AI, Predictive Analytics & Digital Twins Powering FPSO Lifecycle Management

In an interaction with India Manufacturing Review, Philippe Moulin, Operations Manager and Site Representative, SBM Offshore, has shared his views and thoughts on the key technology enablers making digital twin adoption economically viable across new builds and conversions, as well as what training and upskilling initiatives are most effective in aligning local workforce capabilities with next-generation FPSO technologies.

Philippe Moulin is the Operations Manager and Site Representative at SBM Offshore India. With over 31 years at SBM Offshore, he brings extensive expertise in offshore operations, sustainability, and leadership. Over his career, Philippe has held senior global roles including Operations HSSE & Sustainability Director, Operations HR Director, O&M Product Line Director, and General Manager for FPSO (Floating Production Storage and Offloading)/FSO operations across Asia and Africa.

How can predictive analytics fundamentally transform lifecycle asset management to extend the operational lifespan of aging FPSOs (Floating Production Storage and Offloading)? What are the biggest data integration challenges when implementing real-time predictive maintenance systems on legacy FPSOs?

Predictive analytics is reshaping lifecycle asset management by enabling a shift from time-based to risk-based maintenance strategies. This is particularly valuable for aging FPSOs, where optimizing limited resources is essential. By evaluating asset conditions and forecasting potential failures, predictive tools help prioritize maintenance activities where they are most impactful, improving both efficiency and safety.

Predictive maintenance can reduce unplanned downtime and lower maintenance costs. For older FPSOs, the key consideration is data availability. Many were built before the advent of digital infrastructure, and much of their historical data exists in formats like PDFs or static reports.

While retrofitting sensors and condition monitoring tools is increasingly viable, achieving seamless real-time data transmission and integration remains a challenge. Aligning legacy systems with modern analytics platforms requires thoughtful adaptation, but doing so opens the door to smarter, more resilient asset management across the vessel’s lifecycle.

In what ways can AI-driven anomaly detection help balance safety, cost, and operational uptime for mature offshore assets? How do operators quantify ROI when investing in predictive analytics for FPSO life extension projects?

Safety is non-negotiable; we do not balance it against cost or uptime. AI-powered anomaly detection enhances safety by continuously monitoring the health of critical barriers using risk models like bow ties. These tools help identify early warnings of failure, enabling proactive mitigation.

Cost and uptime are addressed early, during the design phase, where system redundancy is tailored to client requirements. During operations, Computerized Maintenance Management Systems (CMMS) manage programmed tasks. Over time, AI helps refine these routines using operational insights, leading to smarter, more risk-adjusted maintenance.

For life extension, we conduct detailed structural and fatigue assessments to ensure safe, continued operations. ROI is measured not just in cost savings, but in extending asset life, minimizing environmental impact, and reducing downtime. Newer units have better emissions profiles, so integrating sustainability is also a core part of long-term value creation.

What role does modular design play in accelerating FPSO deployment timelines, especially in high-CapEx deepwater projects? How do digital twins enhance operational readiness, risk management, and remote monitoring of next-generation FPSOs?

Modular design allows for faster FPSO construction by standardizing components and interfaces. This reduces engineering time, simplifies module integration, and shortens assembly durations, resulting in both time and cost savings.

Digital twins built from engineering 3D models enable operators to simulate processes, validate design assumptions, and train personnel in realistic environments. They are instrumental in commissioning, diagnosing process anomalies, and conducting root-cause analysis. These virtual environments ensure teams are well-prepared before stepping onboard, enhancing safety and readiness.

During the operations phase they can be key to streamline the maintenance process from fault diagnostics, identification of faulty component re-ordering, installing and recommissioning.

What are the key technology enablers making digital twin adoption economically viable across new builds and conversions? In terms of project execution, how do modular FPSO designs impact supply chain complexity and fabrication strategies?

We aim to leverage advanced 3D modelling tools combined with laser scanning post-construction to build accurate digital twins. These models enable engineers to remotely plan upgrades and maintenance campaigns, reducing the need for costly onboard surveys. Keeping the digital twin updated after each modification is essential to ensure accurate future planning and safe operations.

On the project execution side, modular design simplifies supply chains by enabling standardization. This allows us to work through framework agreements and reuse proven equipment designs. It streamlines procurement, reduces lead times, and improves the overall execution efficiency.

How can simulation-based commissioning shorten first oil timelines and improve system reliability?

Simulation-based commissioning allows virtually testing and optimizing commissioning steps before execution, helping with the identification of prerequisites. It enables comparison between theoretical process data and real-time system performance, which is particularly useful during initial start-up.

While achieving first oil involves fewer dynamic elements, the challenge lies in stabilizing systems like gas compression and water injection. These involve complex rotating equipment and are critical for reducing flaring and meeting environmental goals. Thus, simulation tools help shorten the time between first oil and flare-out, improving system reliability and reducing emissions.

In what ways can digital platforms help track, measure, and improve local content compliance? What training and upskilling initiatives are most effective in aligning local workforce capabilities with next-generation FPSO technologies?

In markets with developing digital infrastructure, full integration remains a challenge with local service providers, but incremental progress is enabling greater transparency and alignment.

Upskilling is critical. The ideal local workforce combines domain expertise in FPSO operations with digital proficiency. Bridging these two capabilities is key. Initiatives focused on digital tools for maintenance, analytics, and system diagnostics, alongside core technical training, will prepare local talent to support and grow with next-generation offshore assets.