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文檔簡介
Acceleratinglow-carbonhydrogenandcutting
costswithdigital
technology
Digitalleversfor
enhancingand
acceleratingthe
developmentof
low-carbonhydrogen
Deliveringgreatervaluefromyour
low-carbonhydrogenassetsbyusingbetterassetinformationtoimproveinvestmentdecisionsandoperations.
Siemens
Index
ExecutiveSummaryScopeofthispaper
1.SiemensandCapgeminijointapproachforlow-carbonhydrogenasset
1.1OurValueProposition
1.2SiemensandCapgemini,arelevantpartnershipforthedigitalizationofthehydrogenindustry
2.Settingupthescene–definitions,frameworksandprerequisites
2.1Introducingthedigitaltwinforassetintensiveindustries
2.2Integratedengineering
2.3Prerequisitestounleashdigitalpotential
3.Unleashingpotential:Digitalization’sroleincuttingtheLevelizedCostofHydrogen
3.1Unlockingefficiency:Digitalleversforefficientdesignandengineering,fasterconstruction,andassetreplication
3.2Optimizingproduction:enhancingefficiencyfromenergysupplytooperationandmaintenance
3.2.1Energysupplyoperations3.2.2Productionprocesses
3.2.3Maintenance
3.3Enablingtraceability,compliancetargets,andcarbonintensity
3.4ManageefficientlyAssetsportfolio
3.5LCOHcanbereducedbyanestimated9%to12%activatingdigitalleversandassociatedactions
References
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3
ExecutiveSummary
Despiteadynamictrend,thehydrogenmarketdoesnotprogressasfastasexpected
Thedecarbonizationpotentialoflow-carbonhydrogeninhard-to-abatesectors,coupledwithitscapacitytofacilitateenergytransporttoresource-constrained
regionsatscale,hasgeneratedsignificantenthusiasmwithinthehydrogensectorinrecentyears.However,despitegrowingannouncementsofnewlow-carbonhydrogenprojects–potentiallyreaching38Mtby
2030,ifallannouncedprojectsmaterialize-only4%ofprojectshavereachedthefinalinvestmentdecision
(FID)orconstructionphase,asreportedbythe
InternationalEnergyAgency(IEA).Clearly,wehavenotyetmetourobjectives.
Low-carbonhydrogenstillstrugglestobecomecompetitive
Low-carbonhydrogenremainstooexpensiveandlackscompetitivenesscomparedtocarbon-based
hydrogen.1Thecostrangesfrom6-9€/kg2for
low-carbonhydrogenversus1.5-3€/kgforhydrogenproducedfromnaturalgasreforming(before
subsidies).Thiscostdisparityarisesfromvariousfactorsrelatedtoproduction,infrastructure,and
technologicalrequirements.Transitioningtohydrogen
fromrenewablesisparticularlycostlyduetoexpensiveproductionprocessesandtheadvancedend-use
technologiesinvolved.Establishingthenecessary
infrastructureforhydrogenproduction,storage,anddistributionrequiressubstantialcapitalinvestment,
includingtheconstructionofrenewableenergyplants,electrolyzers,storagefacilities,andtransportation
networks.
Currentlythelow-carbonLevelizedCostofHydrogen(LCOH)producedviaelectrolysisprimarilycomprisespowercosts(representing40%to60%ofthetotal),equipment,engineeringandconstructioncosts(20%to35%)andoperationalcostsof(5%to15%).3The
LCOHishighlyinfluencedbytheloadfactor(includingavailability)whichimpactsproductionvolume,powerconsumption,andcapitalexpenditures(CAPEX)
amortization.
Thehydrogensectorisactivelyseekingleverstomitigatecosts
Asprojectsdevelopersadvanceintoearlyengineeringanddesignstages,assetdevelopersareactively
seekingwaystomitigatecostsandextensiveliteratureoutlinesstrategiestodrivedowncostsandposition
hydrogenasaneffectiveenergytransitionvector.
Whilesomelevershavealreadybeenemployedto
reduceinvestmentcostsinlow-carbonhydrogen,
additionalopportunitiesremainforplayersacrossthevaluechains,especiallyequipmentmanufacturersandassetdevelopers(seefigure1).
Systemdesignandengineering
Standardization
Laborcosts
Systemdesign
optimizationsolutions
SimulationenergyandH2lows(HMS,designtwin)
Developingautomationandvirtualcommissioning
GenerativeAI
ProcurementandConstruction
StorageTechnologies
Electrolyzerstechnologies
Modularization
Laborcosts
Constructiontwin
Dataanalytice
OperationsandMaintenance
Equipments’eiciency
ConnectedWorker
Operationstwin
Maintenancetwin
DigitalleversimpactCAPEX,electricitycostsandotherOPEXaswellasthevolumeofproduction
Electricitysupplycost
FrameworksforPPAcontracts
Flexibilitytechnologies
(Incl.BESS)
CapacitySizingOptimization(incl.RES,BESS)
Predectiveanalyticsforpowersupplystrategy
Digitallevers
Otherlevers
Figure1-LCOHreductionlevers4
4CapgeminixSiemens
5
Whydigitalizationwillplayapivotalrole
Asassetmanagersembracethedigitalage,creating“digitalnative”assetsbecomescrucial.ThisapproachensuresthecomprehensiveavailabilityofoperationalandassetdataforinformeddecisionmakingthroughDigitalAssetManagement.Bystrategicallyfocusing
onkeydecisionswithinassetprocessesand
transformingdataintoactionableinsights,assetmanagerscandeliversignificantbusinessvalue.
Digitalizationwillplayapivotalroleinenhancingtheinvestmentcaseforlow-carbonhydrogenprojectsbyoptimizingthedesign,operationsandmanagementofproductionassets5,asperthefollowingkeyfacts:
?Greenfieldassets:giventhatthelow-carbon
hydrogensectorisstillinitsearlystages,greenfieldprojectsofferasignificantopportunitytodevelopdigitalnativeproductionassetsandleverage
digitalizationevenpriortothecommencementofconstruction.Plantsarebeingbuiltforthefirsttimeandadigitaltwinoftheplantisgeneratedasa
by-productoftheengineeringprocesswithoutadditionaleffort.
?Scale-up:mostoftheplantsandassetscanactasablueprinttobereplicatedlater.
?Securingfinancing:adigitaltwincapableto
demonstratethevalidityoftheengineering,whichcanalsopredicttheeffectivenessoftherunningplantenablethesuccessfulclosingoffundraisingactivity.
?Respectingprojecttimeline:thesimulation
opportunitiesofferedbydigitaltoolsenabletoanticipate,avoiderrorsthatwouldoccurina
first-of-a-kindproject,andprepareforthestartofoperationsatanearlystage,-eventotrain
operators,viavirtualtrainings.
?Innovativefirstofakindplants:beingableto
simulatebeforeinvestinginthefinalconstructionbringsahugeadvantage.
?Newplayersandmaturityofthemarketplayers’roles:similarly,adigitalplantcanhelpovercomelackofexperiencefromnewincumbents.
?Manysimilarbutcomplexpackageunitsandcomponents,wheredigitaltoolsfacilitatethecomprehensiveintegrationofamodularsetup.
1.Forhydrogenproductiontobeconsideredlow-carbon,itmustcomeundertheEU’sproposedemissionsthresholdof3.38kgCO2e/kgH2,whichis70%lowerthanthatofthe
predefinedfossilfuelcomparator,includingtransportandothernonproductionemissions.IntheUS,thecorrespondingcarbonintensityvaluetoqualifyforhydrogenproductiontaxcreditsundertheIRAis4.0kgCO2e/kgH2.
2.Low-carbonhydrogenproducedwithelectrolysis.
3.Thesefiguresvaryaccordingtoprojects’configuration,buttheyrepresenttheorderofmagnitude.
4.PPA:PowerPurchaseAgreement;RES:RenewableEnergyStorage;BESS:BatteryEnergyStorageSystem
5.Thehydrogenproductionassetisdefinedbytheelectrolysisunitandeverythingthatsurroundsit,toenabletheultimateproductionoflow-carbonhydrogen.
KeyeconomicbenefitsfromdigitaltoolsovertheLCOH
DigitaltoolscanbringasignificantimpactinreducingtheLCOHthroughreducingthedevelopmentcostsofaproject,throughmoreeffectiveengineeringand
easierreplicabilityofsimilarprocessesand
components,andtheoperatingcoststhroughtheoptimizeddesignandclosecontrolofrunning
parametersinterfacedwiththedigitaltwindata.
Ouranalysisshowswithaconcreteexampleareductionbetween9%and12%oftheLCOHoverall,applyingthedifferentdigitalleversonareferencescenario.
ActivatingdigitalleversreducetheLCOHby~10%
LCOHinthe
reference
scenario
ImpactonCAPEX
ImpactonotherOPEX
Impactonenergy
costs
Volumee?ect*
LCOHwithdigitallevers
CAPEX
OtherOPEX
Electricitycosts
-4%to-5%
?Systemsdesignoptimization
solutions,mainlyprojecttwin
?GenerativeAI
~-1
?AssetO&Mtwin
(Operationstwinandmaintenancetwin)Connectedworker
-2%to-3%
?Microgridcontrolsolutions,
?BaseLoad
ManagementSystems,
?Energy
managementsystems
?Hydrogen
managementsystem
?Predictiveanalytics
-2%to-3%
?Energyeiciencysolution
?AssestO&Mtwin
?Anomalies
detectionsolutions
?Hydrogen
Managementsystem
*duetoadditionalproductionrelatedtoavailabilityand
e?ciency
CAPEX
OtherOPEX
Electricitycosts
Figure2-ShareofOPEXandCAPEXcostsintheLCOHofa100MWalkalineelectrolysis
installationandpotentialreductionthroughdigitalsolutions.
Especially,this100MWelectrolyzerplant,running8000hoursayear,canreducetheyearlyenergybillby500k€ormorepereachpercentofoptimizationprovidedbythedigitaltwin.Theamountofpotentialcumulatedsavingsalongtheplantlifetimeshouldjustifyhavingdigitaltwinasatier1priorityinanyprojectinthisdomain.
Youwillfindassumptions,furtherdetailsandexamplesofSiemensdigitaltoolsrelatedtotheseLCOHoptimizationinsection3.
6CapgeminixSiemens
7
Weanalyzedtherolethatdigitalizationcanplaythroughoutthevaluechain
SiemensandCapgeminihaveanalyzedarangeof
digitalsolutionsandidentifiedspecificleversthatcanreducetheLevelizedCostofHydrogen(LCOH),
enablingcustomerseffectiveandfastadoptionofatailoreddigitaltoolsetspecificallydesignedtomaketheirprojectcompetitiveandfuture-proof.The
followingleversaredesignedtoassistproject
developers,operators,andassetmanagersin
addressingvariouschallengesandrefertoallphasesofaHydrogenProject.
1.Thedesign,engineeringandconstructionphase
–forprojectdevelopersandassetowners
?Designeffectivelythroughproperinput
requirementsprovidedasperOwner-Operator
mandatesandRegulatoryrequirements.
Optimizingassetdesignandengineeringthroughsimulationshelpsavoidingreworkbyenabling
clashdetections,accessibilityconcerns,etc.therebyreducingcostsandtimetoconstruct.
?Buildfasterandreducetimetooperations,
throughoutadata-centricapproach-especially3DComputerAidedDesign(CAD)-accelerating
collaborativeinteractionsbetweendifferent
engineeringdisciplinesinvolvedandstakeholdersespeciallybetweenEngineeringProcurement
Construction(EPC),OriginalEquipmentManufacturers(OEM)andAssetOwners
Operators(AOO)incompliancewithindustry
processandsafetystandardsusingapre-definedtoolsettoensureallengineeringdataisattheend
consistentandavailableforfurtheruseinoperation.
?Capitalize,replicateandscalefasteratlowercosts,leveragingontheknowledgebaseand
lessonslearntfromoneprojecttoanotherenabledbydigitaltwinblueprints.
2.Theoperationsandmaintenancephase–forassetownersandoperators
?Handoverthephysicalassetfromprojectto
operations,withallthedigitalinformation,
documents,procedures,manuals(operatingandmaintenance),3Dmodelsoftheequipmentand
instrumentationsdeployedintheassetalongwithSafetyandRegulatoryclearances.
?Operateefficientlyfromday1,through
accessibleandactivabledata,optimizingprocessparametersbybalancingproductivity,improvingqualityandmaintainingeffectiveenergy
consumptionacrossthevariouspartsoftheplant.Thisinformation/datadigitallyrecordedand
loggedhelpsfuturefleetofassets,both:
–inthecontrolroom,tomonitortheproduction,orchestrateproductionprocesswhilemaximizingthevalue,basedonmarketsprices,contractualcommitmentsandplannings(incl.maintenance)
–ontheshopfloor,toautomateproductionprocesses
andprovidetheworkerswithrelevantinformation(e.g.usingadigitaltwinformaintenance)
?Improveproductioncontinuity,avoid
unexpectedproductionstopsandmaximize
availability.Thekeyroleofmaintenanceteamsisnotonlytomaintainproductioncontinuitybut
alsotomaximizeassetlifethrougheffective
preventivemaintenanceprograms,leverage
predictivemaintenancedigitaltwinsandplanforsparepartswellinadvancetoensurelong-termreliabilityoftheassets.
3.Traceability–fortheentireecosystem:ensuretraceability,especiallycarboncontenttrackingtocomplywithclients’specificationsorregulatoryneeds.
4.Theassetsportfoliomanagement–forassetowners
?Optimizeassetsplanning.
?IntegratenewassetswithexistinglegacyassetslikeO&GorRenewables.Thiswillalsodefinenewfutureassetinvestmentbusinessmodelsand
organizationalstrategieswhichneedstobethoughtthroughandoptimized.
CapgeminiandSiemensstandreadytosupportthetransitiontowardsalow-carboneconomy.
Anyinitiativetargetingtodelivervalueandatimely
achievementofproject’smilestonestoitsinvestors,
shallputthecreationofitsowndigitalroadmap
amongfirstprioritiessincethebeginningofthe
projectdevelopment.SiemensandCapgeminican
effectivelysupporttogetherthesecustomerswitha
combinedapproachofbroadconsultingservices,
best-of-the-classdigitaltools,experiencedandtrainedengineeringresources.Throughtheirinnovative
solutionsandstrategiccollaborations,CapgeminiandSiemensstandreadytosupportthetransitiontowardsalow-carboneconomy.
Thispaperwillthengiveimportantinsightsonhow
CapgeminiandSiemenscanconsultandsupport
owners,operators,EPCcompaniesinachievingtheir
goalsandovercomingthechallengesrelatedtoscaling
upandindustrializinglow-carbonmarkettechnologies.
Scopeofthispaper
ThispaperdelvesintothedigitalleversthatcanreducetheLCOHwhileintroducingthejointvaluepropositionofCapgeminiandSiemens,
showinghowtheDigitalHydrogenplantwithaholisticdigitaltwin
conceptiskeytoreducingtheLCOH.Itcoverscostsinallphasesofahydrogenproject,fromInvestmentDecisions,BasicEngineering,PlantEngineeringandconstructionuptooperations.
Opportunityanalysis&projectlaunch
Feasibilitystudy
Process
engineering
Plant&packageunitengineering
Construction
Packageunitintegration
FAT
Operations
Figure3-Projectstages
Thefocusofthispapercentersonhydrogen
production,particularlyinacontextofelectrolysis,butitrepresentsonlyafractionofthebroaderscopethatSiemensandCapgeminicancollectivelyaddresswithinthehydrogendomain.Theirtechnologicalexpertise
andindustryacumenextendtodistribution,
derivativesproduction,theutilizationofhydrogentodecarbonizingindustry,transportationandtheenergysector.Asacomplementaryassetinhard-to-abate
sectorswhereelectrificationfaceseconomicor
technologicalchallenges,hydrogencanhaveapivotalrole.
Forexample,sustainableaviationfuel,methanol,andammoniaproductioncanleveragelow-carbon
hydrogenwithadvanceddigitalsolutionsoptimizing
conversionprocessestoenhanceefficiency,
sustainability,andmitigatefinancialandtechnicalrisks.
ProductionDistributionUsage
EnergysourceH2production1)Pre-transportationprocessingStorageandtransportationEndsectors
Directusewithlocalhydrogenproduction
Industry
Chemicals/ammoniaPetroleumreinementSteelproduction
Others
Grid
mgmt.
Water
electrolysis
(incl.ramp-upofelectrolyzerproduction)
BlueandgreyGreen(NEW)
CarbonCapture,
UtilizationandStorage
Renewableenergies(e.g.,solar,wind)
Gaspipeline
(e.g.,compressedH2)
Hydrogen
compressionandpuriication
Batterystorage
Liqueiedhydrogen
Trucking
(e.g.,compressedH2,LOHCintanks)
Mobility
Synthetic/e-fuels
(e.g.,foraviation,marine)
Naturalgas
Steam
Methane
Reforming
Local
storage
and
distribution
GreenH2asfuel
(e.g.,fuelcell,ICE,illingstation)
New
Energy
Re-electriication(e.g.,fuelcells,
gasturbineetc.)
Heatinginbuildings
New
Ammonia
asenergycarrier
Shipping
(e.g.,liquid
hydrogen/
ammonia/
methanolvessel)
Coal
Coal
gasiication
Hydrocarbon(Incl.methanoletc.)
Bulkstorage(e.g.,cavern)
H2
Figure4-Hydrogensupplychain:fromenergysourcetohydrogenusage
8CapgeminixSiemens
1.
SiemensandCapgeminijointapproachfor
low-carbonhydrogenassets
1.1Ourvalueproposition
Combiningdeepknowledgeandexperienceinthe
hydrogenindustry,technicalexcellenceandend-to-endindustrialassetdigitalization,weatCapgeminiandSiemensextendourhistoriccollaborationtothehydrogenfield.
Whetheryouareaplantowner,anEPCoraplant
operator,CapgeminiandSiemenscansupportyouinmeetingyourkeychallenges:
Wemanagecomplexitytode-riskyourinvestment
?Weleverageadvancedsimulationtoolsto
helpyounavigateuncertainty,envisionmultiplecomplexscenarios,andmitigatefinancial,
regulatory,andoperationalrisksallatonce.
?Wecapitalizeonourextensivecrossindustryexperiencetoprojectyourindustrialasset
futureperformanceandmakethebestinvestmentdecisions.
Wedeliverinvestmentandoperationalcostreductiontoclosethecompetitivenessgap
?Weemployourdesign,engineering,and
simulationsolutionsinearlyphasestobuild
aplantthatcloselymeetsyourcurrentand
futureneedswhileoptimizingCAPEXandOPEXthroughouttheentireprojectlifecycle.
?Wealignyourindustrialstrategyandproductionsetupwithtailoredenergyprocurement
strategiestooptimizethepriceoflow-carbon
energy,whichremainsamajordriveroftheLCOH.Wesupplyandintegrateenergymanagement
andflexibilitysolutionstoenablethosestrategies.
?Weassistyouinidentifyingprocess
optimizationopportunities,reducingenergyandwaterconsumption.
Weconnectanddigitalizetheentirehydrogen
ecosystemtoacceleratetheadoptionoflow-carbonsolutions
?Ourexpertiseinthehydrogenindustryallowsustoknowestablisheddatastandardsandthemosteffectivemethodsforstructuringandsharing
information.Byadoptingadata-centricapproachandcreatingasinglesourceoftruth,wefacilitate
collaborationacrossthevaluechainandhelpyouaccelerateyourgo-to-marketstrategy.
?Wedeployend-to-endtraceabilitysolutions
thatarerecognizedbyendusersandpublic
authoritiestocertifythecarbonintensityofthehydrogenyouproduce,ensuringitsmarketabilityandprofitability.
?Wecreatedigitaltwinsthataccumulate
knowledgethroughouttheprojectlifecycle.Thesedigitalreplicasfunctionatdifferentstages—
‘a(chǎn)s-designed,’‘a(chǎn)s-built,’and‘a(chǎn)s-operated’—servingasblueprintsforfuturehydrogenprojects.
Wehelpyoudevelopfuture-proof,robustindustrialassetsfromday1
?Weassistyouinbuildingdigital-nativeassetswithatechstackarchitectureenablingdigitalcontinuity.Youwillbereadytocapturethe
valuethatdigitaltechnologiesoffertodayandtomorrow.
?Withouradvanceddesignandengineering
solutions,youareideallypositionedtoscaleup,usingstandardizedproductionelements,optimizingtheircompatibility,andsimulatingtheexpansionorreplicationofyourplantsinthefuture.
?Weensuretheintegrityofyourindustrialassetswithbest-in-classcybersecuritysolutions.
Weempoweroperationteamstomakedata-informedoptimizationdecisionsthatleadtoprofitableresults
?Wepromoteandenableaholisticdecision-
makingapproach,combiningrealtime
processmonitoringdataandlong-termCAPEXconsiderationstosecureyourtargetlevelizedcostofhydrogenandyourprofitmargin.
?Toachievethis,weimplementacomprehensiveportfolioofsolutionsforon-sitemeasurement,dataanalytics,andreal-timemonitoring.
?Wetranslatecontrolroomdecisionsintoaction
byofferingautomationandconnectivitysolutionsforfieldworkers,whilealsoconductingchange
toeffectivelyharnessthefullpotentialofdigitaltools.
10CapgeminixSiemens
1.2SiemensandCapgemini,arelevantpartnershipforthedigitalizationofthe
hydrogenindustry
SiemensandCapgeminicollaborateas
complementarypartnerstofullyleveragedigitaltransformationthroughoutthe
low-carbonhydrogenvaluechain.Siemens,
withitsexpertiseinenergyandchemicals
sectors,offersadvanceddigitalizationand
automationsolutions.Meanwhile,Capgemini,atrustedbusinessandtechnological
transformationpartnerforglobalindustrialleaders,identifieshigh-valueusecases,
definesdigitaltransformationroadmaps
alignedwithindustrialstrategies,implementstechnologicalsolutions,anddriveschange.
11
2.
Settingupthe
scene–definitions,frameworksand
prerequisites
CapgeminiSiemens
13
2.1Introducingthedigitaltwinforassetintensiveindustries
Thedigitaltwinisavirtualrepresentationofthe
currentandalmostfuturephysicalreality,e.g.,ofa
product,aproductionprocess,aplanthavingmultiplecriticalassets(pumps,motorsandrespectivepipelinevalves,etc.),includingtheirbehaviorandhealthstatus.Itbringstogetherdatafromalllifecyclephasesand
fromallfunctionsandlevels,helpingtounderstand,manageandpredicttheperformanceofthe
correspondingprocessorplantandtherebylayingthegroundworkforinformeddatadrivendecisions
throughdatacentricapproach.
Byreplicatingreal-worldplantoperationsinvirtualsimulations,engineersandoperatorscanfine-tunedesigns,identifypotentialissuesearlyon,and
streamlinetheirprocesses.Thisnotonlyreduces
commissioningtimesbutalsoslashescosts,makinghydrogenproductionmoreeconomicallyviable.Thisenablesthereductionincommissioningtimesfromaregulatoryandauditoryperspective,enhances
informationhandovertoOwnerOperatorsteams
therebyslashingrelatedcosts,fastergotomarketin
termsofproductionoutputmakingitmoreeconomicallyviable.
Butwhatexactlyaredigitaltwins?
Adigitaltwinisavirtualreplicaofaphysicalasset,
suchasaproductionplant,thatconsolidatesdata
fromalllifecyclephases.Byharnessingthepowerofsimulationmodelsandprocessengineeringsoftware,engineerscandesignandoptimizeplantlayouts,
createdetailedprocessflowdiagrams,andplan
automationsystemswithprecision.Italsoenables
bestinclassconstructionpracticesbysimulatingclashdetections,constructionworkersafetyand
accessibilityscenariosandfutureO&MactivitiesfortheAOO.
Anothercrucialaspectofdigitaltwinsisthepotentialforscalabilityandinnovation.Withtheabilitytocopy(bynumberingupper“drag-and-Drop”)andrebuild
entirehydrogenplantsvirtually,engineerscanexplorenewdesignconcepts,usingthedigitaltwinofthe
plantasablueprint,toexperimentwithdifferent
configurations,andscaleupproductionseamlessly.ItisalsothinkablethatanelectrolyzerManufacturer
couldusethattomakeaworld-widefleet
managementofanyoftheirdeliveredelectrolyzerstofurtheroptimizeorprovideserviceandsupport.Thisnotonlyacceleratestime-to-marketbutalsolaysthegroundworkforthewidespreadadoptionofgreen
hydrogenproduction
CapgeminiandSiemensseeaspecialmomentumforadoptionofaholisticdigitaltwinsinGreenH2
Productionlandscapethatwillmaintaininformationcontinuitythroughtheassetlifecycle.
2.2Integratedengineering
Theabove-mentionedstepscanberealizedusing
integratedengineeringtointegratedoperation.Thedigitaltwinisasecondaryresultoftheintegrated
engineeringprocess.
Integratedengineeringactuallyreferstoan
approachofaugmentedengineeringwith
automationandsimulation.Thisrequiresusingadefinedall-embracingtoolsetforsimulationandengineering,tomakesureallengineeringdataisconsistentandaccessibleinoneplatform.
Digitaltwinsenableseamlessintegrationintoexistingenergysystems,allowingoperatorstobettermanagefluctuatingenergysuppliesfromrenewablesources.Byaccuratelysimulatingplantoperations,operatorscanoptimizeenergyusage,minimizecosts,and
maximizeoverallsystemflexibility.
6.Therepresentationsareprobabilisticandapproximateanddependsonaccuracyofhistoricalandreal-timedataandanyunknownphenomenoncanalterfuturerealityevenifallhistoricalinformationiscorrect.Inthatsense,digitaltwinisnotatrue–evenifvirtual–representationofa“futurephysicalreality”.
H2processInput
(i.esimulationwithgPROMS)
Input
?Processandmaterialdata
?Designparameters
?Block?owdiagrams
Engineering
P&IDs
EI&C
PAA
?Automationengineering
?Installation
IntegratedinCOMOS
?Processplanningandengineering
?P&IDs
?El&Cengineering
?Parameterization
Output
IntegratedinCOMOS
DCS
(SIMATICPCS7)
xml-interface
ImportBPCMlibraryExportautomationdata
GUI(GraphicalUserInterface)design
3D-Mockup(simple3Dmodel)
(COMOSWalkinside)
Maintenance,RepairandOperationsManagement
PlantSimulation
(SIMIT)
Results
?Dynamicsimulation
templatesinSIMITlinkedwithSIMATICPCS7
?Layoutplanning
?Plantvisialization
?Maintainancescheduling
?Plantmanagement
?3D-Mockupforeach
templateandthewholeplant
?Virtualcommissioning
?Operatortraining
Figure5-IntegratedapproachwithSiemenssolutionsforholisticdataexchangebetweenmodeling,processengineering,simulationandautomation
Integratedengineeringphaseinvolvescomplextaskstoensuresmoothhydrogenproductiondesign
implementation:
?Ensuringdataconsistencyacrossdisciplinesisaprimarychallenge,asinconsistentdatacancauseerrors,delays,andincreasedcosts.
?Thoroughtestingandtrainingareessentialtoreducestartuptimeandcosts.Virtual
commissioningandoperatortrainingspreventoperationalinefficienciesandsafetyincidents.
Aunifieddatabaseforseamlessdataflowimproves
decision-makingandreducesengineeringcycletimes.
Thismakesitpossibletouse
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