Project Overview

The Orca FPSO, formerly FPSO Gato do Mato, is a new-build floating production, storage, and offloading (FPSO) vessel. It is an under-construction project by MODEC. Located in the Santos Basin, the vessel is designed to produce up to 120,000 barrels of oil per day and will be moored at approximately 2,000 m water depth using a SOFEC spread mooring system. Shell estimates recoverable resources at about 370 million barrels. 

Shell took the Final Investment Decision (FID) on 21 March 2025, with a consortium then comprising Shell (50%, operator), Ecopetrol (30%), and TotalEnergies (20%), and PPSA managing the production sharing contract. The project expects first oil production in 2029. 

Since FID, the ownership has shifted. TotalEnergies agreed to exchange its 20% for an additional 3% interest in the producing Lapa field, taking Shell to 70%. In February 2026, Shell signed an agreement to sell 20% to Kuwait Foreign Petroleum Exploration Company (KUFPEC), leaving Shell at 50%, Ecopetrol at 30%, and KUFPEC at 20%. 

MODEC is building the vessel on its first Next Generation Hull using a multi-yard model: the forward block at SHI-ME's Yokosuka yard in Japan and the aft block at COSCO Qidong in China, and the completed forward section departed Japan for integration in China in early July 2026.

Orca FPSO Project Location

The Orca FPSO Project is located in the pre-salt Santos Basin, offshore Brazil. It is situated approximately 200 km south of Rio de Janeiro state. It covers the Orca and Sul de Orca fields, formerly known as the Gato do Mato development. 

The project lies in deep to ultra-deep water, approximately 2,000 metres deep, and encompasses the BM-S-54 concession and the South Orca production-sharing contract area.

Project Background

The Orca Project combines two contiguous blocks in the Santos Basin pre-salt: BM-S-54, a concession contract Shell entered in 2005, and the Sul de Gato do Mato production-sharing agreement obtained in 2017. 

MODEC was awarded the Front-End Engineering Design (FEED) in March 2024. After FID on 21 March 2025, Shell signed a Purchase and Sale Agreement with MODEC for the FPSO, covering design of the hull and all topsides, with MODEC then operating and maintaining the vessel for 20 years. TechnipFMC was awarded the integrated EPCI subsea contract, worth more than USD 1 billion, at the same time. 

Orca FPSO Current Status

As of mid-2026, the vessel is under construction. The forward hull section left Japan in July. Shell reported construction over 50% complete and ahead of schedule, and ANP approved the development plan on 7 August 2026. 

The project targets first oil in 2029, with current priorities including completing FPSO construction, finalising the ownership transaction and advancing offshore drilling and installation activities. 

Project Stakeholders

Orca FPSO Project Cost

The total estimated cost for the Orca FPSO project is not disclosed officially. Shell’s announcement of the March 2025 Final Investment Decision (FID) confirmed the project scope, including the FPSO and 12 development wells, but did not state a total capital cost. 

Project Timeline

Design & Engineering Details

Conclusion

The Orca FPSO Project boosts Brazil’s deepwater pre-salt production capacity. Developed in the Santos Basin, the FPSO vessel is designed by MODEC, with an oil production capacity of 120,000 barrels of oil per day. The project has moved into the execution phase following Shell’s final investment decision, with FPSO construction progressing in China and Japan.

Upon its full completion, expected by 2029, the Orca FPSO Project will strengthen Brazil’s offshore oil output and support the long-term development of the Santos Basin’s pre-salt resources. The project’s progress will depend on the timely completion and integration of the FPSO, offshore installation, drilling, and regulatory activities. 

Track the Latest & Upcoming FPSO Projects In Brazil

Subscribe to our upcoming and ongoing FPSO Projects in Brazil with ease to access reliable, high-quality insights on forthcoming and completed Projects across the country.

Our user-friendly platform provides essential details, timely updates, key stakeholder contact information, and business opportunities tailored for engineering companies, industry professionals, investors, and government agencies.

Start a free demo to take your business to the next level.