Digital Twin<\/span> Virtual models. The right decision at the right time<\/p>\n<\/div><\/div><\/div> The Digital Twin combines machine data and process parameters to create a realistic digital replica \u2013 for simulation, virtual commissioning and real time monitoring.<\/p>\n The Digital Twin provides more than data. It provides insight for well-founded decisions, reliable processes & deeper understanding across assets and plants<\/p>\n<\/div><\/div><\/div> Gain confidence by virtually designing, testing and commissioning technical changes<\/p>\n Resolve troubles quickly and sustainably<\/p>\n Gain insight in asset performance and find potential for increasing availability and efficiency<\/p>\n Drive cost-effective maintenance strategies and modernization planning <\/p>\n Train operators with ultra-realistic process behavior<\/p>\n<\/div><\/div><\/div><\/div><\/div> Explore amazing opportunities<\/p>\n<\/div><\/div><\/div> We lay the foundation for condition-based maintenance, greater efficiency, and long-term operational reliability \u2014 through digital twins combined with in-depth process understanding and engineering expertise.<\/p><\/p>\n<\/div><\/div><\/div> Virtual commissioning of an extraction turbine<\/p>\n 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.<\/p>\n<\/div> Compressor reverse rotation<\/p>\n 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.<\/p>\n<\/div> Increasing energy efficiency<\/p>\n Using a digital twin to optimize a multi-stage ammonia compressor. Simulations revealed efficiency reserves, improved the control strategy, and reduced steam consumption.<\/p>\n<\/div> Optimization of water pump station<\/p>\n 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.<\/p>\n<\/div> Operator training of compressor control<\/p>\n 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.<\/p>\n<\/div> Drive informend decision-making<\/p>\n<\/div><\/div><\/div> We think people make good decisions when they understand what’s going on.<\/p>\n For us, the Digital Twin means transparency, security, and clarity\u2014especially 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.<\/p>\n<\/div><\/div><\/div> Holistic – includes all relevant process components, consumer and control systems<\/p>\n Fully dynamical – understand effects of process dynamics like startup, shutdown, equipment failure<\/p>\n High fidelity – Digital Twin is trained with process data to capture all relevant operating modes<\/p>\n Connectable – Integrate the Digital Twin with your real asset or connect to other simulation systems<\/p>\n Independet since 20 years – 100% owened by us. 100% control for customer solutions<\/p>\n<\/div><\/div><\/div><\/div><\/div> One Digital Twin following the lifecycle<\/p>\n<\/div><\/div><\/div> 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.<\/p>\n<\/div><\/div><\/div>
\nfor critical assets<\/p>\n
Real decisions.
\nSustained impact.<\/p>\n<\/div>![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-UseCase-VC-ExtractTurbine.webp\" "\\"PRD-002")
<\/span><\/div><\/div><\/div><\/i><\/i><\/span>Details<\/span><\/a><\/h4><\/div>
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<\/i><\/i><\/span>Details<\/span><\/a><\/h4><\/div>
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![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-UseCase-FaultAnalysis.webp\" "\\"PRD-002")
<\/span><\/div><\/div><\/div>![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-UseCase-Energy-Efficiency.webp\" "\\"PRD-002")
<\/span><\/div><\/div><\/div><\/i><\/i><\/span>Details<\/span><\/a><\/h4><\/div>
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<\/i><\/i><\/span>Details<\/span><\/a><\/h4><\/div>
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![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-UseCase-OptimizeWaterPumps.webp\" "\\"PRD-002")
<\/span><\/div><\/div><\/div>![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-UseCase-OperatorTraining.webp\" "\\"PRD-002")
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![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/PRD-002-DT-Lifecycle-2024-02-01.png\" "\\"PRD-002")
<\/span><\/div><\/div><\/div><\/i><\/i><\/span>Simulation-aided Engineering<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>Virtual Commissioning<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>Operator Training<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>Virtual Troubleshooting<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>Smart Monitoring<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>Smart Maintenance<\/span><\/a><\/h4><\/div>
![](\"https:\/\/www.avicomp.com\/en\/wp-content\/uploads\/sites\/2\/2025\/11\/BUS-005-Contact-ACC-LEJ-RIS-2025-11-18.webp\" "\\"BUS-005")
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