{"id":712312,"date":"2026-04-30T07:43:14","date_gmt":"2026-04-30T07:43:14","guid":{"rendered":"https:\/\/www.capgemini.com\/gb-en\/?p=712312"},"modified":"2026-04-30T07:44:52","modified_gmt":"2026-04-30T07:44:52","slug":"why-do-digital-twins-so-often-stall-in-oil-gas","status":"publish","type":"post","link":"https:\/\/www.capgemini.com\/gb-en\/insights\/expert-perspectives\/why-do-digital-twins-so-often-stall-in-oil-gas\/","title":{"rendered":"Why do digital twins so often stall in oil &amp; gas?"},"content":{"rendered":"\n<header class=\"wp-block-cg-blocks-hero-blogs header-hero-blogs\"><div class=\"container\"><div class=\"hero-blogs\"><div class=\"hero-blogs-content-wrapper\"><div class=\"row\"><div class=\"col-12\"><div class=\"header-title\"><h1>Why do digital twins so often stall in oil &amp; gas? How we can get out of Proof-of-Concept Purgatory and into operational reality<\/h1><\/div><\/div><\/div><\/div><div class=\"hero-blogs-bottom\"><div class=\"header-author\"><div class=\"author-img\"><img decoding=\"async\" src=\"https:\/\/www.capgemini.com\/gb-en\/wp-content\/uploads\/sites\/5\/2026\/03\/Mark-Ewen.jpg?w=200&amp;quality=10\" alt=\"\" loading=\"lazy\"\/><\/div><div class=\"author-name-date\"><h5 class=\"author-name\">Mark Ewen<\/h5><h5 class=\"blog-date\">Apr 30, 2026<\/h5><\/div><\/div><div class=\"brand-image\"><\/div><\/div><\/div><\/div><\/header>\n\n\n\n<section class=\"wp-block-cg-blocks-group section section--article-content\"><div class=\"article-main-content\"><div class=\"container\"><div class=\"grid-container\"><div class=\"col-12 col-md-2\"><nav class=\"article-social\"><ul class=\"social-nav\"><li class=\"ip-order-fb\"><a href=\"https:\/\/www.facebook.com\/sharer\/sharer.php?u=https:\/\/www.capgemini.com\/gb-en\/?p=712312\" target=\"_blank\" rel=\"noopener noreferrer\" title=\"opens in a new window\"><i aria-hidden=\"true\" class=\"icon-fb\"><\/i><span class=\"sr-only\">Facebook<\/span><\/a><\/li><li class=\"ip-order-li\"><a href=\"https:\/\/www.linkedin.com\/sharing\/share-offsite\/?url=https:\/\/www.capgemini.com\/gb-en\/?p=712312\" target=\"_blank\" rel=\"noopener noreferrer\" title=\"opens in a new window\"><i aria-hidden=\"true\" class=\"icon-li\"><\/i><span class=\"sr-only\">Linkedin<\/span><\/a><\/li><\/ul><\/nav><\/div><div><div class=\"article-text article-quote-text\">\n<h3 class=\"wp-block-heading\" id=\"h-digital-twins-aren-t-failing-because-the-technology-isn-t-ready-they-re-failing-because-organisations-aren-t\">Digital twins aren\u2019t failing because the technology isn\u2019t ready \u2013 they\u2019re failing because organisations aren\u2019t.<\/h3>\n\n\n\n<p>In this instalment of <a href=\"https:\/\/www.capgemini.com\/gb-en\/industries\/energy-and-utilities\/future-of-energy-transition-utilities\/\">Capgemini\u2019s \u2018Future of Oil &amp; Gas\u2019 series<\/a>, we explore why digital twins so often stall in Proof\u2011of\u2011Concept and what it takes to turn promising pilots into trusted, decision\u2011making operational capabilities.<\/p>\n\n\n\n<p>Digital twins (virtual replicas of physical assets or processes, running off real data) have become one of the most widely piloted technologies in the <a href=\"https:\/\/www.capgemini.com\/gb-en\/solutions\/oil-gas-digital-transformation\/\">oil &amp; gas<\/a> sector \u2014 yet paradoxically, one of the least successfully scaled. Across upstream, midstream, and downstream operations, pilots consistently demonstrate impressive gains in production, reliability, efficiency, and safety. But organisational reality tells a different story: <em>fewer than a quarter of digital twins ever progress into full operational deployment<\/em>, and many stall permanently in Proof\u2011of\u2011Concept (PoC) mode.<\/p>\n\n\n\n<p>Why? It turns out the core barriers have little to do with technology readiness \u2014 and everything to do with mindset, governance, and execution.<\/p>\n\n\n\n<p>This blog explores why digital twins get stuck, what must change, and how Capgemini helps operators turn promising prototypes into embedded operational capabilities.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\" id=\"h-done-right-digital-twins-are-incredibly-valuable\">Done right, digital twins are incredibly valuable<\/h4>\n\n\n\n<p>When implemented well, digital twins deliver substantial and measurable value. They provide a dynamic, data\u2011driven virtual representation of critical assets, enabling organisations to understand and optimise operations in ways not previously possible.<\/p>\n\n\n\n<p>Real\u2011world examples from the sector prove this:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>BP<\/strong>\u2019s global production twin reduced simulation times from over 24 hours to 20 minutes and delivered <a href=\"https:\/\/www.oilandgasiq.com\/digital-transformation\/articles\/how-bp-and-chevron-use-digital-twins-to-optimize-assets\" target=\"_blank\" rel=\"noreferrer noopener\">30,000 additional barrels of oil in its first year<\/a> by accelerating optimisation cycles.<\/li>\n\n\n\n<li><strong>Cosmo Oil<\/strong>\u2019s refinery twin with AVEVA generated <a href=\"https:\/\/www.aveva.com\/content\/dam\/aveva\/documents\/perspectives\/success-stories\/SuccessStory_CosmoOil.pdf.coredownload.inline.pdf\" target=\"_blank\" rel=\"noreferrer noopener\">$2.3 million per year in benefits per crude unit<\/a>, achieving payback in under 12 months.<\/li>\n\n\n\n<li><strong>Equinor\u2019s \u201cEcho\u201d twin<\/strong> <a href=\"https:\/\/www.equinor.com\/energy\/digital-twin\">cut planned maintenance hours by 50%<\/a>, boosting uptime and reducing technician exposure offshore.<\/li>\n\n\n\n<li>A <strong>major European pipeline operator<\/strong> saved <strong>over $1 million<\/strong> and <a href=\"https:\/\/aliresources.hexagon.com\/case-studies\/hexagon-s-digital-twin-helps-major-european-oil-and-gas-operator-streamline-engineering-operations-and-maintenance\" target=\"_blank\" rel=\"noreferrer noopener\">reduced maintenance spend by 10%<\/a> using Hexagon\u2019s asset twin for risk\u2011based planning.<\/li>\n<\/ul>\n\n\n\n<p>Whether improving yield, reducing outages, minimising helicopter trips, preventing failures, or accelerating workflows, digital twins repeatedly prove their capacity to unlock multi\u2011million\u2011dollar results. The value is clear. So, why aren\u2019t these successes scaling across the enterprise?<\/p>\n\n\n\n<h4 class=\"wp-block-heading\" id=\"h-why-digital-twins-get-stuck-in-pilot-mode\">Why digital twins get stuck in pilot mode<\/h4>\n\n\n\n<p>Drawing on Capgemini\u2019s deep industry expertise and hands\u2011on experience delivering digital twins across the oil &amp; gas value chain, we\u2019ve identified a consistent set of reasons why so many promising initiatives struggle to progress beyond the pilot stage. While the technology itself is increasingly mature, organisational realities \u2013 spanning integration, governance, trust, and operating\u2011model alignment \u2013 often prevent pilots from becoming scalable, decision\u2011bearing operational tools. The following themes outline the most common factors that hold digital twins back from achieving their full enterprise value.<\/p>\n\n\n\n<p id=\"h-the-market-wide-integration-failure\"><strong>The market\u2011wide integration failure<\/strong><\/p>\n\n\n\n<p>No major vendor has yet delivered multiple, scaled, decision\u2011bearing twins across diverse assets. Each pilot tends to be bespoke \u2013 tailored to one platform, one piece of equipment, or one refinery unit. That makes it hard to replicate success across dozens of facilities.<\/p>\n\n\n\n<p id=\"h-failure-to-meet-all-four-pillars-of-a-true-digital-twin\"><strong>Failure to meet all four pillars of a \u201ctrue\u201d digital twin<\/strong><\/p>\n\n\n\n<p>Most pilots succeed in demonstrating one or two pillars (often real\u2011time data or simulation), but few deliver all four:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Bidirectional<\/strong>, with data sent from the physical asset to the digital model <em>and<\/em> received in return<\/li>\n\n\n\n<li><strong>Continuously calibrated<\/strong> to reflect and stay synchronised with real-time operational states<\/li>\n\n\n\n<li><strong>Institutionally trusted<\/strong> by engineers and regulators as a source of truth<\/li>\n\n\n\n<li><strong>Decision\u2011bearing<\/strong>, not just providing visualisation<\/li>\n<\/ul>\n\n\n\n<p><strong>Without all four, twins are just compelling experiments, not operational tools.<\/strong><\/p>\n\n\n\n<p id=\"h-the-value-perception-gap\"><strong>The value perception gap<\/strong><\/p>\n\n\n\n<p>According to EY\u2019s Future of Energy survey, only 14% of companies believe digital twins are living up to expectations, despite widespread pilots.<\/p>\n\n\n\n<p>This gap exists because PoCs often focus on proving functionality, not delivering business outcomes. When the ROI isn\u2019t clearly quantified, production leaders deprioritise it in favour of immediate operational pressures.<\/p>\n\n\n\n<p><strong>Data siloes and quality issues<\/strong><\/p>\n\n\n\n<p>Digital twins require integrating data from engineering, operations, maintenance, etc. which are often sitting in different siloes in different formats. In oil &amp; gas particularly, data can be incomplete or unclean. And let\u2019s face it, trust is huge. As soon as end-users see that the twin\u2019s data is wrong, they will distrust the whole system. Which is why Shell\u2019s team implemented the Pin my data feedback loop \u2013 to actively maintain data quality and thus user trust. The trouble is, not all companies have processes like this, and many PoC twins slowly diverge from reality as underlying data isn\u2019t maintained, leading to abandonment.<\/p>\n\n\n\n<p>Integration with live systems is also technically challenging \u2013 connecting a new twin platform to, say, a refinery\u2019s DCS data can raise cybersecurity and networking concerns that slow down projects significantly.&nbsp;<\/p>\n\n\n\n<p><strong>The pilot\u2011to\u2011production \u201cValley of Death\u201d<\/strong><\/p>\n\n\n\n<p>A pilot might be done with a subset of data, maybe in a test environment, to prove a concept. Scaling it means connecting to all assets, automating data feeds, dealing with user access control for potentially hundreds of users, hardening the system for cybersecurity, etc. These tasks are not trivial and often not budgeted or planned for in the pilot.<\/p>\n\n\n\n<p>When the pilot ends, teams can be unsure how to proceed \u2013 they proved value on one asset, but replicating to 50 assets could be non-linear in effort. Without commitment, projects stall.<\/p>\n\n\n\n<p>Also, PoC stall happens when initial results are promising but not overwhelmingly so, leading management to adopt a \u201cwait and see\u201d stance rather than push forward aggressively. Perhaps a pilot saved \u00a31M in a small area \u2013 impressive, but in a company with billions in expenses, some might question if it\u2019s worth scaling right away or if they should try other pilots. This cautious approach can lead to \u201cpilotitis\u201d: always doing pilots, never fully rolling out.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\" id=\"h-what-needs-to-change\">What needs to change?<\/h4>\n\n\n\n<p>There are ways out of PoC purgatory but scaling digital twins requires a fundamental shift from tech\u2011led experimentation to decision\u2011centric operational transformation.<\/p>\n\n\n\n<p>We recommend the following path forward for success:<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>Reframe digital twins as \u201cDecision Twins\u201d<\/strong><\/li>\n<\/ol>\n\n\n\n<p>This aligns the technology to the decisions that matter most \u2013 e.g.,<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>\u201cHow do we reduce compressor failures by 20%?\u201d<\/li>\n\n\n\n<li>\u201cHow do we cut turnaround duration by 5%?\u201d<\/li>\n\n\n\n<li>\u201cHow do we maximise Crude Distillation Unit margin every hour?\u201d<\/li>\n<\/ul>\n\n\n\n<p><strong>2.<\/strong> <strong>Build a scalable data and governance foundation<\/strong><\/p>\n\n\n\n<p>Successful operators treat digital twins as living assets requiring:<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><\/li>\n<\/ol>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A clean, governed, continuously updated data foundation<\/li>\n\n\n\n<li>Clear ownership in operations, not digital innovation teams<\/li>\n\n\n\n<li>Defined model assurance and recalibration workflows<\/li>\n\n\n\n<li>Integrated knowledge management<\/li>\n<\/ul>\n\n\n\n<p><strong>3<\/strong>. <strong>Start with a Minimum Viable Twin (MVT)<\/strong><\/p>\n\n\n\n<p>Over\u2011engineering kills adoption. A twin should begin with the smallest surface area required to deliver value \u2013 one unit, one decision, one workflow \u2013 then expand in manageable increments.<\/p>\n\n\n\n<p><strong>4.<\/strong> <strong>Embed twins into operational routines<\/strong><\/p>\n\n\n\n<p>A twin that sits on a separate portal will never scale. A twin that changes the shift handover, informs the daily production meeting, reduces offshore maintenance visits, and updates the maintenance backlog becomes indispensable.<\/p>\n\n\n\n<p>Twins must be operational capabilities, not products.<\/p>\n\n\n\n<p><strong>5.<\/strong> <strong>Engineer a repeatable path to production<\/strong><\/p>\n\n\n\n<p>We recommend your five-step credible path to production needs:<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>A clearly defined decision domain<\/strong><\/li>\n\n\n\n<li><strong>A validated, continuously calibrated model<\/strong><\/li>\n\n\n\n<li><strong>Hybrid automation with humans in the loop<\/strong><\/li>\n\n\n\n<li><strong>Engineering for scale \u2013 repeatable, standardised, secure<\/strong><\/li>\n\n\n\n<li><strong>Full workflow embedding and organisational adoption<\/strong><\/li>\n<\/ol>\n\n\n\n<p>This is precisely how operators like bp, Equinor, Shell, and Cosmo succeeded with their flagship projects.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\" id=\"h-capgemini-can-help-you-break-out-of-poc-purgatory\">Capgemini can help you break out of PoC Purgatory<\/h4>\n\n\n\n<p>We bring a uniquely integrated capability set that directly addresses the barriers identified in the industry:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Deep engineering and data integration expertise<\/strong> \u2013 We combine asset engineering, OT\/IT convergence, and data platform modernisation \u2013 exactly what\u2019s needed to build the data foundations where most twins fail.<\/li>\n\n\n\n<li><strong>Proven success across the oil &amp; gas value chain <\/strong>\u2013 Our work spans predictive maintenance, lifecycle optimisation, emissions reduction, operations management, and engineering governance \u2014 all areas where digital twins unlock measurable gains.<\/li>\n\n\n\n<li><strong>Leading partner ecosystem \u2013 <\/strong>We work with all major digital twin platforms, including Cognite, AVEVA, Hexagon, Kongsberg, IBM, and Microsoft, ensuring vendor\u2011agnostic, scalable solutions.<\/li>\n\n\n\n<li><strong>Decision\u2011centric transformation frameworks \u2013 <\/strong>Capgemini\u2019s &#8220;Decision Twin&#8221; approach ensures focus on value, not technology.<\/li>\n\n\n\n<li><strong>Change management and operating model redesign \u2013 <\/strong>We help organisations embed twins into real workflows, redesigning processes and governance to ensure sustained adoption.<\/li>\n<\/ul>\n\n\n\n<p>Digital twins have already proven they can deliver millions in value \u2013 increased production, reduced downtime, enhanced safety, lower emissions, and more. But to unlock these benefits at scale, the industry must shift from experimenting with technology to transforming decision\u2011making.<\/p>\n\n\n\n<p>By reframing twins around decisions, investing in robust data and governance foundations, starting small, and embedding outputs into daily operations, oil &amp; gas companies can finally break out of PoC purgatory.<\/p>\n\n\n\n<p>And with Capgemini as your business and technology transformation partner \u2013 combining engineering depth, digital excellence, and operational know\u2011how \u2013 you can transform digital twins from isolated prototypes into the powerful operational capabilities they were always meant to be.<\/p>\n<\/div><\/div><\/div><\/div><\/div><\/section>\n\n\n\n<section class=\" section section--expert-slider wrapper-people-slider wp-block-cg-blocks-wrapper-people-slider\"><div class=\"container\"><div class=\"row\"><div class=\"content-title col-12 col-md-8\"><h2 data-maxlength=\"34\" class=\"people-heading-title\">Meet our Author<\/h2><\/div><\/div><\/div><div class=\"slider slider-boxed\"><div class=\"container\"><div class=\"slider-window\"><div class=\"slider-list\">\t\t<div class=\"slide\">\n\t\t\t<div class=\"box\">\n\t\t\t\t<div class=\"row\">\n\t\t\t\t\t<div class=\"col-md-6 col-lg-4 box-img-wrapper\">\n\t\t\t\t\t\t<img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.capgemini.com\/gb-en\/wp-content\/uploads\/sites\/5\/2026\/03\/Mark-Ewen.jpg\" alt=\"Mark Ewen\"\/>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t<div class=\"col-md-6 col-lg-8 box-inner\">\n\t\t\t\t\t\t<div class=\"row title-social-media-header\">\n\t\t\t\t\t\t\t<div class=\"col-md-12 col-lg-6 mbl-social-icon\">\n\t\t\t\t\t\t\t\t<ul class=\"social-nav\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<li><a aria-label=\"Linkedin\" target=\"_blank\" title=\"Opens in a new window\" href=\"https:\/\/www.linkedin.com\/in\/markrewen\/\"><i aria-hidden=\"true\" class=\"icon-li\"><\/i><\/a><\/li>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<div class=\"col-md-12 col-lg-6 box-container\">\n\t\t\t\t\t\t\t\t<div class=\"box-title\">\n\t\t\t\t\t\t\t\t\t<h3 class=\"people-profile-title\">Mark Ewen<\/h3>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<span>Client Partner, Energy Transition &amp; Utilities, Capgemini<\/span>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<div class=\"col-md-12 col-lg-6 social-box-container dkt-social-icon\">\n\t\t\t\t\t\t\t\t<ul class=\"social-nav\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<li><a aria-label=\"Linkedin\" target=\"_blank\" title=\"Opens in a new window\" href=\"https:\/\/www.linkedin.com\/in\/markrewen\/\"><i aria-hidden=\"true\" class=\"icon-li\"><\/i><\/a><\/li>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t\t\t\t<div class=\"people-info\">Mark is a Client Partner with over 35 years\u2019 experience in technology, consulting, and digital transformation across the energy, utilities, and technology sectors. Mark has led major digital innovation programmes for oil and gas clients, with deep expertise in cloud, data, and AI. He has also held global leadership roles at AWS, ServiceNow, IBM, and DXC, driving complex transformations and building executive-level relationships that deliver sustainable growth and operational resilience.<\/div>\n\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div><\/div><\/div><div class=\"slider-nav\"><button class=\"slider-prev inactive\" aria-label=\"Slider-previous\" tabindex=\"-1\"><\/button><ul class=\"slider-paginator\"><\/ul><button class=\"slider-next\" aria-label=\"Slider-next\"><\/button><\/div><\/div><\/section>\n","protected":false},"excerpt":{"rendered":"<p>Digital twins aren\u2019t failing because the technology isn\u2019t ready \u2013 they\u2019re failing because organisations aren\u2019t.<\/p>\n","protected":false},"author":301,"featured_media":712323,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"cg_dt_proposed_to":[],"cg_seo_hreflang_relations":"[]","cg_seo_canonical_relation":"","cg_seo_hreflang_x_default_relation":"","cg_dt_approved_content":true,"cg_dt_mandatory_content":false,"cg_dt_notes":"","cg_dg_source_changed":false,"cg_dt_link_disabled":false,"_yoast_wpseo_primary_brand":"","_jetpack_memberships_contains_paid_content":false,"footnotes":"","featured_focal_points":""},"categories":[1],"tags":[215],"brand":[],"service":[],"industry":[121,358],"partners":[],"blog-topic":[545],"content-group":[],"class_list":["post-712312","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized","tag-energy-and-utilities","industry-energy-utilities","industry-energy","blog-topic-energy-and-utilities"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v22.8 (Yoast SEO v22.8) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Why Digital Twins Stall in Oil &amp; Gas | Capgemini UK<\/title>\n<meta name=\"description\" content=\"Discover why digital twins fail to scale in oil &amp; gas\u2014and how to move from PoC to operational reality. 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