Structural health monitoring for FPSOs and offshore hulls

On most offshore structures, fatigue is not measured. It is estimated from design assumptions and checked periodically by survey. Light Structures' SENSFIB measures it directly. Fibre optic sensors bonded to the structure read the stress it is actually carrying, continuously and in real time, so the hull or platform reports its own loading history rather than having it inferred. For an operator, that is the difference between knowing how much fatigue life a structure has used and calculating a worst-case estimate. The system is installed on more than 400 vessels across 20 or more countries, and it holds ABS SMART SHM Tier 3 certification.

Why a periodic survey leaves a gap

A class survey is a snapshot taken on a schedule. Between surveys, the structure takes whatever loading the sea and the operation give it, and that history is not captured. For an FPSO that stays on station for years, or a platform past its design life, the gap between snapshots is where uncertainty about remaining fatigue life lives.

What SENSFIB measures

SENSFIB uses fibre optic sensors to read strain, and therefore stress, at points across the structure in real time. That gives a continuous record of the actual loading rather than a design assumption. The operator can see stress concentrations and fatigue accumulation as they happen, on the parts of the structure that matter most.

Why the installation method matters

The sensors are bonded with adhesive, with no welding and no moving parts. No welding means no hot work to install, which matters on a live hydrocarbon asset, and no moving parts means the system does not need annual recalibration. That keeps both installation and ongoing maintenance low-intervention.

From monitoring to a digital twin

Light Structures runs a Hybrid Digital Twin that combines the live stress data with a DNV Risk-Based Inspection framework. That moves the data from a monitoring feed into inspection planning, so inspection effort goes where the measured loading says it should rather than where the calendar says. This is the practical version of a structural digital twin: real measured data driving a recognised inspection methodology.

Where it is proven

SENSFIB is installed on more than 400 vessels, including tankers, LNG carriers, naval ships, and offshore rigs, across 20 or more countries. It holds ABS SMART SHM Tier 3 certification, which is the structural health monitoring standard the classification society recognises. The company is based in Oslo and supported through agents in 20 or more countries.

What this means for a WA operator

For a WA operator running an FPSO or managing an LNG carrier fleet, the question is whether structural fatigue can be measured rather than estimated, and whether inspection can be planned against real loading. SENSFIB answers both, and the no-welding installation means it can be considered for an asset already in service, not only a newbuild.

Common Questions

How do you monitor structural fatigue on an FPSO?

Fibre optic sensors bonded to the structure read stress continuously in real time, which gives an actual loading history rather than an estimate. SENSFIB is installed on more than 400 vessels across 20 or more countries.

What is structural health monitoring?

Structural health monitoring is the continuous measurement of stress and strain on a structure to track fatigue as it accumulates, rather than inferring it from a periodic survey.

Does installing fibre optic sensors require welding?

No. SENSFIB sensors are bonded with adhesive, with no welding and no moving parts, so there is no hot work to install and no annual recalibration.

Is SENSFIB certified?

Yes. SENSFIB holds ABS SMART SHM Tier 3 certification, the structural health monitoring standard recognised by the classification society.

What is a structural digital twin and does Light Structures have one?

Light Structures runs a Hybrid Digital Twin that combines live stress data with a DNV Risk-Based Inspection framework, so measured loading drives inspection planning and predictive maintenance.

Can structural monitoring be retrofitted to a vessel already in service?

Yes. Because the sensors are adhesive-bonded with no hot work, the system can be considered for an asset already operating, not only a newbuild.

How widely is SENSFIB used?

It is installed on more than 400 vessels across 20 or more countries, including tankers, LNG carriers, naval ships, and offshore rigs.

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