Mitigating project delays with innovative hardware-in-the-loop testing
The Autumn 2024 Edition of the Power in Mind magazine explores the latest technologies shaping the future of energy systems. Our recent collaboration with UQ featured in the Autumn Edition, highlighting the factors contributing to project delays, as outlined below.
Navigating the challenges of system integration and delays
Integrating complex systems into the grid is a detailed process, encompassing the development and negotiation of generator performance standards, control system design and modelling, and system commissioning and testing. Delays such as discrepancies between the performance of hardware on site and the modelled behaviour, can extend delays from months to years before achieving full commercial output.
Asset owners are facing significant revenue losses, sometimes exceeding AUD$100,000 per day, particularly in large plants. Construction companies are similarly impacted, dealing with financial losses from liquidated damages and prolonged project timelines, leading to market exits or administration.
Addressing project delays using HIL
At EPEC Group, we believe that innovative solutions like Hardware-in-the-Loop (HIL) testing are essential in addressing these critical issues. Our recent collaboration with the University of Queensland identified several common factors contributing to project delays, as featured in the Autumn Edition of Power in Mind Magazine, Autumn Edition in the article titled “Using Hardware-in-the-Loop (HIL) to Validate Designs and De-Risk Renewable Project Delivery”:
- Design architecture – Where procured equipment is inadequate for the intended purpose, or unnecessary.
- Communication delay – Inaccurate matching in models or missing data on communication delays and controller cycle times can lead to overshoots and instability.
- Modelling differences – Provided models often differ from actual hardware, with missing or additional functionality and unrealistic simplifications.
- Human error – Mistakes in converting model parameters to hardware settings, including incorrect conversion factors, frequently cause delays.
- Integration risks – Multi-vendor projects often face delays due to challenges in integrating systems.
- Hardware/firmware issues – Controllers can underperform or have firmware problems, leading to poor system control.
Transforming HIL testing for proactive project delivery
HIL testing has traditionally been utilised by original equipment manufacturers (OEMs) and researchers for equipment design and testing. However, we have repurposed HIL testing as a proactive project delivery method, specifically designed to mitigate risks in the connections process.
This approach involves a pre-commissioning stage where aggregated plant-level controls—such as the Plant Controller, PQ Meter, and SCADA—are integrated with hardware, while high-power components like inverters and transformers are modelled in software (EMT).
By testing the system according to a typical commissioning plan and validating it against the model, we ensure that the hardware meets designed specifications and regulatory standards. The advantages of HIL testing are manifold, including:
- Rapid design and validation
- Early identification of potential issues
- Avoidance of the electrical network as a test bed
Marty Johnson, Power Systems Engineer at EPEC Group, shared: “In a recent 50MW solar project, EPEC Group utilized the HIL pre-commissioning methodology and resolved over 15 issues related to the integration, modelling, and hardware design of the control system. The time saved from HIL validation is estimated to be approximately 5 months. Additionally, the testing has significantly reduced the risk of liquidated damages for the EPC contractor.”
Application of HIL testing is crucial for de-risking project delivery by validating control systems and simulating real-world conditions with actual hardware before deployment. This proactive approach enhances project efficiency and ensures regulatory compliance while mitigating risks associated with hardware and model discrepancies.
For more details or to access our research paper, contact newbusiness@epecgroup.com.au