A structural digital twin has been deployed at Shell’s Bonga Main floating production storage and offloading (FPSO) unit, located 120 kilometres Southwest of the Niger Delta in Nigeria.

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.

The structural digital twin was selected by Shell Nigeria Exploration and Production Company (SNEPCo), Shell’s deepwater company in Nigeria and operator of the 225,000 oil barrel capacity FPSO, due to its unique ability to realise a number of operational objectives.

These include the identification of critical areas for prioritised inspection, maintenance and repair; a reduction in personnel onboard 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.

The deployment of the breakthrough 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.

Elohor Aiboni Asset Manager for Bonga said the FPSO heralded a number of innovative ‘firsts’ when it was built back in 2004, so it’s fitting that it’s the first asset of its kind to deploy something as advanced as a structural digital twin.

“[We] believe it will create a positive impact on the way we manage structural integrity. It is also a great example of digitalisation coming to life,” Aiboni said.

The Bonga Main FPSO, which became operational in 2004, has a capacity of 225,000 barrels per day and weighs over 300,000 tonnes, making it the largest asset in the world to be protected by a structural digital twin.