6 Politekhnichna Street
Building 5, floor 8, room 801
Project location: Bila Tserkva, Ukraine. Sector: equipment manufacturing. Project year: 2022.
Ukrinterm, a small equipment manufacturer, developed a boiler digital twin with support from KPI’s Centre 4.0 Digital Innovation Hub. The solution combined an upgraded control system and sensors with an edge device, a cloud platform and IoT Hub, digital-twin software, databases and visualisation tools.
The team began with a Technology Application Roadmap (TAR), then specified the required hardware and software. Some equipment was purchased and some was temporarily supplied by Centre 4.0. During the project, the team built the edge device and configured cloud data collection before developing the digital-twin software and improving the dynamic model.
The TAR set seven key performance indicators, including technical measures. Under the tested conditions, the dynamic model reached 82% accuracy against an 80% target. The project calculated potential fuel savings of about 5%, maintenance savings of about 4.4%, and savings of up to 2% through control-system tuning. Remote monitoring was expected to reduce unnecessary service visits and improve commissioning and maintenance work; these were project estimates rather than a measured staffing outcome.
The team prepared a final report, an implementation plan and an intellectual-property report with Centre 4.0’s support. Ukrinterm held two workshops to present the digital-twin concept, and four partners agreed to consider testing the system at their sites. Centre 4.0 contributed roadmap advice, technical consultations, digital-twin training, mathematical modelling support, access to its automatic-control laboratory and temporary use of control equipment. The project team also planned further work with the Centre to develop the system.
