Case Study – Improving Oil Extraction and Workspace Safety Via Digital Twin Genie

Privacy Policy: Some sensitive information that is directly related to the client itself will be purposefully excluded from this summary in order not to jeopardize the privacy of our clients and/or partners that chose to work with the team of Challenge Advisory. The specific information that will be held private will include the names of the companies and its employees (if requested) and all other sensitive details regarding new projects or product releases.


  • Utilizing the Digital Twin Genie software to enhance oil rig performance by reducing downtime and improving monitoring

  • Eliminating failure conditions from the client’s workplace environment to maximize employee safety


The Challenges:

In order to maximize efficiency and get a faster return on investment that would stabilize long-term, the company we’ve worked with has acquired 7 extra oil rigs that were installed on the 3rd of March, 2019. However, due to the increased number of machinery that took an immense amount of investment to acquire, their annual capital funds were nearly depleted. The 7 extra pieces of machinery that were are responsible for extracting 1500 barrels of oil per day soon required an extra of 14 new workers that could monitor the performance. The manual efforts of supervising machinery of such complexity were not cost-efficient enough for the company to become suitable for expansion, thus Digital Twin Genie was introduced as a plausible solution for this. The objectives were set as follows:


  • Reduce the downtime of all 28 oil rigs down to 19%
  • Replace their manual oil rig monitoring procedures to a digitally-centered approach
  • Maximize worker safety by twinning their workplace environment


Our Strategy and Plan of Action:

The entire project took 17 days to implement including the timeframe Digital Twin Genie needed to accumulate performance data.

  1. After delivering the specifically designed development kit of our software, the sensors (mainly motion and proximity) were incorporated
  2. The process of data aggregation and accumulation has been initiated 24h after the sensors were deployed
  3. By digitally twinning all oil rig equipment, engineers had 24/7 visual access to their machinery’s performance metrics
  4. Motion sensors were accompanied by friction/damage sensors which were installed to monitor downtime
  5. The site in which oil was extracted in was fully built digitally using digital twinning
  6. By using shared intelligence, all 28 oil rigs were connected to one central dashboard on Digital Twin Genie
  7. Full visuals were established by collecting digital twin data that tracked oil rig performance – real-time accuracy = 0.4578 seconds


Results and outcomes:

By gaining full transparency on the workflow of the environment and the oil rigs themselves, the friction monitors were able to send feedback to the centralized Digital Twin Genie software. This allowed the engineers to monitor all virtual counterparts of the 28 oil rigs in a group, excluding each rig and identifying key failure points individually if needed. This amount of leverage produced the following results:

  1. Average downtime of all 28 oil rigs = 3%
  2. All digital twins of the oil rigs were controlled in a virtual environment that is located on 1 digital platform = full clarity was achieved
  3. The number of annual accidents experienced a decrease of 31% due to the enhanced supervision Digital Twin Genie provided

More information