Verification and Validation of Rotating Machinery Using Digital Twin

Abstract

Abstract Rotating machinery has extensive usage in industrial applications being either the main equipment (power plants) or auxiliary equipment (oil and gas exploitation). These are extremely complex systems that characteristically demand expensive maintenance programs, due to the high costs involved in an eventual shutdown. Consequently, critical faults diagnosis and prognosis are essential in the operation condition of those systems. Fault identification and classification criticality demand a robust verification of the codes and calculations, as well as a discerning validation of the numerical models used for rotating machinery. Hence, verification and validation (V&V) are an essential initial service for a digital twin (DT) so it may offer some advantages in this application. In this context, the following research question is proposed: Does V&V using DT improve data access and reduce the effort of data exchange? The following objectives are created to address the research question: perform a code verification, conduct the calculation verification, validate the models using two different validation approaches 1 and 2, and demonstrate easy access to asset data. For this study, two hydrodynamic bearings and a non-central disk were considered, representing a laboratory experimental setup. The validation metric requirement is promisingly satisfied for the disk and the bearings according to the validation approaches 1 and 2. Furthermore, validation approach 2 generates even more successful results than approach 1. Accurate estimation and reliable interpretation of the numerical model outcomes guarantee the DT application for future fault diagnosis and prognosis.