FAQs
What is a Digital Twin? Do we need Steady State or Dynamic Simuation?
Keep scrolling for answers to our most common questions…
General
Connected Performance is an approach that unifies people, processes, and technology to give organizations a clear, traceable understanding of how decisions impact performance across the enterprise. Rather than optimizing systems in isolation, Connected Performance connects engineering, simulation, and operational insight to consistently improve outcomes.
A digital twin is a virtual representation of a physical asset, process, or system that mirrors real-world behavior using first principle and/or data models. In industrial environments, the term digital twin can encompass a variety of technologies ranging from process simulation, 3D simulation, asset performance monitoring, monte carlo simulations, advanced process control, and more. Onyx 360 was built to demystify digital twin solutions and help manufacturers understand how various technologies can best be leveraged to support their goals.
Steady-state simulation is a single calculation of the expected or predicted process condition for a given set of boundary conditions. Steady state simulations are beneficial for plant design, process optimization, or decision support.
By comparison, dynamic simulation is a continuous calculation of plant behaviors in real-time. Dynamic simulations are beneficial for operator training, control system testing, automation improvement projects, or dynamic engineering studies.
While both utilize first principle process models, steady state and dynamic simulation are inherently different. A steady-state model generally uses control set-points as constants to reduce the degrees of freedom and predict the process state under those conditions. A dynamic model asks the controller outputs to continuously update and change in real-time. Steady-state models generally do not need information around volumes or valves that change the dynamic behavior of a plant but do need set points for design operation to be defined. In contrast, dynamic models require information about process dimensions and valves, but set points are driven from controls.
Solutions
Multi-Purpose Dynamic Simulation
Simulation allows you to test control strategies and operating procedures in a safe, offline environment. Issues are identified early—when the cost of change is lowest—reducing rework, startup delays, and operational surprises.
Dynamic simulation delivers the most value when introduced early in project design, but it can be applied at any stage—from conceptual design and automation FAT to operator training, virtual commissioning, and ongoing operational improvement.
Yes. Simulation is effective for new facilities, expansions, migrations and long-running plants. Whether validating a new design or improving an existing operation, simulation provides insight without disrupting production.
Development & Test Systems
Simulation provides an offline copy of the automation system paired with realistic process responses. This allows you to fully test logic, sequences, and alarms, automate test execution, and generate documentation without impacting production systems.
Yes. Simulation is commonly used to validate upgrades, test changes across operating conditions, and identify regression issues before deployment—reducing risk during migrations and system updates.
Operator Training Systems
An Operator Training System uses dynamic simulation to replicate the behavior of a plant and its automation systems. An OTS enables your operators to safely practice startups, shutdowns, abnormal situations, and upset recovery without exposing the plant to risk.
Yes. Dynamic simulation enables operational knowledge capture in a structured, repeatable environment. Simulation helps new operators gain hands-on experience faster while preserving institutional knowledge from experienced staff. Manufacturers see lower turnover when operators have the tools and training to be successful and are empowered by their company’s investment in their development.
3D Simulation
3D simulation is used to visualize facilities, plan maintenance, train field operators, perform virtual walkdowns and validate procedures. It reduces the need for site access while improving safety and understanding.
3D simulation can be integrated with dynamic simulation to provide coordinated control room and field operator training, perform immersive startup rehearsal, and improve collaboration across disciplines.
Engineering
Deployment timelines vary by use case and project scope. Automation testing and focused simulations can often be delivered quickly. Larger multi-purpose simulators benefit from more rigorous design and deployment times that are parallel to automation projects. Onyx 360 can advise on how to right-size simulation solutions to fit project timelines and realize the highest return on investment.
Yes. A key advantage of simulation is reuse. Models built for automation testing can often be extended for operator training, virtual commissioning, and optimization—maximizing return on investment.
With most manufacturers being challenged to do more with less, one of the barriers to the successful use of simulation is the maintenance of these systems and keeping them relevant as they age. Understanding this challenge, Onyx 360 offers managed services tailored to your current and future capabilities and bandwidth. We can work with your team to provide ongoing maintenance and administration activities on a predictable annual budget.
Business Value
Simulation helps organizations reduce project risk, accelerate startup, improve safety, increase operational consistency, and make better decisions with less uncertainty.
By providing a safe environment to test ideas, validate changes, and understand system behavior, simulation becomes a long-term asset that supports ongoing optimization and change management.
No. Simulation can be scaled to fit individual assets, single plants, or global enterprises. The key is matching technology, model fidelity, and project scope to meet your business needs.