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KBC Proven Application of Digital Twin

The value of the digital twin, practical applications today and the future digital nirvana
Simon Calverley presented at ERTC19 in Poland

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KBC Proven Application of Digital Twin

  1. 1. Proprietary Information 1111 A practical application of a Digital Twin Integratingsimulationintodaily operationstominimizelostprofit SimonCalverley KBC(AYokogawaCompany) ERTC 2019
  2. 2. Proprietary Information 2222Proprietary Information 2Proprietary Information 2Proprietary Information 2Proprietary Information 2 The Digital Twin Practical Application Today Future Digital Nirvana
  3. 3. Proprietary Information 3333Proprietary InformationProprietary InformationProprietary InformationProprietary Information Most well-run plants will have a simulation model of the plant Generally limited to ad-hoc use by unit engineers for troubleshooting and investigating improvement
  4. 4. Proprietary Information 4444 Digitalizationallowsus tocompress timehorizons& reduceuncertainty LossesDueto UncertaintyReduced Decision-Making Time Horizon Decision Impact Time Horizon SECONDS Ago MINUTES Ago HOURS Ago MONTHS Ago SECONDS Ahead MINUTES Ahead HOURS Ahead DAYS Ahead MONTHS Ahead DAYS Ago NOW Operations Mgmt. Automation Production Mgmt. Business Mgmt. DecisionValue
  5. 5. Proprietary Information 5555Proprietary InformationProprietary InformationProprietary InformationProprietary Information A Digital Twin goes beyond traditional simulation Traditional Particular operating case A snapshot in time Ad-hoc basis to answer a question Owned and used by isolated groups Specific tools for different silos Digital Twin Full range of asset operation Full history and future Automated to business workflows Centralized single version of the truth, used by everyone Single integrated twin of process, utilities and heat exchange sys.
  6. 6. Proprietary Information 6666 Industryis conservativewhenit comestotechnology • Exception rather than the rule • New technology early adopters • Will stay largely the same • Adoption of proven technology Survey conducted for KBC by IQPC (International Quality & Productivity Center) Industry perspectives on adoption of new technology
  7. 7. Proprietary Information 7777 Daily Meeting • Unreconciled and unstructured (spreadsheet) data • No predictive view of performance for current operations Troubleshooting • Data analysis only on specific trends of the data • Ad hoc simulations Planning • Compiling and reconciling performance data • Error identification and time for LP model updates. Reporting • Data gathering and manipulation • Metrics, KPI’s calculations only available in monthly / quarterly reports Unit Performance Monitoring processesare bogged down
  8. 8. Proprietary Information 8888 KBCdecidedtointegratePetro-SIM®andPI
  9. 9. Proprietary Information 99999999 Incorporateresultsfrom Petro-SIMalongsidePIdata Keyunitperformance resultsconsumedthrough PIVision Expertusersarestillableto performdeeperanalysis throughdirectinteraction withPetro-SIM Unit Performance Portal built around PI Vision dashboards
  10. 10. Proprietary Information 10101010 Unit PerformanceAssurance Daily Meeting Summary report’s top 3-5 actions based on value discussed Troubleshooting Plant monitored daily with global network expertise alerted to issues Planning Real Time LP vs calibrated Simulation vs Plant monitoring to generate always up to date LP vectors Reporting Consistent calculation and comparison of metrics, and analytics for each unit
  11. 11. Proprietary Information 11111111 US$0.05 – 0.10/bbl for ensuring that the LP is an accurate representation of the refinery Value of monitoring via a Digital twin Up to US$0.05/bbl for unit monitoring, including: Faster response to/recovery from upsets Remaining on plan – identifying issues and resolving them before operation becomes constrained Identifying improvements to realise increased value 11
  12. 12. Implemented at Gulf Coast refiner Identified opportunities of $8 million in first 6 months. Rationalized and corrected yield accounting and unit material balance. Advanced analytics helped increase uptime of key process equipment Case study 1
  13. 13. Case study 2 US Refiner with 12+ refineries worked with KBC IT and Modelling services to roll out unit health and model monitoring applications on nearly all their process units. Whole program executed in just over two years Uses Petro-SIM & PI architecture Refiner modelling team & SMEs defined KPIs Worked with KBC team to speed up deployment across multiple units
  14. 14. Case study 3 Refiner has seen significant dollar benefits Improved operations and small capex opportunities Monitoring automation giving time back to engineers Greater engagement with simulation and optimization Large US & European refiner uses continual model validation through performance monitoring to give unit engineers confidence in model and to make always up-to-date models available on demand
  15. 15. Proprietary Information 15151515 Individualpointsolutiondigitaltwinsexisttoday,a future digitalnirvanahasonemulti-purposedigitaltwin
  16. 16. THE MANTRA HAS TO BE: Proprietary Information 16 Think Big Start Small Scale Fast Drive Adoption
  17. 17. Excellence is never an accident. It is always the result of high intention, sincere effort, and intelligent execution; it represents the wise choice of many alternatives - choice, not chance, determines your destiny. Thank You 0022-ERTC-PPT-US-112019
  • somnathmitra1

    Mar. 11, 2021
  • ttao434

    Feb. 11, 2021

The value of the digital twin, practical applications today and the future digital nirvana Simon Calverley presented at ERTC19 in Poland


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