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How AS Norske Shell uses Kognitwin Energy and its dynamic workflow to be on top of all simultaneous operations

Doing a proper safe job analysis can be an extensive process. Combining Kognitwin Energy with its SIMOPS application, Shell managed the simultaneous operations in the Nyhamna facility and achieved improvements on collaboration and HSE.

Challenge

Coordinating all the activities on a large gas processing plant like Nyhamna is challenging and requires a deep understanding of potential consequences and interdependencies.  Many activities can be performed safely as a standalone action, but potentially cause catastrophic effects in combination with surrounding activities.

  • How do you identify and visualize the effects and danger zones of an activity with potentially falling objects? How do you adjust other activities within the fall zone?
  • What happens if suddenly need to flare? Do you need to stop any of your ongoing activities?
  • The weather changes: Do you need to adjust anything?
  • What if some of your activities are delayed? Are you then able to adjust dynamically to keep high productivity on your crew?
  • Where do you have blocked gas detectors because of e.g. scaffolding? Which activities do you need to stop if a different detector in the same area fails?

What is typically seen in real plants:

  • Personnel don’t pick up SIMOPS conflicts before they are to be activated in the field, and the customer may miss a full workday for a full crew or even worse.
  • Scaffolding is installed, demounted and re-installed at the same location within some very short timespans, even days.

When Shell decided to move towards Kognitwin Energy as their digital twin solution in Nyhamna, scaffolds were one of the largest OPEX contributors to this facility, and it represented substantial improvement opportunities on coordinating activities more efficiently.

About Nyhamna :

Large process facility in Aukra municipality in Møre and Romsdal - in operations since 2007. Initially built as a land facility for processing and exporting gas from the Shell operated Ormen Lange field. After a significant upgrade, the plant is able to process gas from other fields in the Norwegian Sea connected to the Polarled pipeline. Now a hub for gas processing, Nyhamna exports gas to UK and continental Europe through the Langeled pipeline.

Nyhamna is owned by Nyhamna Joint Venture: Petoro, Equinor, Cape Omega, A/S Norske Shell, Ineos, Wintershall, OMV, Total, ConocoPhillips and North Sea Infrastructure. Gassco is the operator, and A/S Norske Shell is the technical service provider for Nyhamna.

Solution

Through the Kognitwin Energy web interface, all relevant personnel in Nyhamna now have access to data and visualizations to build the situational awareness they need. Work permits, work orders, deviations and notifications are collected from their respective source systems and contextualized.  Their location is then visualized in the 3D model, and potential conflicts are highlighted. Users can easily group disciplines or system numbers according to the required criteria, like geographical site areas, for example.

With flexible time filtering, it became easier to get a better understanding of the optimal timeline for the activities that need attention in terms of simultaneous operations.

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Impact

Since implementing Kognitwin Energy, Nymhana achieved improvements in different aspects, that includes:

  • Increased HSSE performance,
  • Reduction and prevention of unforeseen conflicts that would stop activities in the field,
  • Installations utilization - like scaffolds – ensured for future activities in the same area,
  • Easier grouping and timeline management of activities in the same geographical area, and
  • Easy accessibility of all data from various data sources in the same system, breaking down the silos - e.g. understanding how information from the standalone deviation system will affect the work planning you normally do in your ERP system.