The Birth of Offshore Drilling in the Gulf of America
In 1938, as Pure Oil and Superior Oil Company hammered wooden pilings into the seabed off the coast of Creole, Louisiana, they likely never imagined that nearly a century later, flying drones and AI-powered sensors would map out the final days of offshore platforms. This historic platform, the first of its kind in the open water of the Gulf of America, stood on a 320-foot by 180-foot wooden deck, perched 15 feet above the water, supported by 300 treated yellow pine pilings. The Superior-Pure State No. 1 well struck oil but was ultimately wiped away by a hurricane in 1940. It was the first of thousands of offshore wells that would shape the American energy industry.
Over the next several decades, offshore drilling evolved from wooden structures in shallow waters to towering steel giants in depths reaching nearly 10,000 feet. The Gulf of America became a powerhouse of oil and gas production, with companies drilling approximately 90,000 wells from 6,000 platforms. Yet, as the industry expanded, so did its footprint—leading to an unintended consequence: orphaned and abandoned wells left behind as operators went bankrupt or moved on to new projects.
The Challenge of Aging Infrastructure and Decommissioning
Today, the Gulf of America faces a critical issue: 14,000 non-producing wells and thousands of aging platforms, many of which pose safety and environmental hazards. The Bureau of Safety and Environmental Enforcement (BSEE) currently monitors 1,366 offshore structures, with hundreds awaiting decommissioning. Of these, 273 have submitted decommissioning applications, and 451 sit on terminated leases. Only 192 of those structures have pending decommissioning applications. However, with decommissioning costs ranging from $500,000 for shallow wells to over $50 million for deepwater platforms depending on water depth and complexity, the process is both expensive and complex.
Decommissioning is the process of ending oil and gas operations, plugging wells, dismantling and disposing of platforms, and returning the seafloor to pre-lease conditions. This is generally required within one year of the end of a lease or when it becomes unsafe, obsolete, or otherwise no longer useful for operations.
From the moment they sign a lease, offshore operators accept responsibility for cleaning up the area after drilling and production, including decommissioning facilities and structures placed on the leased site. Over the last decade, companies have decommissioned roughly 200 platforms annually in the Gulf of America.
The creation of orphaned and abandoned wells in the Gulf of America results from multiple factors, including financial, regulatory, environmental, and operational challenges.
Many smaller oil and gas operators that drilled wells in the Gulf have gone bankrupt or ceased operations, leaving behind unplugged wells with no financially responsible party to decommission them.
During oil price crashes (e.g., 2014-2016 and 2020 pandemic downturn), many operators shut in wells or went bankrupt, leaving the government responsible for cleanup.
Some companies sell aging assets to smaller firms that may lack the financial resources to handle the eventual well decommissioning, effectively transferring liabilities until no responsible operator remains.
Traditionally, inspecting these platforms before decommissioning involved sending teams of engineers and divers—a dangerous and time-consuming task. Many of these structures stand in harsh marine environments where waves batter rusting steel, making manual inspections risky.
Enter drones, 3D photogrammetry, LiDAR (Light Detection and Ranging), SLAM-based navigation and 3D modeling, and AI-driven inspections, a revolutionary shift that is revolutionizing the decommissioning process.
The Technology Shift: Drones, LiDAR, and AI in Offshore Inspections
Instead of putting human lives at risk, companies now deploy Unmanned Aerial Vehicles (UAVs) and LiDAR scanners to perform high-resolution inspections. These technologies allow operators to map offshore platforms in precise 3D detail before removal, ensuring a more efficient and cost-effective decommissioning process.
How It Works:
Drones capture high-resolution images and LiDAR scans of platform topsides, support structures, and subsea components to create precise Building Information Modeling (BIM) digital twins of the platform.
Quadruped robotic platforms (‘Robot Dogs’) walk through a structure to create a highly detailed and accurate 3D map.
AI analyzes historical and real-time data to detect corrosion, structural weaknesses, and environmental risks, reducing human error and increasing efficiency.
These models help engineers assess structural weaknesses, material conditions, and corrosion levels without requiring human inspectors to enter hazardous environments.
The 3D models and LiDAR scans generated by drones allow engineers to simulate cut paths, crane lifts, and removal sequences before sending teams into the field.
These insights reduce project risks, optimize dismantling operations, and ensure compliance with environmental regulations.
The Future of Offshore Decommissioning: Automation and AI
Beyond drones, the deployment of advanced robotics and automated systems has significantly reduced human exposure to hazardous environments during decommissioning. Remotely operated vehicles (ROVs) and robotic tools perform tasks such as cutting, inspection, and material handling, minimizing the need for diver intervention. Integrating Underwater Unmanned Aerial Vehicles (UAVs), also known as Autonomous Underwater Vehicles (AUVs), into offshore decommissioning processes has significantly enhanced safety, efficiency, and data accuracy.
Quadruped robotic platforms are being tested on offshore rigs, where they autonomously patrol using LiDAR SLAM, detect gas leaks, and collect environmental data.
AI plays a critical role in processing vast amounts of data collected from drones, SLAM devices, and LiDAR scans. AI-driven insights optimize decision-making, risk assessment, and decommissioning strategies.
- AI processes historical and real-time drone and LiDAR data to identify weak points, rust, and structural risks.
- AI algorithms predict when and where failures might occur during the decommissioning process, allowing for proactive reinforcement before dismantling begins.
- AI-enhanced computer vision scans photogrammetry and LiDAR models to highlight potential hazards, such as unstable pipes, deteriorating walkways, or cracked support beams.
- AI simulates different decommissioning approaches using digital twins, allowing teams to choose the safest and most cost-effective dismantling strategy.
- AI-generated models help determine crane lift placements, cutting sequences, and removal procedures, reducing risks and minimizing costs.
- AI-driven platforms analyze extensive datasets to optimize decommissioning strategies and projected to cut costs significantly, with some estimates suggesting reductions of up to 35%.
Closing the Loop: From Wooden Rigs to Digital Twins
The Gulf of America, which pioneered offshore oil drilling nearly a century ago, now leads offshore decommissioning innovation. From wooden derricks standing on pine pilings to digital twins mapped by drones, the industry has completed a full cycle.
Despite the global push for cleaner energy, offshore oil production is not disappearing overnight. Instead, operators are leveraging automation, AI, and predictive analytics to enhance efficiency and reduce environmental impacts. The oil and gas industry has long been a leader in technological innovation, from deepwater drilling to enhanced recovery methods. As offshore assets mature and environmental regulations tighten, the decommissioning of aging platforms and wells has emerged as a critical challenge. Traditionally, decommissioning was a labor-intensive and high-risk process, but new technologies are revolutionizing how these operations are conducted—improving safety, reducing costs, and minimizing environmental impact.