How Shell is Using XR and Digital Twins to Transform Deepwater Operations

From Shell

In the Gulf of America, Shell is quietly transforming offshore oil and gas operations—not by building bigger platforms, but by thinking smarter and working virtually. From augmented reality (AR) headsets to digital twins and fully remote control rooms, Shell’s integration of immersive and digital technologies is redefining how deepwater assets are designed, built, and managed.

Smaller Crews, Smarter Tools

Shell’s newer platforms like Vito and Whale are designed to operate with a dramatically smaller personnel footprint—just 60 people onboard compared to more than 100 on older facilities. But less doesn’t mean less efficient. By equipping workers with tools like HoloLens AR headsets and intrinsically safe (Class 1, Division 2) iPads, Shell has turned these platforms into hubs of digital collaboration.

AR headsets make it possible for offshore workers to carry out inspections, maintenance, and troubleshooting while connected in real time with onshore experts. Live video feeds, overlaid schematics, and hands-free guidance turn every headset into a remote assistance device. In some cases, U.S. regulatory inspections that previously required time-consuming helicopter trips can now be performed virtually in minutes—with inspectors seeing exactly what the worker sees and even marking up visuals remotely.

Colin Muirhead, information digital technology manager for Shell’s Gulf of America assets, talked to the Journal of Petroleum Technology (JPT) about using headset-enabled remote inspections to save time and money. 

“It’s an inspection that takes 30 minutes to do, but it takes you a day to fly somebody out there and a helicopter flight. And then it’s a quick inspection, and then they leave,” he said. “We got some inspectors with BSEE (US Bureau of Safety and Environmental Enforcement) to start doing these remotely using HoloLens.”

For example, BSEE needed to inspect changes to the gas lift system at the Ursa platform, but weather was going to delay a trip to the facility by several days. Muirhead said, “They used the interactive capability of HoloLens to do this inspection,” which got the well back onstream right away. “For us, that’s hundreds of thousands of dollars in value and production that was unlocked because we were able to do that.”

Virtual Reality for Remote Startups

When Whale, Shell’s latest platform, came online in early 2025, it marked a milestone: the first time Shell started up a deepwater platform entirely from land. Engineers in downtown New Orleans—over 600 kilometers from the platform in the Gulf—brought Whale online from a control room that mirrors the platform. 

Thanks to always-on video connections, the team can oversee systems and ensure operations are running smoothly—without ever stepping onto a helicopter. Staff can carry out the same tasks they would if they were out at sea.

This remote-first model isn’t just about convenience. It lowers emissions, improves safety, and brings significant cost savings. Fewer flights and fewer people offshore mean a smaller carbon footprint and a safer, leaner operation.

“It is a game changer,” said Kimarie Michel, Whale’s senior operations manager. “I can have lunch in downtown New Orleans, and within minutes, I can be in the control room of a facility which is far out at sea. This saves time and money. It also reduces emissions.”

“By moving the control room to the shore, we have reduced the number of flights, reduced our carbon footprint, and saved money,” said Oro Awaritefe, the Whale project manager.

The Power of the Digital Twin

AR is only part of the story. Shell’s use of digital twins adds another layer of intelligence. These models, combined with live sensor data and engineering information, act as an operational cockpit for each platform. Workers can explore the twin to access real-time conditions, verify system changes, and even identify discrepancies between digital plans and physical assets.

In one case, an engineer discovered a mismatched valve configuration using the digital twin, avoiding potentially costly system damage. It’s the kind of value that’s hard to quantify until you realize the alternative is a multi-day offshore trip or a production delay worth hundreds of thousands of dollars.

Wireless sensors, now proliferating across Shell’s platforms, feed real-time pressure and flow data directly into these digital systems. 

At Ursa, offshore workers use to have to read and record pressure gauge data manually on their iPads. Muirhead told JPT, “That took somewhere in the realm of two hours to do the work, and that’s a person that has to spend time going and doing that.” Now, with wireless sensors on the pressure gauges, Shell has eliminated manual readings and the system alerts workers only when action is needed.

The result? Operators can focus their time where it matters most, not on routine checks.

A Blueprint for the Future

Shell’s approach isn’t just a technology demo—it’s a scalable, replicable model. Whale was designed similarly to Vito, and the upcoming Sparta platform will follow suit. Each is built smaller, smarter, and more digitally integrated than its predecessor. And these outcomes are a result of years of integrating AR and headsets into remote service and operations. 

Shell continues to invest in energy platforms, and the focus is clearly on doing more with less: less travel, less physical risk, fewer emissions—and a lot more innovation. These platforms are no longer isolated assets in the ocean. They’re extensions of onshore operations, connected by data, sensors, and immersive technologies that are changing offshore O&G production.

Playbook for Offshore Remote Operations

Shell’s success with XR, digital twins, and remote operations didn’t happen overnight—it’s thanks to years of strategic planning, pilot testing, and scalable deployment. If your organization is ready to take a similar leap, here’s a step-by-step guide to get started:

1. Start with a Pilot, Not a Platform

Before deploying across your fleet or field, select one asset or process for a low-risk pilot. This could be a maintenance procedure, inspection workflow, or startup sequence where remote support would reduce travel or safety exposure.

Action Step: Identify a single workflow that’s time-consuming, travel-heavy, or safety-critical—and assess how XR tools could enhance it.

2. Build Your XR Toolbox

Shell’s digital worker setup includes intrinsically safe AR headsets, tablets, wireless sensors, and cloud-based collaboration platforms. Not every tool needs to be deployed at once—start with what brings the quickest ROI.

Action Step: Choose one or two key technologies (e.g., headsets for remote inspections or integrated sensors) and trial them with a small team.

3. Create a Digital Twin Foundation

Digital twins are most powerful when connected to real-time data. Begin by mapping high-value equipment or processes and layering in live data streams.

Action Step: Work with OT/IT teams to model a core system (e.g., pumps, valves, compressors) and integrate sensor data.

4. Train Teams for the New Digital Workflow

The success of remote operations hinges on adoption. Ensure workers understand how and why to use XR devices and digital tools—especially when they replace traditional in-person tasks.

Action Step: Run a training program with realistic scenarios to help teams gain confidence in remote support and virtual collaboration tools. If you’re feeling fancy, the training itself could take place in VR.

5. Measure, Improve, Scale

Capture KPIs like reduced travel costs, inspection turnaround time, downtime avoided, decreases in safety incidents, or emissions reductions. Use this data to make the case for broader deployment across facilities.

Action Step: Set benchmarks for your pilot project, measure outcomes, and build a business case for expanding the program.

6. Design for the Future

As you upgrade or build new facilities, consider how to design with remote operations and digital workers in mind from the start. Smaller footprints, fewer people, and smarter systems can reduce emissions and operating costs long-term.

Action Step: Incorporate digital twin models and XR-enabled workflows into early-stage project planning for new assets.