Digital Twin

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.

What 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.

Digital twins:

  • Drive improvements through advanced data analytics and operational insight
  • Guide day-to-day decisions with in-depth, accurate data
  • Utilize massive amounts of plant information to enable better decision-making
  • Ensure actual performance meets planned performance


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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.

Increased Profitability

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:

  • Field and line employees have the information they need to understand the bottom-line impact of their day-to-day choices
  • Information flows across organizational boundaries
  • Second-guessing of decisions is minimized
  • Unit issues are identified and resolved faster
  • Lost profit opportunities are minimized
  • Performance gap visibility is improved
  • Modeling, visualization and reporting tools are seamlessly integrated



Yokogawa's Digital Twin Solutions


Enterprise Insight

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.


Capability Assurance

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.


Advanced Production

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.


Advanced Chemistry

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.



The digital twin enables the transfer of “designed intelligence” from the engineering phases of a capital project into “applied intelligence” that operations can leverage.

Application Note
Application Note

Chemical Processing Special Report:  Understand  the Process of Open Process Automation

Sponsored by YOKOGAWA.


Traditional refinery optimization tools that rely on bulk properties are limited in fully achieving the objectives of molecular management.

Key objectives of molecular management are maximizing high-value products and replacing expensive feedstocks with low value streams.

Download the White Paper and learn how to Improve gross product worth by maximizing high value products and, Reduce cost of feedstock by replacing expensive imports with low value streams.

Download Here.


Achieving autonomous operations is primarily about empowering the plant to run, learn, adapt and thrive in tomorrow’s environment—whatever that environment might be. Download this whitepaper to learn the steps in the journey to autonomous operations.

Realizing Next Normal Business Resilience with Agile Autonomous Operations
(Realizing Next Normal Business Resilience with Agile Autonomous Operations)
How Digital Transformation Enables Autonomous Polymer Operations
(How Digital Transformation Enables Autonomous Polymer Operations)
Digitally Transforming Overall Safety
(Digitally Transforming Overall Safety)

A new digital risk management methodology combines four digital technologies to form the foundation of a sustainable safety regimen.

Read all about it, inside.

Y NOW 2021 Opening Keynote on Yokogawa's Vision
(Opening Keynote Outlines Yokogawa's Vision for Autonomous Operations and Smart Manufacturing)
Platform for Shaping the Future of Advanced Manufacturing and Value Chains
(Platform for Shaping the Future of Advanced Manufacturing and Value Chains)
The Emerging Business Risk Management Strategy for OT Cybersecurity
(The Emerging Business Risk Management Strategy for OT Cybersecurity)
Futurecasting the Path to Autonomy
(Futurecasting the Path to Autonomy)
Five Industrial Automation Trends for 2022
(Five Industrial Automation Trends for 2022)
Digitally Transforming to Autonomous Operations and Smart Manufacturing 4.0 (Panel-Discussion)
(Digitally Transforming to Autonomous Operations and Smart Manufacturing 4.0)




A new digital risk management methodology combines four digital technologies to form the foundation of a sustainable safety regimen.

Read all about it, inside.

Product Overview
Product Overview

Watch this on-demand webinar to learn how digital twin technologies are moving process industries towards autonomous operations.


This webinar talks through a case study of how a client is using a remote operations center for their onshore oil field and how people, technology and processes need to be integrated to make it a success.


With many stakeholders in the operations planning process, different tools being used and different datasets it’s likely there will discrepancies interpreting the production results, making it harder to decide on the best improvements. Join this webinar which looks at operationalizing a digital twin in the context of Unit Performance Monitoring.


Join this webinar which focuses on how value chain optimization can improve profitability, enhance capital efficiency and reinforce license to operate. 


This webinar, delivered by KBC’s Pablo Montagna and Motiva’s Raul Adarme, will profile how Motiva’s Port Arthur refinery complex uses online energy monitoring and optimization.


Yokogawa and Sphera have teamed up to enable PHA-Pro® to produce the configuration files required for the Exaquantum Process Safety Monitoring environment. The result is a Digital Risk Management solution that utilizes the entire process safety investment to date.


Learn how to more efficiently match supply to demand through the digital twin.


Looking for more information on our people, technology and solutions?

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