Shell chose the Pulau Bukom site to pilot the Digital Twin, because of its location as an integrated oil and petrochemical hub in Asia Pacific, a strong track record in piloting path breaking digitalisation projects, and its long history. Large amounts of data from the 59-year-old site will be mapped into the Digital Twin’s processor for stronger machine learning. It will be possible for site employees to do their jobs remotely, using AR and VR technologies. While a full rollout across the island is expected in four years, as the workforce capabilities and digital assets mature; this is expected to result in approximately 25% improvements in productivity, reliability and safety. By 2025, all critical field operations at Pulau Bukom will be performed through tablets.
Digital Twin will be a complete virtual representation of the physical elements on site and be able to respond dynamically to conditions based on data from over 20 different technology platforms. The technology that Shell’s Pulau Bukom site will pilot provides many advantages in the industry. Live information of the plant operations can be provided to engineers via augmented reality (AR) and virtual reality (VR), reducing the need to step into the plant. In addition to this, when troubleshooting an issue, various options can be tested in real-time on the virtual platform, before deciding on a solution. Besides improving operational efficiency, this prevents downtime, reduces maintenance costs and allows effective real time collaboration between experts and operators. When fully implemented, the manufacturing site will be safer, more competitive and innovative, delivering new levels of efficiency, safety standards and plant intelligence.
Vice President Manufacturing Singapore/Philippines and General Manager of Pulau Bukom Manufacturing site, Hugues Bourgogne told that they combine human capabilities with advanced digitalisation technologies, to truly transform the ways we work. Stating that in this way, they are committed to making their Singapore sites on Bukom and Jurong Island globally competitive, Bourgogne said; “The launch of the Digital Twin technology is a strong testimony of how we are implementing potentially ground-breaking solutions in a traditional environment to improve productivity and efficiency safely”.
We are building a new digital culture
Projects and Engineering Manager, Narayanan Valayaputtur explained that Shell Bukom’s digitalisation plans; anchored by the Digital Twin, is a shakeup of the plant. Valayaputtur said; “With the setup of a virtual plant through the Digital Twin, and by equipping staff on site with a tablet; we are creating a new culture of allowing work to be done remotely; with the provision of complex data at their fingertips. This is an exciting time as we are not just building digital assets; but also a new digital culture,” and continued his words; “We are telling our staff to pursue their interest of coding applications to make their jobs easier; to think about becoming data scientists or software engineers; all while working in a manufacturing plant with our playground of data”.
It will help Singapore’s digital transformation
At the same time, this move is aligned with the Singapore government’s focus on Industry 4.0. Executive Vice President, EDB (Economic Development Board), Damian Chan said; “We are encouraged that Shell has taken this bold step of piloting the “Digital Twin” solution in Singapore; setting a strong example of how the Energy and Chemicals sector can adopt technology to move towards Industry 4.0 standards”. Noted that Shell’s holistic approach of investing in digital processes, technologies and training to support the workforce is timely; especially with the acceleration of digitalisation in established industries today; Chan told it would help advance Singapore’s push for digital transformation across sectors.