Digital Twin Efficiency: Virtual Commissioning
Minimising Project Delivery Delays
COST OF DELAYS
The cost of a control system implementation in large-scale projects across various sectors can range from 5% to 15% of the total project cost. While these figures are rough estimates, and actual costs can differ based on various factors, what remains clear is that delays during the commissioning stages can incur a significantly higher cost. It’s not uncommon for delays to result in additional costs of up to 25% or even more of the total project cost. One way to avoid such delays is ensuring a comprehensively tested control system software.
DIFFERENT APPROACHES TO TESTING
Before deploying any PLC software (referred to as PLC logic), thorough testing is imperative, regardless of the complexity. This is a sentiment shared among all control systems engineers, each employing their own testing techniques. Some readers might recall panels adorned with switches, potentiometers, LEDs, and indicators. While effective for altering inputs and observing outputs, the associated costs (in terms of time, space, and hardware) make this solution impractical for all but the most repeatable PLC logics.
Another approach is crafting a specialized SCADA system for input and output manipulation. This, too, incurs significant costs and suits scenarios where applications can be deployed multiple times with minimal modifications. Some opt for forcing program inputs and inspecting output statuses through built-in tools in the PLC programming software. However, this method presents challenges, as it requires swift adjustments to inputs once an output is triggered to simulate real-world scenarios—an arduous task for most cases.
An alternative option is embedding logic within the PLC to simulate process behavior. While effective, it introduces irrelevant logic into the PLC, potentially leading to oversight during deployment. To address this, logic is segregated within the PLC and activated only when needed— during testing and deactivated or removed during plant deployment.
Project delays are a Project Manager’s worst nightmare, and commissioning hiccups can be the difference between a happy customer or unpalatable liquidated damages.
VIRTUAL COMMISSIONING
A unique solution to these challenges is the development of a Digital Twin – a replica of the real plant capable of generating the same data traffic as actual remote stations or field equipment. This simulation environment can be programmed to replicate responses from outputs to inputs, ensuring seamless interaction with the PLC. It provides an engineering station for logic simulation
and a human-machine interface (HMI). This software supports rapid development with predefined logic and HMI objects, and offers interfaces for data exchange with other applicants.
The dynamic created during Factory Acceptance Tests (FAT) with a Digital Twin is remarkable. Collaborating with operators, process engineers, and mechanical engineers enriches knowledge exchange and discussions. The use of Digital Twin is not limited to virtual commissioning; it has proven versatile in various scenarios, including operator training, reverse engineering PLC logics, validating third-party control components, and supporting SCADA system migrations.
MAKE THE RIGHT CHOICE
At SPIN, we have leveraged Digital Twin technology for over 8 years, enabling us to perform virtual commissioning by creating precise digital replicas of plants. This approach allows for comprehensive, flexible testing and significantly reduces control system project implementation risks.
Stay inspired, stay relentless, stay SPIN!