Digital Twin
for critical assets

Virtual models.
Real decisions.
Sustained impact.

The right decision at the right time

The Digital Twin combines machine data and process parameters to create a realistic digital replica – for simulation, virtual commissioning and real time monitoring.

The Digital Twin provides more than data. It provides insight for well-founded decisions, reliable processes & deeper understanding across assets and plants

Gain confidence by virtually designing, testing and commissioning technical changes

Resolve troubles quickly and sustainably

Gain insight in asset performance and find potential for increasing availability and efficiency

Drive cost-effective maintenance strategies and modernization planning

Train operators with ultra-realistic process behavior

Explore amazing opportunities

We lay the foundation for condition-based maintenance, greater efficiency, and long-term operational reliability — through digital twins combined with in-depth process understanding and engineering expertise.

Virtual commissioning of an extraction turbine

Revamp of obsolete Woodward speed and Ascania extraction controller incl. valve actuators. The Digital Twin was used to test the new PLC-based controller in closed-loop. Therefore, the Digital Twin has been connected to the PLC in a real-time setup.

  • Test of normal operation, startup & shutdown
  • Pre-tuning turbine controller parameters
  • Reduced commissioning time of turbine control by approx. 50%
  • Stable & high-performance operation from first startup
  • Shorten plant startup to stable operation from 48h to 8h

Compressor reverse rotation

A multi-stage turbine-driven air compressor experienced severe reverse rotation at 80% of rated speed during an emergency shutdown. The Digital Twin was used to reproduce the incident and to provide recommendations for the placement and sizing of additional blow-off valves and silencers.

  • Recommended additional blow-off valve position, size & speed
  • Automated Test of several 100 design alternatives
  • Successfully prevented reverse rotation during ESD
  • Successfully prevented compressor surge during shutdown

Increasing energy efficiency

Using a digital twin to optimize a multi-stage ammonia compressor. Simulations revealed efficiency reserves, improved the control strategy, and reduced steam consumption.

  • Forecasting the effects of a higher gearbox transmission ratio
  • Simulation and energy saving analysis
  • Development of a tailored stage-wise surge limit testing approach
  • Optimization of load distribution between stages

Optimization of water pump station

To optimize energy consumption, a digital twin of three parallel, speed-controlled feed pumps was used. Different pump sizes and combinations have been analyzed. In addition, the control scheme has been optimized to minimize switching events. This ensures higher pressure stability and reduced wear.

  • Goal was to minimize energy consumption and switching events
  • Identification of optimal pump size, combination and vendor
  • Considered typical demand based on current and future requirements
  • Model was later used for virtual commissioning

Operator training of compressor control

The Digital Twin has been used to train upgraded anti-surge control of the cracked gas, ethylene and propylene compressors in an ethylene cracker plant. This builds trust in the control upgrade for operators and improvement team even before hot commissioning.

  • Digital twin connected to ABB 800xA system
  • Theoretical and practical part to explain new features
  • Various scenarios tested with operators from simple to complex
  • New DCS graphics presented, explained and used interactively

Drive informend decision-making

We think people make good decisions when they understand what’s going on.

For us, the Digital Twin means transparency, security, and clarity—especially when complexity becomes paralyzing. It makes the invisible visible and the complicated manageable, so that engineers, maintenance crew, operators, and decision-makers can act with calm and confidence.

Holistic – includes all relevant process components, consumer and control systems

Fully dynamical – understand effects of process dynamics like startup, shutdown, equipment failure

High fidelity – Digital Twin is trained with process data to capture all relevant operating modes

Connectable – Integrate the Digital Twin with your real asset or connect to other simulation systems

Independet since 20 years – 100% owened by us. 100% control for customer solutions

One Digital Twin following the lifecycle

Simulation helps in selecting the control strategy and actuators. This ensures best dynamics and optimal control performance for the machine and for the overall process.

Simulation is put against plant or asset control for ultra-realistic testing of closed-loop control, sequences & dangerous situations. The technical risk is greatly minimized. Saves time & cost during hot commissioning.

Simulation is used to train normal & abnormal operation as well as dangerous situations without affecting the plant. Awareness is built even before commissioning. The risk of improper operator reactions is minimized.

Simulation is used to identify the root cause of process interruption or breakdown and offers a tailored solution. The goal is to avoid unplanned downtimes and restarting delays.

The Digital Twin is used for continuous benchmarking. Comparison of simulated data with the current operation shows how well the asset / plant is working. Track performance as well as efficiency and identify deviations.

Simulation is used detects abnormal plant behavior and assists root cause analysis. The plant health can even be extrapolated to predict future degradation. Plan your maintenance measures more precisely.

Simulation is used to discover potential for improvement and increases the efficiency of machine operation and the process itself. Powerful optimization algorithms consider technical, financial and environmental factors.

Like to discover more or discuss a specific project?

Dr.-Ing. Rico Schulze
Head of Digital Solutions

Phone: +49 341 21787-1791
Mobil: +49 1525 6858222
Email: rico.schulze@avicomp.com
LinkedIn: www.linkedin.com/in/dr-rico-schulze