Transforming Heavy Assets: Shell’s Digital Journey with Digital Twin and AI Technology

Digital twins are used by thousands of experts on many of the company’s heavy assets.

At the Tomorrow Show the conversation around the energy sector's evolution was electrifying. As the industry grapples with climate change and surging demand for sustainable solutions, one thing that really stood out was how Shell’s visionary approach to digital transformation is redefining how heavy asset industries operate.

Through strategic partnerships and groundbreaking technologies like digital twins, the company is setting new benchmarks in safety, efficiency, and innovation.

Learn how an AI-embedded digital twin is helping heavy asset industries improve their operations

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Safety as the Cornerstone of Innovation

At Shell, safety isn't just a priority, it’s a core value driving every technological decision. According to Karina Hernandez, General Manager of Emerging Digital Technologies at Shell, maintaining a strong safety framework while pushing for greater automation is non-negotiable.

Partnering with companies like Kongsberg Digital is integral to Shell’s approach. By leveraging innovative solutions, operational reliability is enhanced while ensuring safety and efficiency coexist seamlessly.

Shell’s adoption of digital twins is impressive. With thousands of active users leveraging this technology across several heavy assets, the results speak for themselves:

The deployments have transformed operations, simplified data management and enhanced safety by addressing unstructured data challenges. Real-time access to critical information has improved decision-making and situational awareness, creating a safer, more reliable operational environment.

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Scaling AI for Maximum Impact

Shell is not just deploying AI; it’s scaling AI for success. Identifying the right use cases, those that deliver measurable, repeatable results is key.

Proven use cases include:

• Predictive maintenance: Thousands of models are driving proactive repairs, reducing downtime, and optimising reliability.
• Production optimisation: Real-time AI solutions are enhancing efficiency across multiple LNG trains, setting a standard for operational excellence.
• Tackling Corrosion Under Insulation (CUI): In harsh environments, corrosion under insulation (CUI) poses a significant challenge. Traditional inspections are costly and time-intensive, requiring insulation removal and coordination across teams.

By implementing a minimum viable product (MVP) that streamlines CUI inspection workflows, engineers can now access real-time data, gaining situational awareness that ultimately enhances asset integrity and operational reliability.

Shell's partnership with Kongsberg Digital is more than a collaboration; it’s a blueprint for the future of energy. Together, we are creating a sustainable, technology-driven energy landscape where digital transformation isn’t a goal—it’s a reality.
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