Cloud Management of Pumping Systems Using Digital Twins Supported by Augmented Reality

Abstract

Smart pumping systems of tomorrow will feature pumps and drives that respond to real-time changes downstream to keep operations at high efficiency and meet growing performance demand. A key component of a smart pumping system is its digital twin, an exact 3D digital copy of the facility. A digital twin enhanced with Augmented Reality (AR) encompasses as-built facility data captured with 3D scanning devices, as well as precise measurement data collected on the actual rigs with high precision instruments. An interactive model based on augmented reality allows the autonomous and efficient use of pumping systems. It provides clear instructions for the step-by-step management of the system. In addition, it shows relevant information with the exploded views of the components for a better understanding of the operation of the equipment. This research is about the interconnection of the digital twin of pumping systems with the real-world using automation and augmented reality systems. In this project, a local area network is configured to exert control and monitoring on an industrial PLC. This PLC controls a test bench with two centrifugal pumps by means of a web page. An augmented reality application is also developed in Unity 3D with the Vuphoria SDK integration.

1. Introduction

Augmented reality (AR) is a technology that has attracted the attention of both researchers and industry professionals. With its ability to combine virtual elements with the real world, AR has opened lots of possibilities across various sectors, transforming the way we interact with information, objects, spaces, and people. Some of the applications of augmented reality in different fields are:

In the field of education, AR has brought new methods to conventional learning. Students now can visualize complex concepts, historical events, or scientific processes through virtual overlays. By augmenting their physical surroundings, AR creates an immersive and engaging learning experience. Moreover, AR facilitates remote collaboration, allowing students and teachers to interact in real-time, regardless of their physical location [1].

From medical training to patient care and surgery, augmented reality has revolutionized medical services in several aspects. Surgeons can now access vital patient information and visualize medical imaging data, which can be overlaid onto the patient’s body during surgical procedures [2]. This not only enhances precision but also reduces risks. Medical students also benefit from AR, as they can practice complex surgeries in a virtual environment, gaining invaluable practical experience before operating on real patients. AR-based applications have also found their way into rehabilitation, providing patients with interactive exercises and visual feedback to aid in their recovery.

In the commercial sector, AR has been used to enable the end user to visualize products before purchasing them. Virtual try-on applications, for example, allow shoppers to see how clothing, accessories, or even furniture would look on them or in their homes [3, 4].

Retailers and politicians have also begun to leverage AR for interactive marketing campaigns, engaging customers with immersive brand experiences [5].

Additionally, AR has found utility in navigation systems, providing indoor wayfinding assistance in malls, airports, and other large venues [6].

AR has also been used in the entertainment and video game industry by blending virtual elements with the real world, AR has created a new dimension for interactive experiences. Mobile AR games like Pokémon Go have captured the attention of millions, by interacting with virtual characters. Live events and performances have also embraced AR, offering audiences unique and captivating experiences that blur the boundaries between physical and virtual elements.

The manufacturing industry has not been left behind with advances in augmented reality either. This has been achieved by optimizing production processes, training workers, and improving maintenance procedures; augmented reality has significantly increased efficiency and productivity. AR enables a work instruction guide, reducing errors and accelerating operations. Technicians, equipped with AR devices, can access real-time data and digital manuals overlaid onto machinery, facilitating repairs, and minimizing downtime. Digital twins, virtual replicas of physical assets, when combined with AR, enable operators to monitor and control equipment like in Figure 1, predict maintenance needs, and optimize overall performance. In general, AR enables having a better understanding of the process or machine or how it is really working.

Figure 1.

Digital overlay onto real machinery [7].

The connection between cyber-physical systems, digital twins, and augmented reality has unlocked great potential in many industries. By the integration of AR with the Internet of Things (IoT) devices and sensors, real-time data can be overlaid onto physical objects, improving process monitoring, control, and decision-making.

According to the National Science Foundation, NSF, cyber-physical systems are devices capable of integrating computational algorithms and physical components, which allow to be equipped with storage and communication in order to control and interact with each other, surpassing the current integrated systems in terms of capacity, adaptability, scalability, resilience, security, and usability. This implies related technical challenges such as the development of control systems with self-learning capabilities and software development that serve as an interface between the physical and virtual system, also supported by the development of new technologies or new concepts such as the Internet of Things (IoT) [8].

Cyber-physical systems and AR have the ability to relate to physical objects from a virtual environment in order to monitor and/or control. They use available information in the collection of data for the virtual world, being able to integrate in some cases automatic learning techniques and decision making.

The design and implementation of cyber-physical systems occupy an important part in the transition toward the fourth industrial revolution (Industry 4.0), which includes the digitalization, networks, and intelligence of the manufacturing industry [9]. Figure 2 shows a general outline of the current framework of cyber-physical systems, focused on the integration, interconnection, and interaction of multiple layers or levels from a physical layer composed of all hardware elements such as sensors, machines, and robots to the most abstract layer to perform monitoring, control, and self-reconfiguration functions, in order to cover the entire value chain in the industry of the future [10].

Figure 2.

Framework of cyber-physical systems [10].

The advantages of cyber-physical systems and AR applications can be exploited in multiple applications such as manufacturing, energy, health, transport, smart cities, and so on. Below are examples of a new generation of development and solutions:

• Control of a machine tool or wind turbine to optimize its performance.

• Monitoring the status of the machine or system and optimizing its operation and maintenance strategy.

• Vehicles that communicate with others and with the road—infrastructure to determine the appropriate speed or routes while real time and augmented reality information is being displayed on the traffic windshield.

A digital twin is the digital replica or virtual representation of a machine in the physical world that simulates the behavior of its real counterpart. In this investigation, the virtual world representation of the real system seeks to control and monitor a centrifugal pump test bench through a web page.

Digital twins are a simulated process that uses real data from a physical model, such as sensors. In this way, they can reflect the life cycle of the process that corresponds to the physical equipment, thus analyzing various scenarios to improve the use of the machine or to be able to prevent failures.

An important requirement in the concept of digital twin is that it must be a dynamically and continuously updated representation of the actual product, device, or physical process. It should not be a static representation of real space. Real and virtual spaces are connected from manufacturing and operation to the disposal of the product, device, or process. Sensor information, user reports, and other information collected through manufacturing and operating processes must be continuously transferred to the digital twin. Predictions, control parameters, and other variables, which can be used to design and operate the real device, must be continuously transferred from the virtual space to the real space.

These are some of the biggest importance of digital twins in industry and pumping systems.

• Digital twins help test different approaches to reduce expenses without putting risk or cost at stake.

• They reduce engineering time, testing, commissioning, and upgrading costs of pumping stations to improve performance.

• The preliminary tests that can be carried out before the installation of the pumping stations can reduce the cost of commissioning and accelerate it, thus increasing reliability.

• Some of the problems such as leakage, water hammer, pump cavitation, or flow-induced vibration are problems that can be treated with a digital twin. At the right moment when the experimental data do not match the digital twin data, an alarm will be generated, alerting the operators that something may be wrong, thus preventing failures. This is how via constant monitoring the digital twin and the cyber-physical system can be linked together.

• One of the pillars of digital twins is to be able to monitor the condition of the process, generating alerts that can trigger preventive maintenance before problems occur; this is of paramount importance since the lives of the staff are at stake and could generate negative impacts on the environment. This information can also be relevant to the scheduling of the maintenance of a piece of equipment, since in this way, maintenance can be avoided ahead of time or worse, after it is needed. A just-in-time methodology could be managed, saving operating costs, spare parts, and staff time, increasing their productivity.

• During the manufacturing process of pumping systems, a digital twin provides relevant information about the performance of the equipment during the entire time of the process.

• In pumping systems, it is important to measure two types of pressure variables at the inlet and outlet of the turbomachine and the flow rate it delivers to the final discharge line. These are the instruments used for data collection and augmented reality visualization of the current value of sensors.

• Immersive applications can be created that represent scenarios that allow the worker to visualize a complete situation in the work environment, which teach about risk prevention and training to avoid making mistakes in practice.

• Through augmented reality, the real environment can be augmented with text, labels, documents, 3D models, and videos, which will lead to fewer errors and faster and higher quality of the service process.

A digital twin consists of 5 components:

1. The physical equipment.

2. The IoT that allows the communication of the information generated by the physical equipment.

3. Storage of information.

4. Analysis of such information. This stage is where the making of the best decisions that the process needs is promoted.

5. Equipment actuators. They allow the information generated and analyzed to meet the initial objective; they will no longer be only calculations and analysis but also actions that directly influence the team, optimizing the process and reducing costs.

2. Literature review

Virtual reality (VR) and augmented reality (AR) have both been employed in a range of educational environments [11], inclusive of: mathematics [12] and geometry [13], chemistry [14], biology [15], and mechanical engineering [16].

For instance, in [17], the authors consider experimental tests in order to validate augmented reality efficiency. They used a centrifugal pump as well. The authors paid attention to the fact that the oil companies in Russia suffered more than 4500 cases of downtime each year due to equipment failure. Repair costs exceeded 2.5 billion rubles. This also means that no raw material is extracted, which leads to a loss of 500,000 tons of oil, which is about 3.8 billion rubles. In Russia, the weather is something to consider; temperatures can reach as low as −50 degrees Celsius. They have to maximize automation and minimize workers. This can be solved with a digital twin that controls the operation on the cloud. The authors argue that VR simulators for training will enable specialists to have relevant equipment testing, perform manipulations without health risk, reduce training time by automating the process of tool operation, and apply various scenarios for the development of the trainee’s skills and thinking strategies in out of the ordinary situations. They tested the disassembly of different parts of the pump, such as the coupling guard, the two halves of the clutch, and the pin, and dismantling of the engine section. The idea was to analyze the times spent by different groups. Some groups had only physical instructions of the process; others had help from an expert; others used the recommendations of the augmented reality system, and the last group used the software and the expert if it was necessary. The group that took the longest time to complete the tests was the group that conventionally worked in the industry, which is to use only the equipment documentation. Always scoring among the best were the teams that used the augmented reality technology when solving the tests. They proved the main hypothesis, which is that the AR system reduces the maintenance time of oil pumps.

In [18], this study proposes the creation of a virtual training system for the installation, calibration, and commissioning of HART transmitters in dynamic and potentially hazardous environments, such as oil and gas process plants. Virtual reality and augmented reality both are processes that optimize and reduce training time and costs. Through interactive AR simulations, trainees can familiarize themselves with the principles of fluid dynamics, pump operation, and pipeline management. By overlaying virtual components, such as pumps, valves, or pipelines, onto a physical training environment, trainees can gain practical experience in a controlled virtual setting. This immersive approach enhances learning outcomes and allows for hands-on practice before engaging with real-world equipment.

The promise of virtual environments in training has been demonstrated because they allow focusing on contemporary training needs and integrating multiple requirements for using field equipment in a single program. The use of VR systems in training procedures has proven to be a significant and useful technology. First and foremost, these technologies, when implemented, help to achieve the goal of reducing economic losses, since incorrect calibrations and configurations in real life would be avoided to a large percentage, besides avoiding the risk that humans present in the process for the oil and gas industries. Employee knowledge and performance is greatly improved through this type of training—an effective and affordable substitute for handling, training, and learning about industrial equipment. All of this is possible in these virtual training facilities. The use of this technology will not only help prepare employees to operate any equipment, but it will also ensure the safety of the user as well as the simulated equipment and process. When some technologies are used improperly and the inherent risks of the technology are present, it can result in accidents that can have a negative impact on the environment, as well as economic and personal losses.

In pipeline inspection and maintenance, by utilizing AR devices, field technicians can access real-time data overlaid onto the physical pipeline infrastructure. This enables them to swiftly identify potential issues, monitor pipeline conditions, and efficiently carry out maintenance tasks. With access to pertinent information such as pipeline parameters, maintenance history, and sensor data, technicians can make informed decisions, ensuring optimal performance and reducing downtime [19].

AR’s ability to provide insightful visualizations of fluid flow within pipelines or industrial systems is another remarkable application. By overlaying virtual representations of fluid movement onto the physical environment, engineers and operators gain a deeper understanding of fluid dynamics. This facilitates the identification of potential bottlenecks, optimization of system design and operation, and effective troubleshooting of anomalies in fluid flow [20].

AR’s remote assistance and collaboration capabilities have transformed the way field technicians and operators tackle complex tasks. Through AR devices, experts can provide real-time guidance and support from a remote location. By sharing their perspectives and overlaying annotations, instructions, or diagrams onto the technician’s field of view, experts can assist in troubleshooting, repairs, and intricate operations related to fluid systems. This seamless remote collaboration reduces travel costs, minimizes downtime, and facilitates efficient problem-solving. Vuforia Chalk, Figure 3, is one of the most famous software related to this topic.

Figure 3.

Vuforia chalk software [21].

Furthermore, AR has found a vital role in safety training and hazard recognition within fluid-related industries. By simulating hazardous scenarios, such as leaks, pressure hazards, or chemical exposures, trainees can visualize potential dangers overlaid onto their physical surroundings. This immersive experience enhances hazard recognition, risk assessment, and emergency preparedness. Ultimately, this application of AR contributes to improved safety protocols, reducing the occurrence of accidents and promoting a culture of safety within the industry. “Safety training and hazard identification: AR can enhance safety training programs by simulating hazardous scenarios and providing interactive training modules. It can also help identify potential hazards on-site by overlaying warning signs, safety guidelines, and visual cues onto the real environment, promoting a safer work environment” [22].

3. Materials and methods

The test bench of multiple centrifugal pumps in variable configuration of UNAB is composed of two Pedrollo brand centrifugal pumps, reference CP 620, pressure and flow sensors, a control panel where the data are acquired and the process variable is manipulated, a PLC S7–1200, a V20 frequency inverter, a CM 1241 module, and an SM 1231 module. An interactive model is required that allows the autonomous and efficient use of the test bench of multiple centrifugal pumps in variable configuration, providing clear instructions and the step by step for the handling of this. This will be worked through a local area network where you can also configure a VPN (if you have the permissions to make configurations on the edge router) to have remote access and be able to acquire data, perform maintenance, or even solve breakdowns, saving costs and time for the company at an industrial level. With augmented reality, the project will have highly visual content with which important digital information will be presented in the context of a physical environment; this allows students to connect and improve academic results; applying it will achieve an optimal way to easily create and distribute work instructions by overlaying digital content in the real world. The following subsections will cover an outline of the interconnection of the cyber-physical system and augmented reality on the test bench of two centrifugal pumps in variable configuration of UNAB.

The development of the digital twin for the pumping system under study was carried out according to the following methodology:

3.1 The 3D model

First, you must have or model the 3D model of the equipment in interest. In this project, the fluid test bench was modeled in the SolidWorks software. The 3D model was modeled at the scale of the real equipment, in such a way that the virtual and real model was approached on the largest possible scale to avoid having tracking and recognition problems when working with augmented reality (Vuforia Model Target) (Figure 4).

Figure 4.

The 3D model.

3.2 Augmented reality interface

The second step is to develop the augmented reality interface for the efficient and safe operation of the equipment. In this project, it was decided to work in unity with the Vuforia SDK where functionalities can be added such as monitoring the sensors, adding information about the pumping equipment, step-by-step instructions for the management of the system and the explosion of the components for an immersion in the operation of the machine (Figure 5).

Figure 5.

Vuforia SDK [23].

Unity is a development engine or game engine. A game engine refers to software that has a series of programming routines that allow the design, creation, and operation of an interactive environment, that is, from a video game. Currently, more than 60% of all content developed with virtual reality and augmented reality is created with this multiplatform. The operation of Vuforia consists of sending captures of images from the camera to its servers and contrasting them with what exists in the database. At the moment when there is a match, it sends us an object with the metadata associated with the bookmark. If this procedure was done constantly, the resources that would be consumed would be enormous, so you have to say “When” you must scan to detect the marker.

These libraries were chosen mainly for their powerful algorithms that, being so developed, offer one of the best results today.

3.3 Target models

The most common tracking methods are images, areas, and targets tracking. The method used in this investigation was model tracking. It consists of recognizing objects by shape using pre-existing 3D models. Figure 6 shows the steps for creating target models.

Figure 6.

Steps for target model creation.

The model must be created in the MTG (Model Target Generator) software provided by Vuforia. A target model requires the user to hold their device at a particular distance and angle so that tracking a target model can be initialized. To help with this process, the application will draw the vertices of the object (guide views) so that by overlapping with the object in the real environment, the augmented reality experience can be initialized (Figure 7).

Figure 7.

Guide views in the MTG [24].

3.4 Automation and web development

Finally, the web application must be developed in which the functionalities of the control and monitoring of the fluid bank will be implemented. A local area network is also configured through which the current state of the sensors of the pumping equipment will be transmitted with the help of objects in unity such as “OnNewSearchResult”and “TargetSearchResult.” “OnNewSearchResult” is an event that is handled when the Vuforia server returns a positive detection. The object returns a “TargetSearchResult,” and the metadata variable has the metadata associated with the detected marker. After this, the monitoring of the object in the marker is enabled so that Vuforia’s artificial vision algorithm tracks the marker (Figure 8).

Figure 8.

Control and monitoring of the pumping system arquitecture.

3.4.1 AWP commands

Automation Web Programming (AWP) commands is a special command syntax for exchanging data between the CPU and the user page (HTML file).

AWP commands are entered in the form of comments in HTML and give you the following options for your user pages:

Read variables PLC.:= < Varname>:

Write variables PLC. <!-- AWP_In_Variable Name = ‘<Varname1 > ‘-->

Read special variables. <!-- AWP_Out_Variable Name = ‘<Typ>: <Name>‘-->

Write special variables. <!-- AWP_In_Variable Name = ‘<Typ>: <Name>‘-->

The storage an analysis of the information is crucial in order to accomplish predictive maintenance or take the best possible choices for the process.

4. Results

Figure 9 shows the augmented reality interface with its buttons to enter each of the sections and monitor the process. In the pressure and flow section, you can access the instrument datasheet information along with related graphs. In the explosion section, you can see an example animation of how the parts can be exploded in augmented reality to get a better insight of the equipment. This is of vital importance for educational environments as well as to fully understand the operation of a process. The assembly section shows animations going from exploded view to normal view. The menu button takes you back to the main menu where you have more options in the application.

Figure 9.

Augmented reality interface.

Figure 10 shows the frontend application. The process control system allows to control the flow rate and the start or shutdown of the machine. It also has a monitoring section, where the information from the four sensors is displayed in the form of a graph that allows an easy interpretation of what is happening with the test bench.

Figure 10.

Web interface.

5. Conclusions

In the field of centrifugal pumps, AR has emerged as a valuable tool for assembly, installation, and maintenance processes. Technicians equipped with AR headsets or mobile devices can leverage the technology to overlay step-by-step instructions and 3D models of pump components onto the physical pump. This visual guidance aids in accurate assembly, mitigates errors, and simplifies maintenance procedures, enhancing overall operational efficiency.

The integration of augmented reality in fluid-related industries exemplifies the transformative potential of this technology. By providing real-time information, visualization capabilities, training simulations, and remote collaboration tools, AR optimizes fluid transport, pipeline management, and centrifugal pump operations. With its ability to enhance efficiency, improve safety, and facilitate informed decision-making, AR continues to reshape these industries, paving the way for a more efficient and sustainable future.

This development improves efficiency, reduces workers’ risk, and improves their productivity.

Augmented reality can enhance the capabilities of apprentices, offering additional information when doing their internships. In addition, they have a wow factor that captures the attention of employees much more effectively.

It provides clear, step-by-step instructions for handling any pumping system or process; accelerates training; transfers expert knowledge to new generations of engineers; and accelerates the learning curve for newly hired engineers through interactive information in augmented reality.

In pumping system equipment, there is a vast amount of technical information, and being able to see it in augmented reality reduces the time required to interpret manuals. This complete information is easily accessible with a simple gesture, which is particularly valuable when dealing with extensive manuals that may not be available on site.

This technology has been shown to improve attention, promote lasting knowledge. and more effectively explain difficult topics.

The digital twin is viable as a design methodology because it can be based on the current product to be able to predict the operation of the device under different scenarios and configurations, optimize its conditions, and evaluate changes effectively without resorting to iterative prototyping investments.

Over time, the value of highly integrated, data-driven pumping solutions will become increasingly apparent and indispensable.

In conclusion, augmented reality is a transformative technology with boundless applications across various industries. Its ability to seamlessly blend virtual and real-world elements has revolutionized education, healthcare, manufacturing, retail, entertainment, and more. As AR continues to advance, its integration with cyber-physical systems and digital twins holds immense potential for reshaping how we interact with and optimize our physical environment. The future of augmented reality is bright, and the possibilities are at the edge of our imagination.

Acknowledgments

The authors acknowledge the support from Universidad Autónoma de Bucaramanga and ECOPETROL to carry out this work.

Conflict of interest

The authors declare no conflict of interest.