside partitioning is considered the primary opportunity for flexibility in FPSO designs because the hull design is usually fixed, and the topside processes determine equipment placement. Hence, partitioning, or modularisation, is the main area where designers can adjust for flexibility to accommodate frequent changes. However, potential constraints include challenges related to space efficiency and management of increased inter-module interfaces, which can complicate integration and operational logistics .

The decision support tool aids FPSO topside modularisation by comparing different modularisation concepts and assessing their advantages, disadvantages, and bottlenecks. It evaluates three primary alternatives: one large module, ten medium-sized modules, and multiple individually moduled topside equipment. The tool uses the insensitivity to frequently encountered project changes as the primary criterion for evaluation. These changes are analyzed within a matrix focusing on their impact on FPSO design and integration processes, thus helping designers optimize the integration process .

A modularisation concept with smaller modules is less sensitive to project changes as these modules have reduced sizes and mass. This can mitigate the impact of changes because smaller and lighter modules are easier to handle and adjust during the integration process. Despite some inefficiencies, such as less effective use of deck space and increased interfaces, the smaller modules permit more flexibility and adaptability to unforeseen changes, which is beneficial for managing the seven major project changes .