In Engineering, Procurement, and Construction (EPC) projects, delivering complex assets like industrial plants or infrastructure on time and within budget is always a challenge. Managing these assets effectively after construction is another. To tackle both, EPC firms are increasingly turning to Digital Twin technology. A Digital Twin is much more than a 3D model—it’s a dynamic virtual replica of a physical asset, packed with real-time data. It enables project teams to make better decisions during construction, while also helping asset managers keep operations running smoothly long after the project is completed.
At Buro Matei, we go beyond the industry norm of using Digital Twins only as visual models. We integrate comprehensive data right from the engineering phase, ensuring the digital version of the asset is developed alongside the physical project. This approach reduces costs, minimizes errors, and provides lasting value for our clients.
What Exactly is a Digital Twin?
To fully grasp how Digital Twins are transforming the EPC industry, it’s important to first understand what they are and how they function. A Digital Twin is a detailed virtual representation of a physical object, process, or system. This isn’t limited to a simple 3D design—while visual elements are important, a true Digital Twin includes all the operational data, attributes, and real-time updates that affect the physical asset’s performance.
For example, imagine you are building an oil refinery. The Digital Twin of that refinery would include not only the physical layout but also detailed data about the equipment, pipelines, and control systems. As the project progresses, the Digital Twin gets continuously updated with data on how each part of the facility is performing in real time.
One common misconception in the industry is that a Digital Twin can be created after construction using methods like 3D laser scanning. However, this approach misses a major opportunity. At Buro Matei, we advocate for developing the Digital Twin during the design and engineering phase, so it is ready at the same time as the physical asset. This way, the Digital Twin can be used throughout the entire lifecycle of the project, from planning and construction to long-term operations and maintenance (O&M).
Improving Project Execution with Digital Twins
Embedding Digital Twin technology during the early phases of an EPC project offers significant advantages. It allows project teams to use real-time data to monitor the progress of construction and ensure that everything is built according to plan. By integrating the Digital Twin from the design stage, we ensure that the project is executed efficiently, and the digital and physical assets remain fully aligned.
In contrast, many EPC firms wait until after the asset is built to think about creating a Digital Twin. This often results in having to backtrack—conducting scans, data mapping, and manual updates to catch up with the physical reality of the project. This reactive approach not only adds costs but also increases the risk of errors.
At Buro Matei, we avoid these inefficiencies by aligning the creation of the Digital Twin with the broader project execution. For example, during the construction of an energy plant, our team ensures that every piece of equipment and structure is accounted for in the Digital Twin. This allows project managers to track progress in real time and immediately spot any deviations from the plan. If an issue arises—such as delays in the delivery of materials or a construction error—the Digital Twin provides actionable insights, enabling the team to make informed decisions and keep the project on schedule.
Real-Time Monitoring and Predictive Maintenance
The benefits of Digital Twin technology don’t end once construction is finished. During the operational phase, the Digital Twin becomes an invaluable tool for asset managers. By continuously monitoring the performance of equipment and systems, the Digital Twin can help predict when maintenance will be needed, preventing costly downtime.
Let’s take the example of a refinery again. Imagine that sensors embedded in a critical piece of machinery send data to the Digital Twin every day. Over time, this data reveals patterns that indicate when the machinery might start to wear out. Instead of waiting for the machine to break down, the Digital Twin alerts the maintenance team to replace the part ahead of time, preventing production delays.
In addition to predicting maintenance needs, the Digital Twin allows operators to test different scenarios and optimize the performance of the asset. For instance, a facility manager might want to know how changing a production process will impact energy use or whether adding new equipment will affect safety protocols. With the Digital Twin, these scenarios can be tested virtually before any changes are made in the real world, reducing risk and improving decision-making.
Further reading
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Why Digital Twins Should be Integrated Early
One of the biggest mistakes in the industry is treating the Digital Twin as an afterthought—something to be developed only after the physical asset is already built. This reactive approach leads to inefficiencies, such as the need for 3D scanning and manual data mapping. These processes take time, increase the risk of data errors, and add unnecessary costs to the project.
By contrast, Buro Matei starts developing the Digital Twin early—during the Front-End Engineering Design (FEED) phase. This ensures that the project data is consistent and accurate from day one. The Digital Twin grows alongside the physical project, reducing the need for rework and ensuring a seamless handover once construction is completed.
Additionally, starting early allows us to integrate standards like CFIHOS (Capital Facilities Information Handover Specification), which ensures that all project data is standardized and easily accessible. This is especially important for clients who need to manage complex assets over the long term. With a fully developed Digital Twin in place, asset managers can access all the information they need—whether it’s to schedule maintenance, manage inventory, or train new staff.
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↗ CFIHOS and Data Standardization in the Petrochemical Industry
Real-World Use Cases and Practical Applications
The potential uses for Digital Twin technology are vast and varied. At Buro Matei, we have seen firsthand how Digital Twins can provide value across different types of projects. Here are just a few examples:
4D Construction Simulation: By linking time and scheduling data to the Digital Twin, project managers can visualize how construction will unfold over time. This helps identify bottlenecks, delays, and inefficiencies before they happen, allowing for better planning.
Safety and Emergency Simulations: Digital Twins can simulate safety drills or emergency scenarios, allowing operators to test their response procedures without interrupting normal operations. This is particularly useful in high-risk industries like oil and gas, where safety is critical.
Asset Management and Documentation: Digital Twins store all the technical information related to a facility, including equipment manuals, maintenance logs, and safety certifications. This makes it easy for asset managers to access the information they need at any time, simply by scanning a tag on the equipment.
Buro Matei’s Expertise in Digital Twin Integration
Buro Matei has extensive experience in implementing Digital Twin technology in EPC projects. We don’t just create a digital model of the asset; we deliver a fully integrated, data-rich platform that supports construction and long-term operations. Even in cases where clients may not have an immediate need for a Digital Twin, we help future-proof projects by ensuring that the technology is in place from the start.
Our commitment to early integration ensures that the physical asset and its digital counterpart are perfectly aligned. Clients benefit from more efficient project execution, better long-term asset management, and reduced risk. Additionally, Buro Matei’s use of industry standards like CFIHOS guarantees that the data in the Digital Twin is easily accessible and ready to support a range of operational needs, from maintenance and safety to process optimization.
Conclusion
Digital Twin technology is revolutionizing how EPC projects are executed and managed. By creating a detailed virtual replica of the asset early in the project lifecycle, EPC firms can improve efficiency, reduce costs, and ensure better long-term performance. At Buro Matei, we believe that a Digital Twin should be developed in parallel with the physical asset, providing real-time insights and future-proofing the project for operational success.
As the EPC industry continues to evolve, having a fully integrated Digital Twin from the start will be essential. Buro Matei is committed to helping clients harness this technology to improve project outcomes and maximize the value of their assets.