(WO) — Shape Digital has expanded deployment of its artificial intelligence-powered flare monitoring technology to 10 MODEC FPSOs in Brazil following a successful pilot, targeting reductions in unplanned gas flaring and improved offshore operating efficiency.
The company’s Shape Lumen platform analyzes data across an asset’s oil, gas and water production systems to identify the root causes of unplanned flaring. The technology monitors operating limits and evaluates sensor data preceding flare events to identify process conditions contributing to the problem.
Shape Digital said the system can automatically classify the root cause of unwanted flaring on an hourly basis, reducing analysis that could previously take engineers as long as 10 days to real-time monitoring.
In one application, the technology contributed to an average reduction of more than 12% in daily unplanned flaring emissions. For a 200,000-bpd FPSO, Shape Digital estimated the reduction could represent approximately $200,000 in annual savings based on gas and carbon prices.
Following an initial pilot, MODEC expanded deployment of Shape Lumen to 10 FPSOs in its Brazilian fleet during 2026.
“Lumen transforms complex process engineering data into direct, mitigating actions so that bottlenecks can be anticipated and non-routine flaring events do not recur frequently,” said Leonardo Machado, vice president of growth at Shape Digital.
The platform also incorporates an AI-based predictive model that projects cumulative flaring for the current month and alerts operators when an asset is trending toward regulatory limits.
Shape Digital said implementation takes approximately one month per offshore unit when basic instrumentation requirements are already in place. The company is targeting further deployment in Brazil and other international markets.
Pictured above: MODEC’s Bacalhau FPSO
