Digital Twins & Virtual Commissioning
PLC and SCADA applications run against virtual equipment and process models, so control behaviour can be operated, tested and accepted before site work.
Operate the system, not a description of it
Clients receive a runnable PLC and SCADA rebuild to operate and inspect before any site work, and confirm control behaviour, screens, alarms and diagnostics for themselves.
Scenarios clients can run
- Normal start and stop
- Auto / manual changeover
- Sequences
- Interlocks
- Alarm acknowledge and reset
- Equipment faults
- Communication failures
- Recovery to normal operation
- Event recording
The test scope is defined for each project.
Normal, abnormal and recovery
Normal operation
Start-up, shutdown, mode changes and sequences run end to end against equipment feedback.
Abnormal conditions
Equipment faults, interlocks, alarms and communication failures are triggered on purpose and the response checked.
Recovery
Return to normal operation after trips, resets and restored communications.
What you receive
- Runnable PLC and SCADA applications connected to virtual equipment and process models
- Test scenarios agreed with the client, including a virtual FAT
- Test records, defects found and their close-out
- A system the client has operated and reviewed before site work
Offline processing and live testing work together. Engineering analysis and rebuild run with no internet connection, while closed-loop testing runs the PLC, SCADA and virtual equipment models together on an isolated local network. Virtual test results and site SAT are recorded separately.
Technical details
The platform, run configuration and model scope are agreed for each project, from equipment-level feedback through to process behaviour where the testing needs it.
Test methods, scenarios and acceptance criteria are written down before testing starts, so results can be reviewed and repeated.
Test before site
Virtual commissioning can be part of a control system rebuild or a new system, or be engaged on its own for an existing application.