On the path to autonomous turbomachinery
Next-level automation means increased efficiency. For us at MAN Energy Solutions, making the operation of turbomachines more efficient is key to supporting the energy transition and ensuring long-term sustainability. Higher levels of automation benefit the environment and improve the cost-effectiveness of industrial plants.
Digitalization and artificial intelligence (AI) will soon enable fully autonomous operation of turbomachinery trains. Already, modern turbomachinery systems such as upstream topside, subsea and midstream applications are fully automated. That means these systems are remotely controlled and unmanned. The highest level of autonomy for process plants with turbomachinery will be energy-efficient autonomous remote operation. Since 2021, MAN Energy Solutions has been able to support customers with near-autonomous operation in all market segments and is aiming to achieve full autonomy for all turbomachinery equipment by 2028. This means uninterrupted, unmanned, safe, reliable, and energy-efficient operation.
Digital twins
We use digital twins to simulate very complex turbomachinery systems and their behavior and management, by means of artificial intelligence, allowing the equipment to be optimized even before it is installed. This lets us accelerate the design of complex control concepts in an early phase and allows for the development of special software functions. The execution of the virtual before real commissioning also reduces real-life setup time. Benefits of using digital twins include customized software solutions, improved software quality, increased efficiency through optimized process control, reduced commissioning time and simulation-based operator training.
Remote services
Turbomachinery constantly generates vast quantities of data. MAN remote services derive benefits from analysis of this data: preventing unplanned downtime, optimizing performance capability, and anticipating future needs. Thanks to high transmission rates via cable or satellite, the best encryption technologies, and cloud-based solutions, our remote services have become the new benchmark. The most important remote services are remote access, inspection, commissioning, troubleshooting and real-time condition monitoring. Using secure technology to connect to MAN PrimeServ’s Remote Operating Centers, PrimeServ Assist is a proactive service solution – based on the MAN CEON digital platform – that constantly monitors and evaluates all parameters affecting engine performance 24/7.
On-premises solutions
Industrial automation requires control systems with powerful computational capacity. For this purpose, we have developed a versatile control system extension that runs locally on industrial personal computers (IPCs). An IPC is an expandable and customizable on-premises hardware solution that offers high performance with industry-standard safety and availability. This boost in performance allows you to enjoy the full benefit of our digital solutions. Connected directly to the control system via a secure and reliable communication channel, the IPC acts as the perfect platform for multiple AI-based apps such as the “virtual sensors app” or the “compressor/heat exchanger performance monitoring app”. As an independent extension, the system can easily be updated, and new intelligent automation solutions can be integrated to suit your changing needs.
Design for digital – engineering transformation
We offer digital solutions that enable unmanned and remote operation of turbomachinery systems, and we are developing further digital modules to achieve the goal of autonomous operation. “Design for digital” describes the paradigm shift that makes autonomous systems possible. It encompasses the whole life cycle of an industrial plant with turbomachinery, aims for autonomous operation, reduces the need for human intervention, and begins with a holistic TOTEX approach in the early phase, during conception and specification. This approach is used to design the entire digital life cycle of a machine plant. We apply the same approach in our marine, power, and process industry business units.
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Remote, unmanned operation will be the new normal soon. [...] And by combining human and digital intelligence, equipment operation will become autonomous within this decade.
MAN benchmarks in turbomachinery automation
MAN Energy Solutions is pioneering the digitalization of turbomachinery equipment. Two reference cases illustrate our advances:
• the first ever remote commissioning of a compressor train
• enabling the unmanned operation of a topside gas compression system.
Case 1
Remote commissioning of a compressor train
In 2020, the Covid-19 pandemic interrupted the construction of a new nitric acid plant in Uzbekistan, forcing engineers from MAN Energy Solutions to embark on a historic step in mechanical engineering: the first fully-remote supervised commissioning of a compressor train using digital technology. Our mobility was restricted but we had completed the necessary preparation and had the required digital tools.
Case 2
Unmanned operation of upstream topside compressors
MAN Energy Solutions is delivering highly digitalized compressors for the first unmanned gas production platform at the Yggdrasil field development in the North Sea. It will be the first gas platform designed from the start for operation without a crew: it will have neither a helicopter deck nor living quarters and will be remotely operated from an onshore integrated operations center and control room. The MAN digital solution allows fully automated operation of the two HOFIM® motor-compressor systems. The unmanned and remotely-operated gas platform represents a massive leap forward for the energy industry. It not only enhances personnel safety and reduces OPEX and CAPEX but also minimizes the environmental impact of offshore operations.