BKTF Knowledge

Digital Twins Implementation Sharing

for Oil & Gas Industry Presented by : Susetiya
Statement
• This presentation is sharing personal knowledge only. It has no relation
with any company.
• All information in this presentation is general information that can be
found on the internet, there in no confidential information belong to
some party/company.
• All data/number used in this presentation (if any) is dummy/simulation
only, not a real production data.
Purpose
• To share the following information:
• Concept of Digital Twins
• The benefits of Digital Twins
• Implementation of Digital Twins
• Cost/Effort/Constraints to implement
• Discussion
Background
Industry 4.0
Industry 4.0 refers to the fourth industrial revolution.
It focuses heavily on interconnectivity, automation, machine learning, and real-time
data
There are 4 design principles:
• Interconnection — the ability of machines, devices, sensors, and people to connect
and communicate with each other via the Internet.
• Information — provides operators with comprehensive information to make
decisions.
• Technical assistance — the technological facility of systems to assist humans in
decision-making and problem-solving
• Decentralized decisions — the ability of cyber physical systems to make decisions on
their own and to perform their tasks
 Background
Digital Twin and Industrial 4.0
• In the age of Industry 4.0, digital twins help
bridge the gap between the physical and
digital worlds.
• A digital twin is a dynamic, virtual
representation of a corresponding physical
product.
• These models range in purpose, but they
serve as a powerful connection to the
product for diagnostics and design changes.
• Companies are increasingly using digital
twins to optimize their products in ways
that were previously either unrealistic or
impossible.
Source: Delloite University Press
International Standard for Digital Twins
• Under development:
ISO/DIS 23247-1 Automation systems and integration — Digital Twin framework for
manufacturing — Part 1: Overview and general principles
What is Digital Twins
• A digital twin is an abstraction of something in the real world.
A digital twin captures the behavior and attributes of its physical sibling with data and life
cycle state changes potentially moving in either, or both, directions.
(Digital Twin Consortium . Org)

• A digital twin is a virtual representation of the “state” of a complex physical

device or system that feeds data back and forth between an asset and its
“twin.” (FutureITOT . Org)

• A digital twin can be defined, fundamentally, as an evolving digital profile of

the historical and current behavior of a physical object or process that helps
optimize business performance. (Deloitte University)
Digital Twins Features
Implementation Category

Optimization
Monitoring/Analyzing/Prediction
• Data Analytics Level / Types

Describe Diagnose Predict Optimize

What Happened? Why did it happen? What will happen? How can we make it
happen?

PAST FUTURE
Examples of Data Analytics Implementation
• Turbomachinery Management System
• Time to failure
• Likelihood of failure in a given time period
• Next Maintenance/Overhaul Schedule
• Evaluate option for optimization
• Equipment / Major Equipment Performance Metrics
• PM Program optimization
• Prediction on equipment availability
• Pipeline Corrosion and inspection
• Corrosion analytics/prediction
• Inspection optimization
• Safety Critical Element Analysis / Maintenance
• Automatic generate PFD/Availability data
• Adjust the proof test/maintenance period based on the analytics
Implementation Category

Optimization
Process Optimization
Process Optimization
Process Optimization
Process Optimization
Process Simulation ? Hysis etc?
Implementation Category

Optimization
3D Visualization
Physical Digital Twins
3D Visualization
PDMS + P&ID + Tag Relational =
3D Visualization
PDMS + P&ID + Tag Relational =
Digital Twins Implementation:
• Benefits:
• Efficient Engineering Job
• Easier find the document
• Site survey may not necessary
• Integrated Documentation : Valid and controlled.
Augmented Reality
• Augmented reality is the result of using technology to superimpose
information — sounds, images and text — on the world we see.

• Digital Twin Visualization can also be combined with the VR/AR technology
for:
• Training / Familiarization
• Maintenance / Troubleshooting
• Start-up guidance
• Remote Support
• Remote inspection
Augmented Reality
Video:
AR1
AR2
AR3

• Benefits:
• More easy and quick on Field Inspection
• Remote Assistance
• Visual SOP
• Easy to identify equipment
• Integrate all related data that scattered in some locations.
• Provide the last inspection data on the plant
• Improve skills and standardize the hands-on/knowledge
Digital Twins Implementation:
• Pre-requisite
• Internet of things : Sensor, equipment, final element, controllers, Software, data
base: Traditional or New concept.
• Network Infrastructure: Cyber Security Consideration
• Integrated Database
• Integrated Documentation : Valid and controlled.
Network / Data Flow Topology

Historian
System
Example of Digital Twins System Architecture (1)
Architecture (Another Vendor)

April 14, 2021 26

Example of Digital Twins System Architecture (2)

Emerson hosted and operated AWS and Azure Cloud

Emerson AWS Cloud Emerson Azure Cloud

Remote HTTPS IIOT Data Plantweb Optics

Experts Location & IIOT Plantweb Optics Relay
Data Back End AR Service Restful API Server v1.6
Back End
( Read only)
Remote Assistance
Push IIOT Data:
HTTPS Every 30mins

Plantweb Optics AR Mobile app,

Web Portal & Live Remote Plantweb Optics AR On Premises
Customer Site
Assistance Web Portal
Services Modules
• Plantweb Optics AR (Basic Offering)
• Plantweb Optics AR+
• Hero
• Knowledge Field Engineer/
Deep Linking Devices/Instruments/Sensors
• Logic Technician
Plantweb Optics
Mobile App
Concerns
• Cyber Security Issue:
• Shall comply to ICS/PCN Security standard
• Potential become audit finding when not properly implemented

• Data Residence Policy:

• Permen ESDM Nomor 7 / 2019

• Data Confidentiality Policy

• Budget
Cost/Benefits Analysis
• Benefits:
• Tangible:
• Data Analytics:
• Optimum Maintenance Strategy: Reduce Maintenance Cost
• Reduce operation cost by running the best scenario
• Increase the equipment lifetime
• Process Optimization:
• Improve production
• Reduce operating cost
• Visualization:
• Reduce man-power
• Reduce shutdown time
• Reduce training cost
• Reduce engineering cost

• Intangible:
Cost/Benefits Analysis
• Benefits:
• Intangible:
• Efficient Work
• Increase Safety by eliminating the human error
• Data/Document Integrity
• Easier to perform the job
Cost/Benefits Analysis
• Cost:
• Green Field
• Brown Field
How to start?
• Green Field:
• Easier to develop the program

• Brown Field:
• Chose one (from 3 category) that easier to implement
• Road Map Approached is the best strategy (Multi years program)
• Example:
How to start
• Example:

AR for small Expand the Integrate with Full

Facility AR Visualization Implementation
/Documentation
Terima Kasih