High-tech partnership develops digital twins to help engineers replicate real-life training scenarios

KNOWLEDGE TRANSFER: From left, Dr Baseer Ahmad and Professor Dhaval Thakker of the University of Hull, Jan Antons of Innovate UK, and Iain Elliott of HETA

By Rick Lyon, Co-Editor

A new collaboration between industry and academia will give businesses high-tech access to full-scale production rigs without disrupting their own premises, plant and manufacturing processes.

The Knowledge Transfer Partnership (KTP) between Humberside Engineering Training Association (HETA) and the University of Hull will create digital twins of existing training rigs, enabling businesses to try new ideas with zero risk to their current systems.

HETA and the University both see the venture as a commercial opportunity which can support engineering projects across the Yorkshire and Humber region and beyond.

Their confidence is shared by UK Research and Innovation (UKRI), which has committed funding for the partnership through Innovate UK.

HETA invested in the rigs at its Hull headquarters five years ago as additions to its industry standard facilities for learners and employers, and particularly those working in petrochemicals across the Humber.

From the outset the rigs enabled process apprentices to carry out the full range of duties they will be exposed to in industry – tasks including starting up and shutting down processes, carrying out monitoring and sampling duties and adjusting process conditions.

Dhawal Thakker, Professor of AI and Internet of Things at the university, said the project will help HETA upgrade its plant and in doing so teach to the advanced industry 4.0 module, bringing significant benefits for engineering businesses further afield.

He said: “With an unwavering commitment to progress, the University of Hull is investing in the skills and infrastructure needed to meet the region’s economic priorities.

“We’re delighted to work with colleagues at HETA to develop state-of-the-art training facilities and programmes, offering businesses and learners opportunities to be at the forefront of change in a rapidly evolving industry.

PARTNERSHIP: From right, Dr Baseer Ahmad and Professor Dhaval Thakker, Jan Antons and Iain Elliott of HETA

“These new facilities will encourage businesses to take advantage of cutting-edge digital technologies, offering flexibility to develop and refine processes and greater efficiency.

“We welcome the support of Innovate UK and look forward to working with industry partners, innovators and problem solvers, to deliver more sustainable growth across our region.”

Iain Elliott, CEO of HETA, said discussions are under way with prospective clients who recognise the potential of the project.

He said: “Both rigs are big pieces of equipment which can be of use to industry as test rigs which are full scale. They can use them to find out if their technology works rather than disrupting their own premises and plant and they can create a digital twin to develop their concepts.

“If a manufacturer needs to make changes to their factory, they can do it by trying them on the digital rigs. Maybe try speeding up a conveyor line to see what difference it makes in terms of productivity or anything else.

“It also helps you look into predictive maintenance – you can put sensors on the equipment and it will feed back information on how it is performing. It can help you identify why things are breaking down and how you can stop that. Essentially it helps you keep the equipment as efficient as it can be.”

KTPs have driven innovation and growth by creating collaborations between businesses and academic institutions since 1975. They generated more than £2bn for the UK economy between 2010 and 2020 and currently support more than 800 businesses.

Jan Antons, Innovate UK’s knowledge transfer adviser for Hull, Humberside and North Lincolnshire, said: “This Knowledge Transfer Partnership is a fantastic example of how collaboration between academia and industry drives real impact.

“By combining cutting-edge research with practical application, we are driving innovation that delivers real benefits, including advanced digital skills to businesses and the wider community.

“It’s a privilege to work with this incredible project team, and to support a knowledge transfer that creates lasting impact.”