The Mero oil field, located in Brazil’s ultra-deepwater Santos Basin, is one of the world’s most significant pre-salt discoveries, holding approximately 3.3 billion barrels of oil equivalent. The field is managed by the Libra Consortium, comprising Petrobras, Shell, TotalEnergies, CNODC, CNOOC, and Pre-Sal Petróleo. Divided into four development areas – Mero 1, Mero 2, Mero 3, and Mero 4 – each area presents unique technical challenges in production and integrity management.
This case study focuses on the Mero 3 FPSO, named Marechal Duque de Caxias, owned by MISC, which utilizes cutting-edge technologies, including Metegrity’s Visions Enterprise and ABS Digital Solutions, to ensure operational readiness and compliance with stringent regulatory requirements.
The Marechal Duque de Caxias FPSO is among the world’s largest ultra-deepwater FPSOs, designed to operate efficiently in the challenging conditions of the Santos Basin. Converted from the Bunga Kasturi Dua, a VLCC shuttle tanker, the FPSO integrates high-pressure separation (HISEP) technology to manage CO₂-rich gas streams – a global first. Key specifications include:
The FPSO achieved its first oil on October 30, 2024, and is chartered to Petrobras for 22.5 years.
Given its size and operational scope, Mero 3 FPSO posed several challenges for integrity management:
To address these challenges, MISC solicited proposals from leading solution providers. After an exhaustive evaluation, MISC selected ABS, supported by ABS Consulting and Metegrity, for a comprehensive AIM Digital Solution and RBI solution. The contract was divided into two phases:
Metegrity’s Visions Enterprise® was central to managing the integrity of topside static equipment, piping systems, pressure safety valves (PSVs), pressure relief valves (PRVs), and pressure relief devices (PRDs). Its key contributions included:
ABS deployed its NS5 Enterprise solution, which included:
ABS Consulting conducted RBI assessments for hull structures, mooring systems, and topside equipment. The process involved:
The collaboration between MISC, ABS, and Metegrity delivered several measurable benefits:
Comprehensive risk assessments enabled targeted inspections, reducing unnecessary interventions and downtime.
Automated reporting ensured alignment with DNV classification and Brazilian regulatory standards.
Proactive Maintenance
Predictive analytics identified potential failures, supporting timely interventions to minimize risks.
The AIM digital solution interfaced with MISC’s Data Hub and CMMS, streamlining operations.
Real-time monitoring and advanced methodologies enhanced asset reliability and longevity.
The Mero 3 FPSO project exemplifies the importance of integrating advanced digital solutions in offshore integrity management. Metegrity’s Visions Enterprise®, combined with ABS’s expertise, delivered a comprehensive AIM and RBI solution, enabling MISC to meet operational and regulatory demands while ensuring safety and efficiency.
As FPSOs continue to play a critical role in global energy production, such innovative approaches set a benchmark for the industry, demonstrating the value of collaboration and cutting-edge technology in addressing the complexities of offshore operations.
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