Plant Reliability/Sustainability with Digital Twin

Sreekumar Pillai, Manager, Consulting Services


The concept of digital transformation with ‘Digital Twin’s is about creating a digital representation of physical assets of a plant with 3D Intelligent model creation (governed by PDS, PDMS, SP, AUTOCAD, STAD, CAE and CAM software), as well as the enterprise and product lifecycle data management applications (SAP, WRENCH, project lifecycle/data management
and other software). This will be supported by AI (Artificial Intelligence) algorithms and adoption of IIoT (Internet of Things), smart sensors, which helps in predictive analysis of the asset but also enables in quickly running through the historian data, with the objective of achieving plant safety, reliability and Sustainability.
Digital twins are used throughout the asset lifecycle to simulate, predict, and optimize the equipment performance and production system before investing in real physical assets.
By incorporating multi-level simulation, data analytics, and machine learning capabilities, digital twins can demonstrate the impact of design changes, real time scenarios, environmental conditions, and other variables, reducing development time, and improving quality of the final product or process.

Some of the features that make ‘Digital Twins’ a major breakthrough-.

  • Asset Integrity Management.

Digital Twin is designed to deploy evolving technologies such as Artificial Intelligence and Machine Learning to analyze tasks and learn and evolve from experience. The data generated in the process is continuously analyzed and saved in the cloud.

  • Predictive Analysis

Digital Twin enables the maintenance team or operations team, in predicting the asset performance, which supports asset lifecycle management; thus, preventing failures of industrial machines.

  • IT – OT Convergence

Digital Twin’s provides a complete solution to plant reliability. In other words, it enables convergence of technology such as Big Data, ML, Cloud Computing, AI, and IIoT.


A mechanical engineer with 35 years of international experience and sound knowledge of industry standards. Leading the engineering team on hydrocarbon mid & downstream, upstream, fertilizer, petrochemical, power, EPC projects in India and global; customer relationship, scope/commercial, design , construction support, subcontract and risk management; on-time delivery, with Quality, within budget cost and safe execution for client’s viz. ARAMCO, EIL, IOCL, ONGC, GNFC, HPCL, RCF, GASCO , MRPL… Integrated solutions for E, P & C, using latest innovative technologies, digitalization; driving operational efficiency and productivity, developing a high-performance engineering capability centre utilizing process improvements, creativity, building competency; and teamwork to design and execute solutions that create customer value Project training schedules, plans, policies and ensure projects are followed within the estimated time frame.