IN08
Course Contents
Module 1: Foundations of Digital Twins and Process Simulation
- Core definitions, history and maturity levels of industrial digital twins
- Architecture: physical assets, virtual models, data links and user displays
- Types of models: steady-state vs dynamic, empirical vs physics-based
- Value proposition: risk reduction, virtual testing and lifecycle management
- Standards, interoperability and data exchange frameworks
- Industry use cases across refining, upstream, power and chemical plants
- Strategic planning: identifying high-impact applications and setting goals
Module 2: Process Modeling and Data Integration Methods
- Principles of building fit-for-purpose chemical and process models
- Mass, energy and momentum balance equations in dynamic simulations
- Connecting models to live plant networks and data historian platforms
- Managing data quality, sampling rates, metadata and model input streams
- Model boundary conditions, environmental variables and external disturbances
- Data synchronization, time alignment and buffering techniques
- Resolving data mismatches and reconciling virtual and physical metrics
Module 3: Instrumentation and Control System Simulation
- Simulation of primary sensors, transmitters, loops and signal noise
- Control valve dynamics: simulating deadband, stiction and non-linearities
- Modeling PID controller behavior, interactions and tuning assessment
- Interlocks, permissives, alarm configurations and sequence block simulation
- Model-in-the-loop, software-in-the-loop and hardware-in-the-loop configurations
- Scenario testing for instrument faults, loop failures and drifting sensors
- Model calibration techniques, validation metrics and uncertainty checks
Module 4: Virtual Commissioning and Operational Applications
- Virtual commissioning workflows, test plans and acceptance criteria
- Testing and validating PLC and DCS logic code before plant deployment
- Operator training simulators (OTS) and operator competency development
- Predictive monitoring, virtual sensors and equipment health assessment
- Evaluating advanced control strategies and process optimization paths
- What-if analysis for extreme operating states and emergency scenarios
- Performance dashboards, diagnostic views and operational decision support
Module 5: Deployment, Security and Lifecycle Management
- Comparing edge, on-premise and cloud deployment architectures
- Integration protocols: OPC UA, MQTT, web APIs and industrial buses
- Cybersecurity for connected virtual twins and active control interfaces
- Role-based access control, encryption and secure remote support pathways
- Model versioning, change management workflows and configuration records
- Performance tracking, automated drift detection, recalibration and retirement
- Developing a scalable, multi-phase digital twin implementation roadmap
