Digital Twin
Complex deployments where integration, safety, and operational handoff determine production success.
Inside this journey
-
Customer Discovery
Align on the pilot asset, desired engineering outcomes, decision makers (engineering, operations, IT/OT), data availability, and measurable success signals.
Discovery Questions
Start Here — What's the single asset that keeps you up at night?
- Which asset or unit would you pick for a pilot if you had to choose one today?
- Why that asset? Describe the specific operating risk, cost, or safety concern that makes it a priority.
- How often does this asset experience meaningful deviation from expected performance (unplanned downtime, derates, trips, or near-misses)?
- Can you point to a recent incident, upset, or near-miss where having a reliable simulation would have changed the decision made on the floor?
- Who on your team is closest to the day-to-day performance questions for this asset?
- If we could cut the frequency of unplanned events on this asset by half, what would that free up for your team—time, budget, confidence, other?
Show Me Where It Hurts (and what you’ve tried so far)
- Have you been accepting recurring losses because your current tools make testing changes feel too risky, too slow, or too uncertain?
- What monitoring, analytics, or models are you already running against this asset today (select all that apply)?
- When an alert or anomaly appears today, who typically starts the investigation and how long before action is taken?
- Tell us about a diagnostic or corrective action you tried that didn’t work—what did you learn and how did it change your expectations?
- Which outcome frustrates you most when current tools fail—false positives, missed degradation, long root-cause cycles, or lack of operator trust?
- How does that frustration show up in daily operations—pressure on shifts, overtime, delayed turnarounds, or conservative operating limits?
If you could simulate one change before touching a valve, what would it be?
- What specific operational question would you most want the twin to answer before you test it on the live asset?
- How often do you need to run these ‘what-if’ scenarios—daily, weekly, seasonally, or only for big changes?
- Which types of scenarios matter most to you (select all that apply)?
- What trade-offs are you willing to accept between model speed, interpretability, and raw predictive accuracy (e.g., a slower but explainable physics model vs a faster black-box ML model)?
- Have you used physics-based models before? If yes, describe what worked and what didn’t for adoption and accuracy.
- What would make a simulated scenario recommendation persuasive enough that an operator or engineer would act on it?
Where your data lives — and where it falls apart
- If an external team asked for historian and sensor data for the pilot today, how often would that data arrive complete, time-synced, and labeled without rework?
- Which systems will we need to integrate with for this pilot (select all that apply)?
- What typical sample rates, tag counts, and retention windows should we expect (e.g., 1s for control, 1min for trends, 5 years retention)?
- Describe common data quality issues you face (sensor drift, missing timestamps, unit mismatches, tag renaming, noisy signals, etc.).
- Does your organization have any data access or cyber requirements we need to plan for (e.g., DMZ, read-only accounts, on-prem agent, vendor security review)?
- How long does it typically take to get data access approvals from IT/OT in your org?
Who's in the room (and who needs convincing)
- Who would effectively block a pilot if they felt it created more work or risk than value (names or roles)?
- Which stakeholders need to sign off on the pilot to proceed (select all that apply)?
- Who on your side is likely to be the strongest internal champion for the twin, and why will they champion it?
- What are the executive priorities that will determine whether the pilot is seen as a success—cost reduction, safety, uptime, regulatory compliance, or innovation?
- How does procurement typically prefer to structure pilots (PO for services, time-and-materials, fixed-scope pilot, master services agreement)?
- What internal objection have you seen most often when a new analytics or simulation tool is proposed?
How we'll know it's working — real signals, not hunches
- If the twin produced highly accurate predictions but operators never used the outputs, would you consider that a successful pilot?
- Which measurable success signals matter most for your team (select up to three)?
- What validation window would you prefer for pilot acceptance (we typically recommend 30–60 days):
- What threshold of prediction performance would you need to see for engineering to sign off (e.g., X% within Y units, or specific alarm reduction)?
- Who will be the formal pilot acceptance signer(s) on your side?
- How do you want results delivered during the pilot—daily dashboards, weekly review calls, automated alerts, or integrated control-room displays?
Obstacles, deadlines, and the small print
- What hidden constraints might quietly kill a pilot before validation—staff bandwidth, scheduled outages, upcoming upgrades, or contract/legal issues?
- How many engineering hours per week can you realistically commit to the pilot for data prep, calibration reviews, and validation feedback?
- Do you have any fixed deadlines or windows (regulatory inspections, peak seasons, maintenance windows) that will determine our start or validation timeline?
- What contractual or IP concerns should we be mindful of (data ownership, model IP, derivative insights)?
- If we hit a technical roadblock, who should we escalate to on your side and what’s the fastest way to get an unblock?
- Assuming alignment, what is your desired pilot start month and an acceptable hard deadline for completion of validation?
- What would make you comfortable moving from pilot to production (example: proven X% uptime improvement, 6-month ROI, operator adoption metric)?
-
Solution Experience
Validate how the digital twin will answer the customer’s operating questions with their asset data through realistic what-if scenarios and a defined validation plan.
Experience Meetings
- Solution Experience Kickoff — Current State, Consequence & Future State
- Validation Plan Workshop — Metrics, Window & Acceptance Criteria
- What‑If Scenario Definition Workshop — Realistic Inputs & Expected Outputs
- Model Calibration & Data Quality Session
- Parallel Validation Review & Acceptance Decision
- Host to run first baseline calibration and deliver initial performance plots for the checkpoint meeting.
- Customer to submit one-sentence current state, one-sentence future state, and consequence summary document.
- Customer to provide a sample extract (7–30 days) from historian/SCADA/DCS and metadata mapping.
- Introductions & Meeting Objectives
- Anchor: Future State -> Problem Mapping
- Create 3–5 high‑value, realistic what‑if scenarios explicitly tied to customer operating questions.
- For each scenario, document inputs, expected outputs, and the KPI-based pass/fail rule.
- Agree the data slices and event markers necessary to run each scenario.
- Define the validation checkpoint scripts to force SME confirmation after runs.
- Customer SMEs to approve the final list of scenarios and provide any missing event annotations.
- Host to create scenario templates and baseline scripts that map inputs to expected outputs and KPIs.
- Data owner to extract and deliver the agreed representative data slices and event logs.
- Calibration Approach Overview
- Agree the calibration approach, timeline, and checkpoints.
- Document data quality issues with owners and a remediation plan.
- Schedule the first baseline run and define expected outputs for review.
- Agree pre-work deliverables and schedule for the validation activities.
- Customer to provide corrected metadata, sensor units, and any missing tags flagged in the data review.
- Host and customer to agree on temporary imputation rules or virtual sensor definitions for the validation window.
- Recap Accepted Criteria & Future State
- Demonstrate that the twin proves the defined future state for the prioritized scenarios.
- Reach an explicit acceptance decision tied to the numeric KPIs and the operational consequence.
- If not accepted, agree a concrete iteration plan with owners and timeline.
- Define immediate next steps for production integration or remediation.
- Host to publish the full validation report with scenario results, plots, and pass/fail summary.
- Acceptance authority to sign acceptance, conditional acceptance, or request iteration within the agreed timeframe.
- If accepted, schedule the first deployment/gateway meeting and assign integration owners; if iteration, create a remediation backlog.
- Obtain a crystal‑clear current state stated in one sentence by the customer.
- Quantify the consequence of the current state in operational/financial terms.
- Agree a one‑sentence future state outcome that the Solution Experience must prove.
- Confirm available data streams, identify gaps, and assign owners for access.
- Host to prepare a tailored validation plan template based on the inputs for the next workshop.
- Recap Objectives & Constraints
- Agree a measurable validation plan with explicit KPIs and numeric acceptance thresholds.
- Lock the validation window and representative operating cases to be used.
- Assign owners and an acceptance authority along with a decision timeline.
- Document key validation risks and immediate mitigations.
- Host to publish the validation plan document with KPIs, thresholds, window, and roles for signature.
- Customer to confirm acceptance authority and provide final dates for the validation window.
- IT/OT to provision read access to selected historian slices and confirm data delivery method.
- One‑Sentence Current State (Customer‑led)
- Results Presentation — Scenario by Scenario
- Prioritize Operating Questions
- Validation Approach Overview
- Live Data Quality Review
- Calibration Tasks & Checkpoints
- Diagnosis: Failure Modes & Residuals
- Define Success Metrics & Acceptance Thresholds
- Consequence Quantification
- Define Scenario Templates
- Gap Remediation Plan
- Validation Decision & Rationale
- Identify Representative Data Slices & Event Markers
- One‑Sentence Future State
- Select Validation Window & Sample Cases
- Next Steps: Production Handover or Iteration Plan
- Baseline Run Schedule & Outputs
- Validation Checkpoints & Acceptance Phrases
- Roles, Governance & Decision Rule
- Data Inventory & Access Readiness
-
Solution Scope
Define the pilot scope: selected asset, data integrations (historian/SCADA/DCS), model approach (physics + ML), calibration tasks, validation window (30–60 days), deliverables, and responsibilities.
Scope Configuration
- Historian Data Ingestion and Cleaning
- Equipment Design Data Import
- Physics-Based Asset Model Implementation
- Data-Driven ML Model Training
- Model Calibration to Historical Operations
- Parallel Live-Data Twin Deployment
- Real-Time Monitoring Dashboard Deployment
- Automated Alert and Anomaly Rules Deployment
- Virtual Sensor Creation and Deployment
- Degradation Prediction Engine Deployment
- What-If Scenario Simulation Workspace
- DCS/SCADA Integration via OPC/REST
- CMMS Integration for Maintenance Workflows
- Engineer and Operator Training on Twin Use
- Continuous Model Retraining Pipeline Deployment
Scope Questions
Historian Data Ingestion and Cleaning
- Which historian(s) or time-series systems hold the asset data we should ingest?
- What variables/tags are required for the pilot twin (e.g., temperatures, flows, pressures, setpoints)? List key tags or upload a sample mapping.
- What is the typical sampling frequency and expected data volume for the selected tags?
- What common data quality issues should we expect (select all that apply)?
- Are there any access, security, or privacy requirements for historian ingestion (VPN, jumpbox, read-only accounts, anonymization)?
Equipment Design Data Import
- Do you have equipment design documents available for the pilot asset (P&IDs, datasheets, nameplates, OEM curves)?
- In what formats are design documents currently stored?
- Are there existing thermodynamic or process models (e.g., Aspen, HYSYS, vendor models) we can reference?
- Are OEM performance curves or calibration constants required from vendors to build the physics model?
- Please list any critical mechanical or control limitations (e.g., max RPM, bypass valves, safety interlocks) that must be represented in the model.
Physics-Based Asset Model Implementation
- Which physical phenomena must the physics model capture for the pilot (e.g., thermodynamics, fluid dynamics, heat transfer, rotor dynamics)?
- Do you require a first-principles model from scratch, adaptation of an existing model, or a hybrid physics+data approach?
- What level of fidelity is required for the pilot (steady-state only, dynamic transient response, sub-second dynamics)?
- Are there proprietary equations, vendor IP, or safety constraints that limit the model implementation decisions?
- Who will be the technical owner for physics model decisions on the customer side (role/title)?
Data-Driven ML Model Training
- Which ML objectives are prioritized for this pilot (e.g., residual correction, anomaly detection, virtual sensors, predictive degradation)?
- What historical data window is available for training (e.g., 3 months, 1 year, multiple years)?
- Are labeled events available for supervised training (e.g., failures, maintenance logs, performance test labels)?
- What are acceptable model development constraints (training on-prem vs cloud, data retention, compute limits)?
- Do you require explainability/feature importance reporting for ML models to satisfy engineering reviews?
Model Calibration to Historical Operations
- Which historical period should be used for calibration to represent typical and extreme operating conditions?
- What calibration accuracy targets or KPIs will determine success (e.g., RMSE, MAE, % error bounds)?
- Who will sign off on calibration results (roles: reliability engineer, process manager, operations lead)?
- Are there maintenance or operational records available to correlate model errors with equipment state?
- Are we allowed to run calibration iterations against live historical data or only offline sandboxes?
Parallel Live-Data Twin Deployment
- Do you want the twin to run in parallel with the live asset during a validation window of 30–60 days?
- What target latency is required for parallel predictions (real-time, 1–5 min, 5–30 min, hourly)?
- Who will monitor the parallel run on your side and how should discrepancies be reported?
- Are there constraints for connecting to live systems (maintenance windows, read/write restrictions)?
- What acceptance criteria must be met at end of parallel deployment to consider pilot successful?
Real-Time Monitoring Dashboard Deployment
- Which users/groups need dashboard access (operators, engineers, managers, executives)?
- What KPIs and visualizations are required (e.g., predicted vs actual, residuals, trends, alarms)?
- Do dashboards need to be embedded in existing control-room displays or served via web/mobile portals?
- Are there authentication/SSO requirements or role-based views to implement?
- What refresh frequency and historical window are required for dashboard charts?
Automated Alert and Anomaly Rules Deployment
- What types of alerts are needed (threshold breaches, anomaly detection, model divergence, maintenance triggers)?
- What delivery channels should be used for alerts (email, SMS, SCADA alarm, CMMS ticket)?
- What severity levels and escalation paths should alerts follow?
- Are there existing anomaly rules or thresholds we should import, or should we define new ones?
- Do alerts require enrichment with process context or suggested actions (e.g., checklist for operators)?
Virtual Sensor Creation and Deployment
- Which physical measurements are unavailable or unreliable and should be replaced with virtual sensors?
- What accuracy and latency requirements do virtual sensors need to meet?
- Are virtual sensors for control loops (closed-loop) or for monitoring/analysis only?
- Where should virtual sensor outputs be published (historian tags, dashboards, control system)?
- Do virtual sensors require certification or validation by OEM or plant engineering before use?
Degradation Prediction Engine Deployment
- Which degradation modes are most important for the pilot (e.g., fouling, erosion, bearing wear, efficiency loss)?
- What lead time do you require for actionable degradation predictions (days, weeks, months)?
- Do you have failure/performance thresholds that should trigger maintenance workflows?
- How should predicted degradation translate into actions (automated CMMS ticket, investigation alert, schedule maintenance)?
- Are there historical failure/inspection records to validate degradation models?
What-If Scenario Simulation Workspace
- Which scenario types should be supported (operational setpoint changes, equipment failures, feedstock changes, ambient variations)?
- Who will be allowed to run scenarios (operators, engineers, managers) and what guardrails are required?
- Do scenarios need to run real-time interactive simulations or offline longer-horizon analyses?
- Should scenario results be stored and auditable for regulatory/process reviews?
- Are there pre-defined scenario templates or use cases you want pre-built for the pilot?
DCS/SCADA Integration via OPC/REST
- Which protocols and endpoints are available for integration (OPC DA/UA, Modbus, REST APIs, MQTT)?
- Are integration connections allowed directly to DCS/SCADA or must they go through an intermediary (e.g., historian, DMZ)?
- Do you require write-back capabilities (setpoints, advisory commands) or read-only integration?
- What change management approvals are required to integrate with operational control systems?
- Are there latency or determinism requirements for data exchanged with DCS/SCADA?
-
Mutual Commit
Agree commercial terms, pilot acceptance criteria, data access approvals, timelines, and governance for moving from pilot to production.
Agreement Modules
- Non-Disclosure Agreement (NDA)
- Master Services Agreement (MSA)
- Statement of Work (SOW)
- Commercial Terms & Order Form
- Payment Schedule & Invoicing
- Pilot Acceptance Criteria & Validation Plan
- Data Access, Integration & Security Approval
- Data Processing Agreement (DPA)
- Service Level Agreement (SLA) - Pilot Support
- Intellectual Property & Licensing Agreement
- Roles, Responsibilities & Governance Plan
- Change Control & Scope Amendment
- Production Transition & Expansion Agreement
- Regulatory & Compliance Confirmation
- Insurance, Liability & Indemnity Confirmation
-
Deployment
Execute onboarding: ingest data, build and calibrate the twin, run parallel validation, integrate dashboards and alerts, and deliver operator/engineer training with clear owners and milestones.
-
Success
Confirm prediction accuracy against success signals, complete handover to operations, document learnings, and plan asset expansion while tracking issues and enhancements.
Success Reviews
- Pilot Validation & Acceptance Review
- Operations Handover & Runbook Workshop
- Lessons Learned & Continuous Improvement Retrospective
- Asset Expansion Prioritization & Scale Roadmap
- Issue Triage & Enhancement Governance Setup
Issues & Enhancements
- Produce a prioritized expansion roadmap document with owners and high-level estimates.
- Deliver and get sign-off on operational runbooks, dashboards, and alerting behavior.
- Align on operational owners, SLAs, and escalation paths.
- Schedule and commit to operator and engineering training with clear acceptance criteria for proficiency.
- Share final runbooks, playbooks and access credentials to operations and archive in the agreed repository.
- Configure and test alert delivery path and confirm a test alert with operations.
- Schedule operator training sessions and assign trainees for completion tracking.
- Purpose, Scope and Ground Rules
- Document a clear, actionable lessons-learned report capturing root causes and mitigations.
- Create and prioritize an enhancement backlog with owners and estimated effort.
- Agree updates to standards and processes to reduce recurrence of identified issues.
- Draft and circulate the lessons learned report including RCA and recommended mitigations.
- Populate the enhancement backlog in the issue tracker and assign owners with target dates.
- Update modeling and data quality standards documents and circulate for approval.
- Recap of Pilot Outcomes and Business Case
- Create a prioritized, time-bound expansion roadmap for additional assets.
- Align on resource commitments, estimated effort and preliminary commercial approach.
- Identify key risks and mitigation plans for scaling the program.
- Introductions & Meeting Objective
- Prepare detailed SOW and commercial proposal for the first 1-2 expansion assets.
- Schedule a follow-up governance meeting to approve funding and start dates.
- Purpose and Cadence
- Establish a documented triage and governance process with SLAs and owners.
- Assign and schedule resolution for outstanding issues from the pilot.
- Agree on a safe, repeatable release process for model and dashboard updates.
- Create the triage board in the issue tracker with severity fields and SLA automation.
- Assign owners and target dates to all outstanding validation issues.
- Publish the release management checklist and schedule the first maintenance release window.
- Verify the twin meets the predefined success signals with evidence and representative examples.
- Secure a formal acceptance decision or a prioritized remediation plan with owners and timelines.
- Ensure all stakeholders confirm that demonstrated outcomes tie directly to their stated operational consequences.
- Produce and circulate a validation evidence package (metrics, plots, datasets, and test cases).
- If remediation required, create a remediation plan with tasks, owners, acceptance criteria and target completion dates.
- If accepted, schedule the Operations Handover & Runbook Workshop and assign initial owners for handover artifacts.
- Handover Status & Acceptance Recap
- What Worked Well
- Roles, Responsibilities and SLA Overview
- Severity Matrix, SLAs and Escalation Paths
- Selection Criteria & Candidate Review
- Current State, Consequence, Future State (Preconditions)
- Estimate Effort, Data Readiness and Risk per Asset
- Review Outstanding Validation Issues & Assign Owners
- Validation Methodology & Dataset
- Runbooks, SOPs and Playbooks
- What Did Not Meet Expectations
- Results: Metrics, Time-series Overlays, and What-if Cases
- Root Cause Analysis
- Phased Roadmap & Resource Plan
- Dashboards, Alerts and KPI Definitions
- Release Management and Test Requirements
- Improvement Backlog & Prioritization
- Data Access & Integration Handover
- Reporting, Metrics and Continuous Feedback Loop
- Commercial Model and Governance for Scale
- Forced Validation Checkpoints
- Decision: Accept, Accept-with-Conditions, or Remediate
- Update Standards & Next Steps
- Decision, Risks and Next Steps
- Training & Knowledge Transfer Plan
- Confirm Recurring Meeting Invite and Charter