AI Predicts Trouble Before It Strikes at Sea

AI-powered predictive maintenance is transforming FPSO operations, cutting risk, downtime, and costs

7 Jan 2026

A quiet but consequential shift is unfolding across floating production, storage and offloading vessels supporting U.S. offshore energy production. Artificial intelligence, once tested in limited pilots, is now being applied more broadly to maintenance and operational risk, according to industry participants.

At the center of the change is predictive maintenance, a practice that relies on continuous analysis of operating data rather than responses to equipment failures. AI systems monitor performance patterns in pumps, compressors and turbines, identifying subtle signs of stress before conventional alarms are triggered. Operators say the approach gives crews time to schedule repairs and avoid unplanned shutdowns that can disrupt production.

Recent digital partnerships have helped accelerate adoption. The collaboration between SLB and SBM Offshore reflects a growing view that operational data is not simply a reporting output but a strategic asset. By combining engineering expertise with advanced analytics, the companies have framed predictive maintenance as a core operational capability rather than an experimental add-on, analysts said.

Large automation providers, including Emerson and Honeywell, have also expanded AI-enhanced monitoring within industrial control systems, a trend that has carried into offshore operations. The focus, companies say, has been on usability. Predictive insights are integrated into familiar dashboards, allowing offshore teams to act on recommendations without needing to interpret complex models. Early deployments across the sector have been associated with improved equipment reliability and fewer instances of unplanned downtime, according to company statements.

The economic rationale is clear. A single day of unexpected FPSO downtime can result in significant production losses, with revenue impacts that quickly outweigh the cost of digital systems. Predictive maintenance allows work to be aligned with planned shutdowns, reduces the need for emergency repairs and can improve safety by limiting high-risk interventions in remote and weather-sensitive environments.

Obstacles remain. Many older vessels operate with aging sensors, and inconsistent data quality can weaken confidence in analytics. As systems become more connected, cybersecurity and data governance have drawn increased scrutiny from regulators and industry groups.

Still, the direction is increasingly defined. Predictive maintenance is moving toward standard practice for FPSOs, and as data foundations improve, AI is expected to play a larger role in extending asset life and stabilizing offshore production in the years ahead.