Optimizing FPSO Maintenance Decisions with Akselos Digital Twins. Case Study

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1 Optimizing FPSO Maintenance Decisions with Akselos Digital Twins Case Study

2 Challenge An FPSO has been in continuous operation in extremely harsh offshore conditions for 20 years. It has reached the end of its original design service life. Ensure that risks associated with the FPSO s operational condition and life extension are understood and are effectively controlled. The need now is to understand the current state and the remaining safe lifetime of the asset. Today, conventional analysis tools, such as FEA, are used for structural integrity studies. However, in the case of a large-scale FPSO, these tools are incapable of supporting global system models at a level of sufficient detail to incorporate detailed inspection results, for example. According to the company, a months long manual process is used today requiring expert interpretation and affording little insight into what is the true asset condition. The solution is to provide an analysisready Digital Twin model incorporating all available design specifications and leveraging ongoing inspection data. Using Akselos Integra, a complete suite of simulations is run ensuring compliance and safety. Solution Akselos Integra software is used to create a true condition-based Akselos Digital Twin of the FPSO. Benefits Using the Akselos Digital Twin, the company obtains actionable insights for proactive maintenance and operational safety margins. The company is achieving significant OpEx savings by confidently extending maintenance intervals while ensuring safe operation. Static linear analysis for a full condition-based FPSO model using 2D elements. Bigger assets, harder decisions In order to reduce OpEx costs, operators need to optimize all processes for maximum efficiency and safety with no delays or downtime. As aging FPSOs are operated beyond their original design life, operators must deepen their understanding of the asset s current condition and degradation processes. This operational context is necessary for decision makers to manage risks and ensure the operational safety of their assets.

3 Engineering the Solution Using the Akselos Integra platform tools, engineers create an Akselos Digital Twin and then incorporate all relevant inspection data. Hundreds of simulations are performed for a range of model configurations for ballast, topside loading, storage levels, and varying wave states. Because of the tremendous speed and accuracy of these simulations, the company is able to create a full array of distinct scenarios as needed for compliance, what-if studies, contingency planning, hot spot identification, fatigue, and buckling analysis. This is only possible because of the unique and patented modeling method in Akselos Integra. In this component-based modeling approach, large-scale models are built using a set of fully parameterized components, enabling engineers to rapidly incorporate defects at the component level without having to update the global model. The Akselos Decision Support System is comprised of a series of steps and proprietary technologies: 1. A detailed CAD model is created representing the full geometry of the FPSO hull. This includes non-structural features such as ladders and tanks. 2. The CAD model is imported into the Akselos Integra Modeler and is used to create a full structural model consisting of components. 3. The Akselos Digital Twin of the FPSO. This model provides a detailed representation of the hull s primary structure, including stiffeners, plates, girders, and frames. 4. The Component Library is used to include parameters into the model. The ship hull is modeled by shell elements. The representation of the topside structure is simplified by using mass elements located at the centers of gravity of the topside modules, and beam elements to transfer the topside load to the hull. 5. Using the Akselos Modeler, the Akselos Digital Twin model is updated with relevant inspection data to incorporate cracks, corrosion, damage, etc. 6. Finally, the Akselos Cloud platform is used to perform fast structural analysis. The Akselos Modeler is used to evaluate various load combinations and to detect which structural components have a higher risk profile for each scenario. Crack analysis within a full FPSO model.

4 Take control of downtime by mastering all possibilities The company reported that by using the Akselos Digital Twin to analyze the structural integrity of the FPSO model, the response time was literally minutes per run using Akselos Integra. This compared to the days per run required using conventional methods, at lower resolution. Akselos-generated information provided the company with a qualitative engineering evaluation of the operational condition of the FPSO, at the same time incorporating the latest inspection data and accumulated asset condition. Using the Akselos Digital Twin enables: Leveraging existing data by producing condition based results under real-world(and certification compliant) conditions. Reducing OpEx costs by optimizing repair strategies and eliminating unplanned maintenance interventions. Gaining a deeper understanding of the operational safety margins and providing increased confidence that the company could be ready and develop contingency plans for the unexpected. Components identified at high risk of failure after running an automated analysis study using Akselos Decision Support system.

5 About Akselos Akselos is a digital technology company headquartered in Switzerland, with operations in Europe, the USA and South East Asia. The company has created the world s most advanced engineering modeling, and fastest simulation technology, to protect the world s critical infrastructure today and tomorrow. The technology has the power to revolutionize how we build and manage our critical infrastructure, and pushes the boundaries of what modern engineering and data analytics can achieve. Developed by some of the world s best minds, the MIT-licensed technology builds something far beyond the capability of a conventional digital twin a digital guardian that allows operators to not only monitor an asset s condition in real time, but helps them to see the future. North America Europe/Middle East/Africa Asia-Pacific AKSELOS, Inc 210 Broadway, #201 Cambridge, MA 02139, USA AKSELOS S.A. EPFL Innovation Park, Building D 1015 Lausanne, Switzerland AKSELOS Vietnam 125/167 Dinh Tien Hoang street, Binh Thanh Dist. Ho Chi Minh city, Vietnam