Shape Digital expanded its AI-powered flare monitoring technology to 10 MODEC FPSOs in Brazil after a successful pilot. The deployment centers on the Shape Lumen platform, which analyzes production data and sensor signals to identify the causes of unplanned flaring (via www.worldoil.com).
The company also says the system can classify the root cause of unwanted flaring on an hourly basis, cutting analysis that could take engineers up to 10 days. Shape Digital said implementation takes about one month per offshore unit when basic instrumentation is already in place.
What Shape Lumen is doing inside the asset data stream
Shape Lumen analyzes data across an asset’s oil, gas and water production systems to identify the root causes of unplanned flaring. It monitors operating limits and evaluates sensor data before flare events to identify process conditions contributing to the problem.
The platform also includes an AI-based predictive model that projects cumulative flaring for the current month and alerts operators when an asset is trending toward regulatory limits.
Measured effects and the savings estimate
In one application, the technology contributed to an average reduction of more than 12% in daily unplanned flaring emissions. Shape Digital estimated that, for a 200,000-bpd FPSO, that reduction could represent approximately $200,000 in annual savings based on gas and carbon prices.
Leonardo Machado, vice president of growth at Shape Digital, said: “Lumen turns complex process engineering data into actions so bottlenecks can be anticipated and non-routine flaring events do not recur frequently.”
Deployment timing and next-step geography
Following an initial pilot, MODEC expanded deployment of Shape Lumen to 10 FPSOs in its Brazilian fleet during 2026. Shape Digital is targeting further deployment in Brazil and other international markets.
Droam Perspective
For offshore operators and production teams, the disclosure is less about the AI label than the operating mechanics: hourly root-cause classification, pre-flare sensor analysis, and a one-month implementation window when instrumentation is already in place. The commercial signal is the combination of a reported 12%+ reduction in daily unplanned flaring emissions and Shape Digital’s estimate of about $200,000 in annual savings for a 200,000-bpd FPSO. The current-model flaring forecast and regulatory-limit alerting point to use cases beyond after-the-fact reporting.