PC-DEC22-PG54-55.1_Layout 1 06/01/2023 12:34 Page 54
PROCESS SIMULATION
TIME TO EMBRACE TOTAL SIMULATION
Nathalie Marcotte, SVP & President, Process Automation at Schneider Electric,explores why total simulation through digital integration is the next critical step for industrial efficiency and sustainability
oversight of operations to make the right decisions. However, realising this new era requires an entirely holistic approach. While the digital simulation of plants is being realised, not enough attention is given to process simulation. From the need to accelerate
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decarbonisation and reduce energy use, to improving employee health and wellbeing, digital technologies play a pivotal role in industrial future-proofing. Meeting these challenges requires total investment in digital integration to create a fully sustainable future.
Next-generation process simulation In 2019, EY analysed 500 completed oil and gas capital projects of $1bn or more from the previous five years. Of the projects analysed, 60% experienced schedule delays, and 38% had cost overruns. These losses were found to be a result of absent, unreliable or badly managed data, poor processes and poor communication. As EY states: ‘digital technology provides greater insights and control over each project, at every stage of
igital simulation represents the move into the next industrial era; one where digital technology provides complete
execution.’ Process simulation is a vital component of this new approach. Process design has traditionally been
overly complicated, with various disconnected tools and complex incompatible models, siloed from other disciplines. However, digitalisation is removing these siloes. For example, the use of digital twins provides engineers with one platform within which to explore all dimensions of a design, from conception to
delivers on all levels. It results in process, people and planet-friendly progress
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implementation and use. In the process industries, engineers can use digital twins to innovate and optimise processes, evaluate design concepts and make ongoing operational decisions quickly and safely. Now, with first principles, physics-based
models meeting data-analytics and hybrid models, the integration of Artificial
54 DECEMBER 2022/JANUARY 2023 | PROCESS & CONTROL Total simulation
Intelligence (AI) within cloud-based digital twins enables lightning-fast innovation and global collaboration across disciplines. For example, until recently, efforts to
optimise an engineering or operational domain were done in isolation. Digitalisation is removing these siloes, allowing meaningful acceleration and optimisation. Process and electrical engineering have
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often worked together inefficiently, being siloed despite their interdependence. Digitally integrating power and process enables the delivery of critical digital twin elements from the project phase into ops and maintenance, contributing to successful start-up and production. An electrical digital twin integrated with the process digital twin facilitates predictive operations and a holistic approach to asset and power system performance management. Across the lifecycle, this integrated approach has been shown to deliver 20% EI&C-related CAPEX cost reduction, 15% reduced downtime in ops, 10% process energy usage reduction, and 3pts profitability improvement.
Process simulation for sustainable innovation This new approach is also crucial in meeting sustainability targets. Decarbonisation is an
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