Digital Twins:

Myths vs. Reality

Wednesday, September 11, 2019

© Copyright 2019 OSIsoft, LLC
Speakers

Improving SCADA
Information Management
with Real-Time
Data Infrastructure
Wednesday, August 28, 2019
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Defining the Modern Digital Twin
Agenda
• What is a Digital Twin?
• Why are we discussing Digital Twins now?
• How are Digital Twins being utilized?

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What is a Digital Twin?

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What is a Digital Twin?

“…a cross-domain digital model “…a near-real-time digital image of

that accurately represents a a physical object or process that
product, production process or helps optimize business
performance of a product or performance.”
production system in operation.”

“…a representation of a physical asset that

has a level of completeness and accuracy
and includes context information that
allows the user to understand its behavior
and performance.”

“In short, the digital twin concept “Digital twins are virtual replicas of
combines the ideas of modeling physical devices that data scientists
and the Internet of Things (IoT).” and IT pros can use to run
simulations before actual devices
are built and deployed.”

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Digital Twin: A Sum of Constituent Parts

1) Physical Asset or
2) Digital Model 4) Analytics
Process

1) Reality
2) Abstraction
3) Knowledge
3) Real-time Data
4) Intelligence

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Digital Twin Variations

ASSET/PROCESS MODEL
• Product • 3D Model
• Production Asset • Process Model
• Process • Schedule

Unique
Digital
Twin
Machine
Health DATA ANALYTICS
• Safety • Artificial Intelligence
• Process • Physics Simulations
Environmental • Equipment • Dashboards
Data • Environmental

Process Data

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Why Are We Discussing
Digital Twins Now?

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Emerging Generation of Digital Twin Enabling Technologies

Digital Model Data Aquisition Analytical Tools

Building Information Industrial Internet of
Machine Learning
Modeling (BIM) Things (IIoT)

Digital Manufacturing Cloud Computing

Simulation Technology Edge Device Technology Simulation Technology

3D Scanning &
5G Communication Big Data Analytics
Photogrammetry

Cyber Security

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Enabling an Information Value Cycle

Project Digital Twin

• Accelerate Program Timing Build & Connect &
• Increase Product Fitness
• Provide Performance Baseline
Model Collect
• Close the Engineering Loop

Analyze
Performance Digital Twin
• Optimize Operating
Performance Execute &
• Create & Optimize Services Innovate
• Drive Project Decisions
Optimize

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How Are Digital Twins Being
Implemented?

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Project vs. Performance Digital Twin

Greenfield

Brownfield

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 Digital Twins Throughout Asset Lifecycle

Modeling & Simulation Predictive Maintenance

Construction Sequence Process Optimization
Virtual Commissioning Energy Management
Design Operate &
& Build Continuous
Handover
Maintain

Convergence

• Increase throughput
• As-Designed • Real-time IoT data
• Improve product quality/yield
• As-Built • Analytics
• As-Maintained • Simulate what-if scenarios for new • Alerts
processes/parameters
• Model demand-supply requirements
• Minimize energy costs
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Digital Twin for Maintenance
Strategy Description
• First Time Fix Rate
• Mean Time to Repair
Prescriptive Model and knowledgebase*
• Mean Time Between Failures
identifies an issue and what
to do for repair. • Reduced Losses
Mature Digital Twin • Optimized Equipment Lifecycles and
Predictive Equipment specific Spare Parts Usage
(PdM) algorithms* or machine
learning*. Multi-variate.
Failure Starts Failure can be
Condition Alerts for bad trends or other detected
Based (CBM) rules-based logic using a
single data value.

Asset Condition
Preventive Service in a fixed time or
cycle interval
Failure occurs

Reactive Run to failure, and then

repair

Operating Time P-F Interval

Asset Management Maturity Model P-F Curve

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Considerations For Your Digital Twin Initiative

$
Economy of Data Collaboration Data Governance Scalability
• Volume • Build • Integrity • More Data
• Fidelity • Maintain • Availability • More Analytics
• Application • Utilize • Security • More Uses

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 Thank You.
For more information, contact the author at
whastings@arcweb.com or visit our web pages at
www.arcweb.com
Operational Digital Twins in Action
Enrique Herrera - Industry Principal, Manufacturing

September 11, 2019

© Copyright 2019 OSIsoft, LLC

© Copyright 2019 OSIsoft, LLC
Operational Digital Twins in Action

• Organize operational for multiple users

• Visualize modeled results with actual measurements

• Train employees with actual operational data

• Optimize after service with advanced analytics

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Organize Data for Specific audience and goals
Engineering Operations Maintenance

• Create asset-centric
models:
• Target audiences and
goals
• Implement models in
operational analytics
• Re-use models across
multiple sites

Operational
Source: https://www.osisoft.com/pi-system/pi-capabilities/pi-server/
Data
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OSIsoft Asset Framework

Analyses
• Efficiency analysis Time-series
• Key Performance • In-Flow
Indicators (KPI) • Pressure
• Vibration data

Asset details
Events • Name
• Downtime
• Model
• Startup
• Manufacturer
• Failure

External data
Notifications • Performance curves
• High speed • Last maintenance date
• Rotor failure • Design documents
• Low pressure • Best operating procedures

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Organize and Synthesize Operations Data before Analyzing
BI Model Training
Tools Data
Lake Data
Hub
Data
Warehouse

Bulk Data Streaming Data

Enterprise Operations Infrastructure

Assets Automation Systems Edge Devices / Sensors IoT solutions

Source: https://www.osisoft.com/pi-system/pi-capabilities/pi-server/

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Visualize Actual with Desired / Predicted

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About Phillips 66

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Data Flow

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PI AF Template-based Solution

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 Ship Builder & Solution Provider:
Crew Training System

Source: OSIsoft EMEA User Conference 2017 Presentation: https://www.osisoft.com/pi-system/case-studies-and-testimonials/all-case-studies/DelfiEMEA2017story/

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Opportunities from New Digital Services

Product Optimized
Innovation Design

New
Asset
Services Efficiency
Digital
Transformation

Operational Reduce
Costs
Excellence

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Source: OSIsoft User Conference 2017 Presentation: https://www.osisoft.com/pi-system/case-studies-and-testimonials/all-case-studies/caterpillaruc2017story/

© Copyright 2019 OSIsoft, LLC

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© Copyright 2019 OSIsoft, LLC
© Copyright 2019 OSIsoft, LLC
Takeaways
• Optimize “brownfield” in parallel to “greenfield” scenarios

• Contextualize operational data to also serve engineering

• Use digital environment with operational data to train employees

• Optimize equipment performance with after service providers

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Enrique Herrera
eherrera@osisoft.com
+1 (734) 377-6080
Industry Principal – Manufacturing
and Connected Services
OSIsoft, LLC

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© Copyright 2019 OSIsoft, LLC