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In 2016, plans were being finalized for one of the most ambitious capital projects the world had ever seen. While this was rightfully a cause for celebration due to the jobs this would create and the resulting economic boon that would come thereafter, it would be fool-hardy to dive into such a vast project without the correct planning or tools.
Capital projects are a lengthy and expensive process – and the management of one is notoriously tricky to underpin.
That is, until, iHawk came in.
In June 2016, Shell made the decision to construct a world-scale
petrochemicals manufacturing plant near Pittsburgh, Pennsylvania, USA.
The plant will consist of an ethylene cracker and three polyethylene
derivatives units. In November 2017, they completed extensive site
preparation and the multi-billion-dollar project entered its main
construction phase.
The facility is being built on the banks of
the Ohio River in Potter Township, Beaver County, about 50 kilometers
(30 miles) north-west of Pittsburgh. The plant is strategically
positioned close to both feedstock and the customer base. More than 70%
of the North American industrial polyethylene demand originates in the
North-East, within a 1,100 kilometer (700-mile) radius of Pittsburgh –
this means that the plant’s Pennsylvania location offers customers a
short, dependable supply chain.
The project’s scale is
impressive with 300 miles of pipe, more than 1,600 items of manufactured
equipment (the largest lift – 1,400 metric tons) and 294 pre-assembled
modules. The construction workforce reached its peak in 2019 and into
early 2020 with up to 8,500 workers on site, including more than 30
contracting companies.
Due to the intense level of construction activity, careful planning
and continuous information sharing were critical to maintaining project
schedules. We knew that managing Pennsylvania’s largest construction
project for decades demanded a new way of working with a groundbreaking set of tools.
An
innovative new digital approach was the answer to managing that
informational flow in this vast construction project; that way
stakeholders could make informed decisions, develop and adjust execution
plans, stay on top of progress and costs, ensure quality and, above
all, keep people safe. The team sought to contextualize multiple layers
of information in an interactive, map-based platform taking the
digitalization to the next level, enabling full progress visibility,
operational efficiency and stakeholder communication at all levels.
Interested to learn how iHawk can support your project?
Download your free capital projects capabilities overview pack now!
In 2017 Shell Polymers selected Cyberhawk’s iHawk – Cyberhawk’s capital project management software
– to use as the foundational tool for managing their construction site.
The two companies started to collaborate to develop a set of unique,
differentiating capabilities to meet a wide range of challenges that the
project team was facing.
iHawk, a cloud-based, IoT-enabled
visualization interface, enables a community of 700 active users from
Shell and 40+ execution contractors to work off the same baseline – in
the office, in the field on mobile devices and remotely. 45 interactive,
touch-enabled screens have been deployed around the construction and in
the future operation team’s offices, in meeting rooms and to
collaboration areas. Everyone on the team has a direct, on the spot
access to iHawk. The easily accessible smart screens foster
collaboration and teamwork and have made iHawk an integral part of all
planning and coordination meetings on the construction project.
Today,
iHawk combines visual data gathered by the UAVs (drones), ground 360
cameras with data from a myriad of field sensors and IoT devices
enabling real-time equipment location tracking and performance
monitoring, locating construction materials across five laydown areas
using RFID technology and more into a single visual interface for site
planners, contractors and executives. According to the Shell IT director
on the project:
“iHawk has become an inseparable part of
what we do, it is now part of the landscape for Pennsylvania Chemicals
and for all future Shell projects.”
Visual data management is not limited to drone imagery. Site inspection imagery, for example, taken in large volumes by quality inspectors and construction engineers, is notoriously difficult to gather, catalog and manage centrally. On this project, Shell and Cyberhawk developed a simple self-service workflow for this kind of content to be captured, uploaded, linked to an equipment tag and assigned keywords in a few clicks, or screen taps on a mobile device. The images can then be instantly shared across the construction project team, for example, to report the need for remediation action.
The Site Master Plan module was developed in response to the needs of the main EPC contractor managing the site. The joint owner and EPC project management team relies on the high-resolution GIS data, developed from drone imagery and enriched with layers of contextualized information, to plan heavy equipment moves and oversized deliveries, organize equipment staging and to manage congested laydown area space across the busy 380-acre construction site.
Historically difficult to manage offline with Gannt charts, space planning clashes and constraints can be instantly detected and resolved in a visual domain. The ability to assign a physical area for a specific task and purpose, assign a responsible individual and publish this information to the stakeholders, is crucial. Not only does iHawk put hundreds of real estate assignments on the timeline and make them visible to everyone on the team, but it also helps to drive personal accountability for the success of every task.
The team uses iHawk to track the position and usage of construction equipment – in this case, the dozens of heavy cranes deployed across the site by seamlessly integrating industry-leading IoT solutions.
The cranes are fitted with vibration sensors that report uptime and other telemetry data, which is aggregated in iHawk for interpretation and analysis, helping the area managers to derive the most value from the investment in the equipment.
Interested to learn how iHawk can support your project?
Download your free capital projects capabilities overview pack now!
The collection of site imagery captured over time by 360-degree
ground cameras and by drones has contributed to countless progress and
cost reviews with the major contractors and subcontractors, making them
factual, evidence-based and ultimately transparent and fair.
iHawk
empowers cross-functional teams to hold each other accountable every
day, generating significant value. The monthly cumulative usage of the
portal approaches 10,000 hours, exceeding the most optimistic targets
and expectations. It is estimated, that every hour of iHawk’s usage
translates in the equivalent, often even greater, efficiency gains in
the field.
The FindAll module was developed to address one of the
most significant challenges inherent to large, complex projects –
finding the relevant information quickly. FindAll reaches across
multiple databases and information sources, historically disparate, to
locate and retrieve engineering, procurement, construction and
commissioning documentation and data, up to 90% quicker than some of the
traditional methods and tools, saving 3-5 minutes per search. Up to
50,000 searches are performed each month.
“Since the introduction of iHawk
to the project, we have seen an exponential increase in the usage of the
GIS information across critical execution activities such as field
engineering, site coordination, environmental monitoring, construction
management and workforce planning, materials management and many others.
iHawk
has enabled a digital revolution across the owner’s team and the
contractor community. We see iHawk as a tool that offers opportunities
for safety improvements through increased efficiency and improved
visualization prior to work activities."
If you would like to learn more about iHawk and want to speak with one of our experts, you can get in touch here.