Increasing plant complexity requires more sophisticated ways of approaching KPI's and targets. In process industry applications, the ability to use technology to make better decisions faster is vital for delivering superior results. One such technology, which can be applied in multiple ways, is a digital twin.
A digital twin is a digital representation of a human, device, system, or process, that mirrors the actual process and has full knowledge of its historical performance. By simulating devices, systems, or processes to predict future performance, digital twins drive agility and convergence of understanding to enable effective decision-making and determine strategies to maximize safety, reliability, and profitability. The digital twin captures data to determine real-time performance, which can be used across the entire lifecycle of an asset for optimization and predictive maintenance.
The Benefits of Digital Twins
More Effective Decision-Making
Experts can review recommended strategies to assess the impact of each recommended approach.
Improved Safety & Reliability
Digital twins mimic asset performance, which can be used to predict failures and avoid risks; this improves worker safety and plant reliability.
The digital twin allows “What if?” and “What’s best?” scenarios to be run simultaneously to determine available strategies that maximize profitability.
Digital twins also offer value in operational efficiency and insights into how products are used and how they can be improved:
A series of business and financial Key Performance Indicators (KPI’s) are updated in real-time, plan versus actual, as part of an enterprise-wide balanced scorecard for corporate situational awareness. Advanced logic is applied to real-time operations data to project current and future understanding of the business for executives.
Key operator actions are captured, controlled and manipulated in real-time through monitoring and control of work processes. Minimize the learning curve for new operators, support change management and enable vastly improved scenario validation through operator training simulation and an ISA106-compliant modular procedure automation solution.
Multivariable predictive controls drive the plant continuously to its optimum constraints by reacting to disturbances in a closed loop.
Value Chain Optimization
Drive agile and efficient alignment of supply of premium products as closely as possible to market demand with sufficient resilience or operational flexibility to readily adjust production and exploit market opportunities through supply chain planning, scheduling and production accounting.
Automation and Control Integrity
Digital representation of the live plant and its automation algorithms through the “twin” function of an Integrated Control and Safety System (ICSS) allows engineers to conduct fundamental process control tests at an engineering workstation, as well as any proposed adjustments before they are applied on the live plant.
Instrumentation and Equipment Productivity
Minimize the need for breakdown and preventative maintenance, reduce OPEX through advanced online monitoring and prediction of field device health, and process interface conditions that reduce unnecessary trips.
Highly intelligent devices, such as pumps, flowmeters, transmitters, and chemical analyzers provide total insight into their ongoing performance as well as the ability to adapt to changing duty requirements throughout the measurement device lifecycle.
Plant Process Optimization
Online and offline high-fidelity models for non-linear performance monitoring, simulation, and optimization using first principle kinetics deliver optimized yield performance, flow assurance, energy efficiency improvement, enhanced reliability and operator capability assurance.
Digital Twin: The Yokogawa Difference While most digital twins today emulate individual assets or devices, the Yokogawa/KBC thought process is far more extensive. In this Eugene Spiropoulos focuses on the powerful, context-driven digital twin concept, which encompasses multiple digital twins emulating not only devices but also systems, processes and human behavior. Benefits extend across the value chain throughout the entire enterprise.
Learn how to more efficiently match supply to demand through the digital twin.
Watch this on-demand webinar to learn how digital twin technologies are moving process industries towards autonomous operations.
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