Solution Brief

TRANSFORMATIONAL DIGITAL TWIN TECHNOLOGY FOR BEST-IN-CLASS STRUCTURAL INTEGRITY MANAGEMENT THROUGHOUT ALL PHASES OF FPSO LIFECYCLE

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Floating Production Storage and Offloading (FPSO) units have been used in the oil & gas industry since the 1970s. The initial approaches to FPSO operation were based on maritime experience, and involved regular dry-docking for maintenance and repair.

The industry evolved by the mid 1990s to a solution in which FPSOs were permanently moored in place. Due to the limitations in knowledge and technology available at the time, over-design of these assets was essential. The extra costs involved with over-design and overly-conservative operations were acceptable to operators at that time.

What is different now?

• Operators prepare for oil prices that are lower for longer, hence no room for over-design or overly conservative operation.

• Society demands even safer operations.

• Topsides are heavier than ever, since increasing throughput boosts economics.

• Operators face challenges for both new and aging units: New units are larger and more complex than ever, and aging units have significant uncertainty on structural integrity.

• Climate change is bringing more severe environmental loads than were originally considered during design.

What is mandatory now, to keep competitive in this new scenario?

• A rigorous way to monitor and visualize structural integrity of FPSOs based on their AS-IS condition.

• A high-fidelity system to ensure that it accurately represents the structural integrity status of the offshore unit.

• A user-friendly tool allowing any stakeholder, designer, or operator to intervene whenever necessary to ensure safe and efficient operation.

• Avoid unnecessary downtime and allow a conscious decision to keep producing for longer with a lower cost operation.

INDUSTRY NEEDS TO CHANGE TO SURVIVE AND THRIVE.

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A TRULY TRANSFORMATIONAL TECHNOLOGY. HIGH-FIDELITY, GLOBAL SIMULATION REPLICATING THE AS-IS STRUCTURAL STATUS OF AN OFFSHORE UNIT.Akselos provides breakthrough digital twin technology that delivers unique solutions to the challenges that the oil & gas industry is facing.

• Near real-time simulation of large-scale models (at least 1000x faster than conventional methods), while also increasing model detail by 100x.

• User-friendly visualization of the ‘as-is’ structural integrity through a continuously updated and high-fidelity digital twin.

• Advanced design tools based on Akselos’ powerful

simulation technology to enable lean design and safe operations to face new economic scenarios.

• Means for a quick verification and evaluation of situation for decision makers in case of any accident.

• Best-in-class tool for analysis of large-scale hulls which can bring value in all phases of asset lifecycle: Design, operations, life extension, decommisioning.

This technology is provided in the Akselos Integra® platform, which provides a best-in-class digital twin platform for offshore structures.

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Akselos physics-based digital twin technology is the backbone of a digital thread. A digital thread refers to a data-driven architecture that links together information generated from across the asset lifecycle to deliver value to asset owners and operators. From design, where with the augmented simulation power, you can expand the design space, enable rapid customization (for example when bidding for new projects) and really close the loop on operational experience. Through construction, where at any given time you can validate the construction process and deal with changes, or non-compliance in a rapid, transparent way, and of course most importantly in the operations phase, where having a clear picture of an asset state, allows fleetwide savings across:

Inspection

• Prescriptive RBI approach

• Guided general visual inspection, ultrasonic testing, close visual inspection, & remotely operated vehicle inspections of ‘critical’ areas, not pre-defined hot spots

• Migrate routine monitoring and visual inspection

outputs to RT digital twin incorporating “as-is condition”

• Proactive management and RBI for topsides and hulld Code Compliance / Validations

• Digital thread feeding MoCs and Risk Register quantifications for probability and severity of failures.

Maintenance

• Prioritized maintenance/avoidance of vessel suspension to operate

• Enables SCM optimization & Procurement influence, including spare inventory/material management

Repair

• Fitness for Service & RT Repair Validation

• Justify dry-docking urgency and/or postponement

• Advanced warning and mitigation using RTM

• Loss of Life Prevention /Environmental Exposure Drive to Zero

• Reduce/Prevent Loss Production Events

HOW? AN ACCELERATED DIGITAL THREAD, FIT FOR OPERATORS.

DESIGN CONSTRUCTIONS OPERATIONS

DIGITAL THREAD THROUGHOUT ASSET LIFE CYCLE DECOMISSIONING• Design Optimization with in-comparable simulation power

• Enabling rapid customization of modular design – bid stage

• Truly closing the loop with operational experience

• Validation of construction process

• Non-compliance verification

• Minimizing inspection $• Reducing repair require-

ments• Reducing POB• Lowering insurance costs• Supporting MOC• Avoiding major failure• Repair planning• Life extension

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DIGITAL TWIN MODEL

INCORPORATE INSPECTION DATA

MEASURED LOADING DATA: SEA STATES, DRAFTS, TANK FILL

LEVELS, MEASURED AT 3-HOURLY INTERVALS

TOPSIDE WEIGHT DATA

HYDRODYNAMIC LOADS

STATIC LOADS

CONDITION-BASED DIGITAL TWIN

1T MESH IN ALL FATIGUE HOTSPOTS

SIMULTANEOUSLY

RISER PORCH & MOORING FAIRLEAD

TOPSIDE ASSESSMENT

STRENGTH ANALYSIS

FATIGUE SCREENING

DETAILED FATIGUE ANALYSIS

Auto-generated reporting at regular intervals (e.g. weekly, monthly) summarizing current asset

status and changes since last report

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SIX MONTHS OF RE-ANALYSIS, IN AN AUTOMATED 2 HOUR WORKFLOW, WITH A 10X INCREASE IN ACCURACY.

01 AUTOMATED DIGITAL TWIN UPDATE BASED ON AS-IS CONDITION

The Akselos digital twin is automatically updated with inspection data to obtain a condition-based model of the FPSO. The update takes a file storing thickness data as an input and automatically updates the thickness in a visual way everywhere in the model.

• INCORPORATE INSPECTION DATA

• LOAD CONDITION Static load conditions and hydrodynamic load cases are configured and incorporated into the digital twin, and typically a digital twin includes thousands of distinct load cases. These cases are automatically re-analyzed each time the digital twin is updated, e.g. based on new inspection data, or topside weight changes, or if new “what if” scenarios are being considered, and following the re-analysis, reports are auto-generated based on the industry-standard assessments described below.

Thickness loss throughout the hull, color-coded by severity.

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Automated analysis and reporting types that are provided by the Akselos Integra® platform for FPSO digital twins are listed below.

Even though your asset may be on a 5 years rolling inspection program. The Inspection & operational data you’ve received this week could mean you have to take action immediately. Only Akselos can

bring you instant analysis of an entire FPSO with the required level of accuracy to take the right decisions.

SCOPE EXAMPLES OF IMPLEMENTED STANDARD

Fatigue

DNVGL-C203

DNVGL-CG-0129

DNVGL-CG-1052

Buckling (strength check)

Lloyd's Register - ShipRight Procedure for Ship Units, July 2014

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ONLY AKSELOS CAN DELIVER THOSE RESULTS.

In order to pitch this next computing power into a 2h digital thread, Akselos has to leverage 20 years of research in numerical analysis, for which we

have the exclusive license from MIT.

SPEED - 1000 TIMES FASTER THAN FEAFULL SPECTRAL FATIGUE ANALYSIS 100 MDOF 100O SOLVES

FEA SOLVE3 MONTHS SOLVE & POST-PROCESS

AKSELOS RB-FEA SOLVE2 HOURS < 14 SECONDS 100 MDOF SOLVES

SCALE - HOLISTIC AND DETAILED MODEL

PARAMETRISATION

Akselos enables detailed and holistic structural analysis of large-scale offshore units, including all current condition data and loading data. This ensures that the cumulative effect of structural anomalies are accounted for, allowing users to reduce uncertainty and unlock spare structural capacity at the same time.

Akselos parametric model updates can be performed based on automated calibration to sensor or inspection data. Akselos’ RB-FEA is the only technology to do parametric FEA.

4X

CREATE/UPDATE COMPONENTS

SET PARAMETERS AND SOLVEASSEMBLE MODEL

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LONGER FATIGUE LIFE DUE TO HIGH FIDELITY MODELING

1000X FASTER SIMULATION, 100X INCREASED DETAIL.

02 AUTOMATED RE-ANALYSIS BASED ON THOUSANDS OF RB-FEA SOLVES, WITH POST-PROCESSING AND REPORTING BASED ON INDUSTRY STANDARDS

• FULL FATIGUE SCREENING OF THE ENTIRE HULL Why does Akselos have a unique capability to perform structural screening of an entire hull?

An Akselos RB-FEA model provides a highly detailed representation of the entire asset (including hull and topsides), and also incorporates the as-is condition and up-to-date loading data. This enables accurate stress data to be provided throughout the entire asset, which in turn enables detailed fatigue screening and risk ranking to be performed.

• Screen tens of thousands of potential hotspot locations throughout a hull (typically details such as toe of stringer and bracket toe of transverse web frame details, or longitudinal stiffener-frame connections) and identify a small subset (100 or so) of locations that are critical.

• Display the screening results in plots of fatigue hotspots, color-coded based on criticality, superimposed on inspection maps, as shown in the figures below.

• Hotspots identified by the screening can then be assessed with detailed fatigue analysis with a “txt” mesh (i.e. element size is equal to steel thickness).

• Prioritize inspection and maintenance via a risk-based inspection program.

230

15’000

FATIGUE HOTSPOTS IDENTIFIED.

FATIGUE LOCATIONS.

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FROM

TO

Any fatigue hotspots identified by the global hull fatigue screening, or any other hotspots identified by the shipyard or a class society standard, can then be assessed using workflows for detailed spectral fatigue analysis. This follows the usual workflows for spectral fatigue analysis e.g. as per standards from the major class societies, and in particular refined txt mesh regions are introduced at the fatigue hotspots. The key difference in the RB-FEA approach, however, is that we use a single holistic model that includes all txt regions, i.e. there is no need for “submodeling” workflows. This increases the fidelity of the results, because submodeling is an inherently low-fidelity method that relies on coarse modeling at the global level. Also, the detailed global RB-FEA model incorporates all condition data and hence this is all included in the fatigue analysis. These capabilities ensure that the Akselos workflow is the most powerful and most accurate approach for fatigue analysis of hulls.

• DETAILED FATIGUE ANALYSIS AT HOTSPOTS

• STRENGTH ANALYSIS Akselos also provides standards-based checks for strength analysis, again based on the high-fidelity global Digital Twin. The buckling checks involve post-processing of stress data according to class society standards in order to identify any critical areas. Strength reports are auto-generated by the Akselos Digital Twin platform at regular intervals, or after each update to the Digital Twin, to summarize the current state of the asset and identify any areas of concern.

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Due to the scalability of the RB-FEA approach, Akselos Digital Twin can also incorporate a fully-detailed topsides model, as shown in the figure below. This enables a holistic hull + topsides assessment with a single model, and ensures the most accurate analysis is performed which properly accounts for interactions between the hull and topsides structures. Automated code checks for topsides modules are performed based on API and AISC standards.

• TOPSIDE ASSESSMENT

• ASSESSMENT FOR RISER PORCHES AND MOORING FAIRLEAD SUPPORTS Riser porches and mooring fairlead supports can be included within the global Digital Twin, again modeled in full 3D detail. Loading is applied to these structures and then reports are auto-generated based on fatigue and strength analysis of these critical parts.

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Utilization of members in topside structures based on API and AISC standards.

SCOPE EXAMPLES OF IMPLEMENTED STANDARD

Topside structures API-RP2AAPI-2VAISC 360 : 2016

The analysis types described above are used to generate structural integrity reports. The reports are auto-generated based on the current state of the digital twin, incorporating the latest inspection data and loading data. Report formats are fully customizable, and can be used to generate, for example, inspection maps that incorporate risk ranking levels, or to highlight the changes that have accumulated since the previous report to give an understanding of the changes to the asset.

In addition, Akselos Digital Twins enable all relevant structural metadata to be stored in the model, including plate and member specifications, links to structural drawings, and inspection history. This assists operators in managing all necessary information of the structure in one place within the Akselos Integra® platform.

• AUTO-GENERATED REPORT, VIA WEB-BASED DASHBOARD, BASED ON AS -IS CONDITION

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AKSELOS DIGITAL TWINS INTEGRATE WITH ALL RELEVANT SENSORS AND INFORMATION TO KEEP AN UP-TO-DATE DIGITAL REPLICA OF THE UNIT.An Akselos digital twin is connected to all available asset data that is relevant for structural integrity purposes. The table below summarizes some typical data sources, and the frequency of data updates.

DATA UPDATE

FREQUENCY

PROCEDURE FOR UPDATING THE DIGITAL

TWIN REPORTING

Automated load monitoring, e.g. sea states, drafts, tank fill levels, staring gauges, accelerometers

3 hourly Automated data feedFeeds into fatigue analysis performed at the end of each month, leading to a report that summarizes the changes in the past month

Tank thickness inspection 1 to 2 monthsAutomated web-based tool for importing thickness data

After each thickness update, strength and fatigue assessments are automatically triggered, leading to reports that highlight trends, hotspots, and any areas of concern.

Topside inspection reports 1 to 2 monthsAutomated web-based tool for importing topside inspection data

After each update, strength and fatigue checks are automatically triggered, leading to reports that highlight trends, hotspots, and any areas of concern.

Topside weight changes As-needed Automated web-based tool for importing topside weight data

After each weight update, strength and fatigue assessments are automatically triggered (for hull and topsides), leading to reports that highlight trends, hotspots, and any areas of concern.

Accidents or damage As-neededManual update to the digital twin to model the damage region (e.g. dent in the hull)

Global or local assessments can be auto-matically performed after the update.

“What if” scenarios As-needed

The digital twin can be updat-ed to model any number of “what if” scenarios, for contin-gency planning, or assessment of asset modifications

Reports can be auto-generated as needed for the assessment purposes.

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SHELL’S BONGA GETS A DIGITAL TWIN Akselos SA has deployed a structural digital twin for Shell Nigeria Exploration and Production Co.’s Bonga Main FPSO, located 120 km southwest of the Niger Delta.

WORLD’S LARGEST STRUCTURAL DIGITAL TWIN With near-real time analysis, the physics-based model of the asset allows Shell and Akselos to monitor the overall health of the asset, reduce downtime and boost efficiencies, all while enabling safe asset life extension.

AKSELOS AWARDED AS TECHNOLOGY PIONEER BY WORLD ECONOMIC FORUM The World Economic Forum announced its selection of 100 of the most promising Technology Pioneers of 2020, who are shaping industries from agriculture to healthcare, energy sustainability and much more.

AMERICAN BUREAU OF SHIPPING PARTNERS WITH AKSELOS ABS is partnering with digital twin specialist Akselos to explore developing cutting-edge digital services to clients.

FPSO WORLD CONGRESS 2020: ESTABLISHING FPSO INTEGRITY THROUGH INNOVATIVE DIGITAL TWIN TECHNOLOGY Structural digital twins are being used to revolutionise asset integrity management for FPSOs. Hear about the world’s largest, physics-based digital tiwn in action.

SPE PAPER: PREDICITVE DIGITAL TWINS FOR STRUCTURAL INTEGRITY MANAGEMENT AND ASSET LIFE EXTENSION Akselos delivers a true digital twin of the asset and offers compelling and cost-effective method for offshore assets that are facing life time extension beyond what current methodologies can provide.

STATE-OF-THE-ART DIGITAL TOOLS FOR OPERATION AND INTEGRITY MANAGEMENT.

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WE ARE VERY EXCITED ABOUT THE NEW CAPABILITIES THAT AKSELOS BRINGS AND BELIEVE IT WILL CREATE A POSITIVE IMPACT ON THE WAY WE MANAGE STRUCTURAL INTEGRITY. AKSELOS IS A GREAT EXAMPLE OF DIGITALISATION COMING TO LIFE.Shell’s Bonga Asset Manager, Elohor Aiboni

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SEAMLESS COLLABORATION:HOW YOU CAN WORK WITH AKSELOS. ASSET MODEL SUPPORT • Option for project initiation; digital twin set-up with a starter pack of support

and services.

• We can help you get your digital twin up and running quickly.

TRAINING CENTER • Training for your engineers to help and manage digital twins.

• Online knowledge base with detailed information.

• Fully documented self training center.

FULLY CLOUD-BASED • Accessible from anywhere on the internet.

• Promoting team work between geographies and companies.

SOFTWARE AS A SERVICE • Akselos’ main offering is a SaaS Software with a license-based subscription.

• Other licensing options are available on request.

• More information: info@akselos.com

ABOUT US Akselos is the creator of the world’s most advanced engineering simulation technology – Reduced Basis Finite Element Analysis (RB-FEA).

Founded in 2012 and with operations in Europe, the USA, and South East Asia, the company’s products are designed specifically to help protect the world’s critical infrastructure with real-time, condition-based monitoring for large critical assets. Using patented algorithms developed over 15 years of research at MIT and funded by the US Department of Defense, Akselos’ digital twin solution is helping the energy sector optimize operations, lower operating costs, and extend the life of ageing assets.

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European Headquarters, LausanneEPFL Innovation Park | Building D | 1015 | Switzerland

US Headquarters, Boston 1309 Beacon Street | #300 Brookline | MA 02446 | United States of America

CONTACT US info@akselos.com

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Sales Hub, Houston 2101 CityWest Blvd | TX 77042 | United States of America

Sales Hub, London 27 Old Gloucester Street | WC1N | 3AX | United Kingdom

Operations, Ho Chi Minh Thao Dien Ward | No. 67-69 Ha Noi Highway | 1st Floor | District 2 | Vietnam

®Akselos S.A. 2020. All rights reserved. While Akselos has made every attempt to ensure that the information contained herein is accurate at the time of printing, Akselos is not responsible for any errors or omissions, or for the results obtained from the use of this information. All information herein is provided “as is”, with no guarantee of completeness, accuracy, reliability or of the results obtained from the use of this information, and without warranty of any kind, such as but not limited to warranties of performance, merchantability, and fitness for a particular purpose. Akselos will not be liable for any losses and/or damages in connection with the use of this document.