A real-time understanding of the structural integrity of flexible risers is critical to avoiding failures as well as unnecessary and costly replacements. Accurate and efficient computation of tensile armor wire stress time-histories is the key to enabling the implementation of a flexible riser digital twin. Accuracy requires capturing the nonlinear kinematics of the flexible’s helically contra-wound tensile armor layers and their interaction with the other metallic and thermo-plastic layers in a dynamic simulation. While it is generally accepted that high-fidelity 3D finite element models best capture the complex kinematics required to produce accurate stresses, the main issue is that simulation time remains prohibitive, for example, a single bending cycle on modern day multi-core computers typically requires 24-48 hours. Therefore, any successful implementation of a flexible riser digital twin requires an accelerated solver capable of real-time computation of 1000s of bending cycle inputs into the high-fidelity finite element model. This paper demonstrates a flexible riser digital twin applications centered around the accelerated solver FLEXAS.

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