The document explores the practical application of digital twins in minimizing lost profit through integrating simulations into daily operations. It emphasizes the advantages of having a centralized digital twin that maintains a complete history and future projections, enhancing decision-making and operational efficiency. Case studies demonstrate significant financial benefits achieved through real-time monitoring and model validation in refining processes.

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A practical application
of a Digital Twin
Integratingsimulationintodaily
operationstominimizelostprofit
SimonCalverley
KBC(AYokogawaCompany)
ERTC 2019

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The Digital Twin
Practical Application Today
Future Digital Nirvana

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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

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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

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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.

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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

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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

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KBCdecidedtointegratePetro-SIM®andPI

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Incorporateresultsfrom
Petro-SIMalongsidePIdata
Keyunitperformance
resultsconsumedthrough
PIVision
Expertusersarestillableto
performdeeperanalysis
throughdirectinteraction
withPetro-SIM
Unit Performance Portal built
around PI Vision dashboards

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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

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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. 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. 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. 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

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Individualpointsolutiondigitaltwinsexisttoday,a future
digitalnirvanahasonemulti-purposedigitaltwin

16. THE MANTRA
HAS TO BE:
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Think Big
Start Small
Scale Fast
Drive Adoption

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