Shell’s Bonga Main FPSO is largest asset in the world to be protected by a structural digital twin

Akselos has successfully deployed a structural digital twin for Shell’s Bonga Main floating production, storage and offloading (FPSO) vessel located in the Niger Delta, Nigeria. The FPSO, which became operational in 2004, has a capacity of 225,000 b/d and weighs over 300,000 tonnes, is reported to be the largest asset in the world to be protected by a structural digital twin to date.

The digital twin is a physics-based model of the asset, which represents its entire physical counterpart in absolute detail and accuracy. The model is updated with loading conditions and inspection data on a regular basis, providing the ability to carry out structural assessments based on the ‘as is’ condition, from anywhere and at any time. 

Based on Akselos’ patented RB-FEA technology, the digital twin is able to realise a number of operational objectives, including the identification of critical areas for prioritised inspection, maintenance and repair; a reduction in personnel on board the asset; reduced necessity for physical inspections in hard-to-reach areas such as cargo tanks; and to support scenario planning for extreme weather events and asset modification. Deployment of the simulation technology will also enable safe asset life extension by replacing the over-conservative estimates made with conventional simulation software with accurate assessments that reflect actual remaining fatigue life, reports Akselos.

Bonga Main FPSO
Photo: Akselos