Breakthrough in powertrain innovation.

University College London's (UCL) HyperMile Racing Team proudly announces a pioneering advancement in automotive technology aimed at revolutionising efficiency in the Shell Eco-Marathon. Harnessing the power of Sensor Technology's TorqSense rotary torque transducer, the team has developed an innovative powertrain system poised to redefine performance standards in the eco-racing sphere.

UCL's HyperMile Racing Team, known for its dedication to pushing the boundaries of sustainable transportation, has partnered with Sensor Technology to integrate cutting-edge torque measurement capabilities into their vehicle design. This collaboration has resulted in the creation of a highly efficient powertrain system meticulously engineered to maximise energy utilisation and minimise waste.

The use of Sensor Technology's TorqSense transducer provides the team with real-time insights into the performance dynamics of their vehicle, enabling precise adjustments to optimise efficiency on the track. By leveraging this advanced sensor technology, UCL's HyperMile Racing Team aims to achieve unprecedented levels of fuel efficiency and endurance in the upcoming Shell Eco-Marathon.

"We are thrilled to unveil our latest innovation in collaboration with Sensor Technology," says Bartol Vahcic, Technical Director of UCL's HyperMile Racing Team. "By integrating the TorqSense transducer into testing our powertrain system, we are confident that we can push the boundaries of eco-racing and set new benchmarks for sustainability and performance." 

The Shell Eco-Marathon serves as the ultimate proving ground for innovations in energy efficiency, attracting top engineering talent from around the world. With the introduction of their groundbreaking powertrain system, UCL's HyperMile Racing Team aims to make a significant impact on the future of sustainable transportation and inspire the next generation of eco-minded engineers.

This years competition takes place on May 22nd -24th at Circuit Paul Armagnac, Nogaro, (F), and Sensor Technology will be willing the UCL team on.

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Virtual real world torque measurement!

Student engineers are using a newly launched torque sensor for predicting the energy efficiency of a competition-grade electric car.

Young technologists from the University of Sheffield alleviated their disappointment at the Covid-cancellation of Shell Eco Challenge Rally by instead developing a computer simulation tool for predicting electric cars’ energy efficiency.

The university has a long association with the Shell Eco Challenge, in which student teams from around Europe compete to see whose car electric will cover the greatest distance on a single charge. So, when Covid shut down the event, rather than abandon their efforts Team Sheffield shifted their focus and set about a related project.

“We have been developing our own computer simulation tools for predicting our electric vehicle’s (EV’s) energy efficiency,” says student Lucy Edwards. “This has let us calculate our vehicle’s competition score for the 40 minute/15km competition run.”

To put the competition into context, Shell Eco EVs achieve upwards of 800 km/kWh, whereas the EVs on the road today may achieve only 15 km/kWh (at the same 25 kph). The competition EV are of course ultra lightweight, very aerodynamic single seaters and the drivers chosen by weight, whereas their road-going counterparts are better adapted for say a family day out. However, the competition demonstrates the potential of electric propulsion and, over the years, has undoubtedly helped development of the technology.

Sheffield’s involvement is extra-curricular but provides a great opportunity for the students to apply what they have learnt in lectures in a practical context.

To build the simulation tool, the students used their knowledge of engineering theory to create a mathematical representation of all the energy losses present in the car. A key piece of data was the motor efficiency curves, which were derives using a dual-purpose powertrain test rig and motor dynamometer. This was developed in-house and based around a TorqSense SGR521, the latest product from from Sensor Technology Ltd.

In fact, Sensor Technology is a regular supporter of Shell Eco Challengers; over the years it has supported several teams from mainland Europe and now one from Britain. “The student teams basically need to run lots of tests on their drive motors and map out the results,” explains Mark Ingham of the company. “As such they are really no different from motor test engineers the world over.

“We are far and away the most active supplier of torque measuring technology and expertise to the Eco Challenge. It is very gratifying to know we give young engineers at the start of their careers a solid grounding in such an important subject, which they will be calling on for decades to come.”

Like their professional counterparts, the young engineers tend to want to develop a test rig that is accurate and easy to use. Usually, they also have space and time constraints, so want a compact design which is quick and easy to set up for each test.

“Our new SGR510/520 range fulfils all these requirements,” says Mark. “It’s only been on the market for a couple of months but is already proving itself to be a favourite in EV test labs around the world – and that is a rapidly growing market at the moment.”

For the Shell Eco Challenge, teams across Europe have to design and build their own electric cars and motor controllers in-house. Typically, powertrains are based on either a brushless DC, or PMSM motor - and complex control algorithms are needed for precision control. This requires custom electronics, typically based on MOSFETs and other carefully chosen low power loss components.

In fact, the rules of the Challenge are such that the controller is included in the motor testing that is done on each teams’ entry. In effect, the capabilities of each piece of hardware are quantified so that the teams can see how they compare with each other.

Lucy sums up the team’s year: “With the tools and hardware we have developed we have posted competitive competition scores. Of course, we are all hoping that soon Covid restrictions allow us to meet our competitors face to face and compete car against car. That will be real world engineering at its best.”

@sensortech @shell_ecomar @sheffielduni #Education  #Transport 

Passively-cooled cabinets protect instrumentation on world’s largest vessel!

High performance environmental protection cabinets for Shell’s ‘Prelude’ floating liquefied natural gas project are being supplied by Intertec. Designed specifically for extended service life in hazardous areas, the shelters incorporate innovative semi-passive cooling technology and are some of the most stringently specified instrumentation protection solutions that Intertec has ever produced.

Shell’s Prelude floating liquefied natural gas (FLNG) project is setting new engineering records. Designed to liquefy natural gas extracted from subsea wells by chilling it to -162 degrees Celsius, and to then store the liquid until it is offloaded to large LNG carriers, the vessel will be the largest in the world, with a length of 488 metres and a width of 74 metres. The hull of the vessel was constructed in South Korea and launched in December 2013. Due to enter service in 2017, the vessel will be towed to the Prelude and Concerto gas fields in the Browse Basin near Timor, about 200 km off the northwest coast of Australia, where it will be permanently anchored for about 25 years. After this time it will be inspected, overhauled and possibly moved to a new location, where it will be expected to provide a further 25 years of service.

Much of the on-line process analysis instrumentation on the Prelude FLNG vessel will be housed in purpose-built environmental protection cabinets supplied by Intertec. In total, the company is supplying 90 cabinets for sample conditioning systems and 30 cabinets for process analyzers, each designed to match the instrumentation content and layout precisely in order to optimise thermal performance.

As Intertec’s Commercial Director, Hans Geiger, points out, “Only three of the 120 cabinets that Intertec is supplying for this project are the same size. Our specialised design and automated manufacturing capabilities enable us to produce custom environmental protection products very easily, to optimise performance and match the space available on demanding applications like this.”

The cabinets are required to be capable of withstanding severe Category 5 tropical cyclones with wind speeds in excess of 252 km/h (157 mph) and to have a minimum service life of 25 years - with 50 years as a design aim. Additional requirements include a high degree of resistance to corrosion being caused by the saline environment and the presence of sour or acid gas, and the ability to cool electronics equipment without using explosion-proof air conditioning systems, which incur high capital and operating costs.

These environmental protection cabinets are constructed from a proprietary composite material comprising sandwich walls of long-fibre glass reinforced polyester (GRP) sheets, enclosing a core of polyurethane foam. The material has a similar strength to that of stainless steel but is about four times lighter, making it ideal for use on offshore platforms and floating structures, where every effort is made to minimise weight.

Other advantages include a very low thermal conductivity which facilitates the construction of efficient, condensation-free cooling cabinets, and an inherently high resistance to corrosion caused by salt or aggressive chemicals such as sulphur or chlorine. For this project, the external surfaces of the cabinets are further protected by a thick layer of UV-resistant gel coat. In order to meet the application’s high wind speed requirements, each cabinet is equipped with special built-in mountings – which are external to the thermally insulated parts of the enclosure – to secure the top and base to Prelude’s deck structure. All external metal components are fabricated from 316 stainless steel with a corrosion-resistant protective coating that is specified for ship use.

Each of the 120 Intertec cabinets incorporates a unique form of semi-passive cooling technology. The internal face of the cabinets' rear walls are fitted with a high efficiency heat exchanger, comprising one or more aluminium cooling plates and stainless steel coolant pipes connected to Prelude’s cold water supply system, which obtains ‘cold’ water from the deep sea by a 150 m long pipe below the vessel. Heat dissipated by the equipment in the cabinets is absorbed by the water and transferred to the vessel’s main water cooling system, where it is dissipated to the environment. The size of each cabinet depends on the power dissipation of the contained sample conditioning or process analyzer system, which ranges from 140 W to 900 W.

This form of distributed cooling has enormous technical and economic advantages, especially in hazardous areas or where space and weight is at a premium. It provides a very efficient means of removing heat from the cabinets without requiring local air conditioning systems, which would necessarily need to be explosion proof – and therefore expensive. Furthermore, transferring heat from individual air conditioners of below-deck cabinet installations to the ambient environment would be a major challenge and involve significant amounts of space-consuming air ducting. The semi-passive cooling system is inherently safe for use in a hazardous environment; at the cabinet level it requires little or no electrical power of its own and is virtually maintenance-free, making it ideal for long life-cycle applications.

The intended operating environment for Shell’s Prelude FLNG vessel poses significant instrumentation protection challenges. The Browse Basin is very close to the Equator, which means that it has a tropical climate with an average temperature of about 32 degrees Celsius. This moist and hot environment, combined with a salt-laden atmosphere, is highly conducive to rust formation, making non-metallic protection cabinets a sensible design choice. In some of Prelude’s more confined spaces, the ambient temperature could reach more than 50 degrees Celsius. Even under these extreme conditions, all of the passively-cooled cabinets that Intertec is producing for the project are designed to keep their internal air temperature below 35 degrees Celsius

Single source supplier for the provision of instrumentation products

Shell's Enterprise Framework Agreement with Parker Hannifin covers the supply of instrument tubing fittings, manifolds, valves, process-to-instrument valves and related products

Parker Hannifin Corporation has signed an Enterprise Framework Agreement (EFA) with Shell as a single source supplier for the provision of instrumentation valves, manifolds, process-to-instrument valves, fittings, tubing, protective enclosures and related products. Under the terms of Shell's EFA - which runs for an initial period of five years - Parker's Instrumentation Group will supply Shell and its affiliates worldwide with a broad range of process instrumentation products.


"We are delighted to win this contract with such a major player in the oil and gas business, and are confident that our manufacturing resources on three continents and our global Parker Sales Company support network will meet the enormous challenges of this supply agreement", says Ian Huggins, General Manager of Parker Hannifin's Instrumentation Products Division in Europe. "We are also excited with the prospect of closer engineering cooperation, as this will give us a front row view of emerging technical challenges in critical application areas."


"We see this agreement marking the start of a sustained period of progress in instrumentation technology", adds Sheldon Banks, EMEA Sales and Marketing Manager of Parker Hannifin Instrumentation Products Division in Europe. "We believe that such a cooperative relationship between major players in their respective spheres will help to establish many new standards for performance, safety and cost reduction."

Over the last decade, Parker has invested heavily in innovation, and has made many significant advances in areas including safety, speed of installation and maintenance, and lowering emissions. In particular, Parker's new products can dramatically reduce the number of potential leak paths in a fluid flow system, and improve ergonomics for instrumentation and maintenance engineers. Its core values of 'faster, smarter, cleaner, safer' capture the company's goal of leadership in the process instrumentation market.

Also important is Parker's long experience in designing and manufacturing instrumentation using specialized alloys that optimize protection against corrosion - a major problem for many current oil and gas projects.

The Instrumentation Group is dedicated to being the global leader in the design, manufacture and distribution of high quality, critical flow and ultra-high purity components for the petrochemical, chemical processing, oil and gas, power generation, water analysis, biopharmaceutical, semiconductor, and analytical equipment industries.

Technology agreement

Rigorous simulation and optimisation to help achieve real-time operational excellence!

Invensys Operations Management has signed a multi-year, multi-million dollar contract to deliver comprehensive software solutions and services for Shell.

Under a new Corporate Enterprise License, Invensys will provide a suite of its SimSci-Esscor® simulation solutions to improve Shell’s global upstream, downstream and petrochemicals production, helping it to achieve operational excellence. A critical part of the agreement will be Invensys’ ROMeo® solution, an integrated software platform for simulation, data reconciliation, optimisation and operations decision support. Invensys will also supply its PRO/II®, PIPEPHASE® and DYNSIM® software, along with several other software solutions, training and support services. The Corporate Enterprise agreement allows Shell access to Invensys software packages on a global basis within Shell’s IT infrastructure, enabling enhanced use of simulation software across all Shell business units.

“Shell needed cost-effective, flexible access to our open simulation and optimisation software across its global organisation without any restrictions,” said Tobias Scheele, vice president, advanced applications, Invensys Operations Management. “We have been working with Shell and providing them service and solutions for more than 30 years. This Corporate Enterprise License strengthens our long-standing relationship with Shell. Shell will use our SimSci-Esscor ROMeo optimisation software and our other family of simulation and modeling solutions to deliver increased value around the globe, helping them to achieve operational excellence in real time.”  

Invensys Operations Management’s ROMeo software provides a leading unified modeling environment for off-line and on-line optimisation. In use at dozens of upstream facilities, refineries, petrochemical and chemical plants worldwide, the software supplies a scalable environment for optimising all major units, as well as other aspects of plant profitability, such as utilities and instrument/equipment performance. Additional benefits are derived from leveraging the rigorous predictive models to enhance planning and scheduling decisions, leading to increased margins.

New flowmeter developed

Shell and Krohne signed an agreement to commercialise a new multiphase flowmeter based on the Magnetic Resonance principle for oil and gas field installations. The agreement comprises the manufacturing, marketing and sales of the new meter which was developed through an R&D collaboration between Shell and magnetic resonance specialist Spinlock. The aim is to bring the first generation flow meter into operation in 2012.

The Magnetic Resonance (MR) principle is based on strong permanent magnets, excitating the medium particles to oscillate and measuring the resonance frequency. Krohne is the first manufacturer to implement this measurement principle in an inline multiphase flow meter for use in oil and gas field applications, allowing to measure both gas and liquid flow phases simultaneously. The most important field of application for this type of flow meter will be the measurement of crude oil directly at the well where it is basically a mixture of oil, natural gas and water. The application of a MR flow meter will give oil companies major cost reduction.

“Leveraging enhanced and more cost-effective multi-phase metering solutions in our operations is a priority area for Shell. With Krohne we have found a recognized partner to commercialize this exciting technology” said Jeroen Regtien, Vice-President Hydrocarbon Recovery Technologies.

“This new and highly innovative measuring principle fits perfectly in the KROHNE culture and is a strategic addition to the existing product portfolio“ said Stephan Neuburger, Managing Director of the Krohne group.

Successful evaluation for automation system

ABB System 800xA receives technical approval for use by Shell

ABB's Extended Automation System 800xA has successfully passed an extensive technical evaluation by Shell Global Solutions, for potential future use in the oil company’s projects worldwide without further technical review. Shell tested the System 800xA core system, as well as its integrated System 800xA High Integrity SIS. (Safety Instrumented System)

Shell Global Solutions provides technical and operational support to Shell, which produces around 3.5 million barrels of oil equivalent a day and is active in more than 130 countries and territories worldwide.

The rigorous technical assessment process takes almost one year, and documents the product’s ability to perform against Shell’s detailed technical specifications. It also examines the system supplier’s project execution capabilities. As a result of the evaluation, ABB has been approved for use in Shell as a MAC/DCS supplier for System 800xA and System 800xA High Integrity (SIS).

 “ABB’s System 800xA performed very well in wide range of simulated operating conditions during our assessment,” commented Audun Gjerde from Shell Global Solutions. “We found that it can integrate multiple systems and processes, while maintaining a high level of system security and process safety.”

Shell’s evaluation noted several strengths for System 800xA, including its ability to integrate process and power automation on a single platform with related integration and control of IEC61850 devices. This capability further enhances System 800xA’s fully integrated power management capability, and the ability to remotely access and control switchgear. This capability reduces commissioning time, while allowing for faster online modifications during operation.

System 800xA’s ability to integrate multiple control and other plant systems, to enable control of several plants from one central location, was another key capability cited in the evaluation. Integral asset monitors provide constant visibility to the operations personnel, thereby reducing downtime through the use of intelligent field and electrical devices. One of the major advantages of this capability is the reduced cost associated with reduced maintenance schedules.

System 800xA’s engineering tools were also noted as a unique strength. These tools promote consistency, reuse and redeployment of engineering configurations and strategies across numerous projects, as well as maintainability of delivered systems throughout the entire lifecycle.

ABB’s Process Automation division delivers integrated automation solutions for control, plant optimisation, and industry-specific application knowledge and services to help process industry customers worldwide improve their energy efficiency and meet their critical business needs in the areas of operational profitability, capital productivity, risk management and global responsibility. These industries include oil and gas, power, chemicals and pharmaceuticals, pulp and paper, metals, minerals, cement, marine and turbocharging.

Automation in LNG facility

Emerson selected as main automation contractor for Shell floating LNG facility

Shell's floating LNG concept!

Emerson Process Management has been appointed by Technip Samsung Consortium to serve as Main Automation Contractor for the Shell “Prelude” project, which will potentially be the world’s first Floating LNG (liquefied natural gas) development. Emerson Process Management was selected by Technip Samsung Consortium due to its Global Framework Agreement with Shell, announced in February 2010. This is the first project award for Emerson Process Management resulting from this Agreement.

Supporting Technip Samsung Consortium, the project’s overall front end engineering and design contractor, Emerson will be responsible for providing the strategy, design, and engineering of the process control and monitoring technologies to support the production facility.

Floating LNG unlocks gas reserves that would otherwise be stranded as they might be too far offshore. It is the next step in LNG production, which eliminates the need for transportation pipelines of gas to shore and onshore processing. The new production facility will operate as an integrated extraction, gas processing, and liquefaction plant, all directly above the gas reserves.

With rich experience in offshore production and project execution, plus global leadership in LNG automation, Emerson is perfectly positioned to support Shell’s goals for the initial construction project and long-term operational success.

“We are thrilled to support Shell’s vision for Floating LNG production,” said Steve Sonnenberg, president, Emerson Process Management. “Emerson’s track record of successfully delivering innovative projects like this suits us well for the challenge.”

The Shell Floating LNG facility is expected to have dimensions of 480 metres in length by 75 metres in width, a production capacity of 3.5 million to 4 million tonnes of LNG per year, and the ability to also process and export liquefied petroleum gas and condensate depending on gas composition. When fully ballasted, the vessel will weigh an estimated 600,000 tonnes. It will also have the flexibility to relocate to another gas field once production at one gas field is complete.

The Floating LNG project is located in the remote Browse Basin off the coast of Western Australia. The project is currently in the engineering and design phase of development and subject to a final investment decision.

Worldwide alliance in automation

Yokogawa Electric Corporation has been selected by Shell as a main automation contractor (MAC) for integrated production control and safety instrumented systems, and that the two companies have signed a Global Framework Agreement (GFA).

Starting in 2009, Shell has worked to reduce the number of equipment and systems suppliers for its plants, and has assessed and narrowed down the list of contractors that it works with in the control systems field. Thanks to its outstanding delivery record to Shell, highly reputed technologies, and strong health, safety, security, and environment (HSSE) policy, Yokogawa
was chosen to be one of Shell's main suppliers. The contract includes ongoing maintenance of systems and the supply of new systems for both brownfield and greenfield projects. The agreement brings advantages to both companies by improving the efficiency of the activities undertaken by buyer and supplier. The move is part of Shell's initiative to achieve top quartile performance across categories in support of its "More Upstream, Profitable Downstream" strategy.

Nick Curley, Shell's Upstream Automation Portfolio Manager, says, "This GFA marks a completely new approach within Shell: this is a long term, competitive, collaborative, and performance based relationship that will facilitate the delivery of value to both parties."

With this agreement, Yokogawa has successfully strengthened its partnership with the Shell Group and its business with the Group will increase. Encouraged by this contract, Yokogawa will expand its control business worldwide.

Agreement for technologies & services!

Emerson Process Management has entered into a 5-year Global Framework Agreement (GFA) with Shell to serve as a Main Automation Contractor (MAC) on future capital projects globally.

Under the Agreement, Emerson will provide project and support services for Main Automation Systems, including Distributed Control Systems (DCS) and Safety Instrumented Systems. The contract also provides for ongoing maintenance of existing systems, plus the supply of new systems for Brownfield and Greenfield facilities. While Shell has utilised a MAC strategy in its Downstream businesses for years, the Company is expanding the concept to make it a centre-point of an enterprise-wide automation strategy.

“This Global Framework Agreement marks a completely new approach within Shell,” said Nick Curley, upstream automation portfolio manager for Shell. “It is a long-term, competitive, collaborative, performance-based relationship that will facilitate the delivery of considerable value to both parties. We will be looking to emulate this approach in many other key global categories in the future.”

“This new agreement will put Emerson in a position to substantially broaden its Main Automation Contractor footprint within Shell,” said Ronaldo Marques, general manager, equipment, for Shell’s Enterprise Categories & Suppliers division. “For the first time in history, Emerson will have full and open access to all Shell business units - Upstream, Downstream, Wind, Power and Biofuels - plus affiliated Joint Ventures.”

"We have enjoyed a solid relationship with Shell for decades," said Steven A. Sonnenberg, president of Emerson Process Management. "This Global Framework Agreement symbolises the shared belief our two companies have that early engagement, clear objectives and collaborative work practices result in more predictable success for projects and operations. We are thrilled to be selected by Shell for the role of Main Automation Contractor."

Mobile workforce @ Shell

Improving in-the-field decision making for operations workforce

Royal Dutch Shell’s Downstream Manufacturing Division has entered into a multi-year partnership with Invensys Operations Management. Shell will utilise Wonderware’s Mobile Collaboration Solutions mobile workforce and decision-support solution as one tool in the Ensure Safe Production (ESP) initiative at 29 of its global manufacturing facilities. The Mobile Collaboration Solutions system will provide downstream operations with configurable software and rugged, intrinsically-safe mobile hardware to more effectively manage the equipment-surveillance process and regulatory compliance tasks. By implementing this module, field operators will be able to optimise work processes, resulting in improved asset reliability and availability and reduced overall maintenance costs.

Invensys will provide this mobile workforce solution to help Shell operators, field engineers and supervisors create, define and routinely execute equipment surveillance and regulatory procedures following best practices, corporate policies and regulatory mandates. When executing these in-the-field procedures using the Wonderware Mobile Collaboration Solutions solution on their mobile computers, operators are made aware of potential equipment issues in real time so that they can take corrective action immediately, as well as maintain regulatory compliance.