Hardware in the Loop (HIL) Testing
For many years, HIL has been utilised in industries like automotive, aerospace, and defence to design and test processes concurrently, allowing for the simulation of real-world scenarios and the implementation of enhancements. Now, our pre-commissioning platform for renewable generators facilitates the discovery and diagnosis of model-hardware mismatch issues prior to or during the commissioning phase.
Utilise our real-time platform to test a variety of integrated control systems, including supervisory plant controllers, power quality meters, SCADA systems, and more. Validate your designed control systems in a real-world setting with a real-time simulator (RTS) that serves as the interface between the hardware and the modelled electrical network.
Hardware-in-the-Loop (HIL) connects real control system hardware to a real-time simulated power system, allowing signals to flow between the two as they would on site. This closed-loop interaction enables equipment such as plant controllers and SCADA systems to respond dynamically to simulated network conditions and disturbances.
By identifying model-to-hardware mismatches early, HIL reduces commissioning delays, avoids costly rework, and de-risks project delivery while improving overall system performance and reliability.
Plant Pre-Commissioning Testing
Ensure your plant's control systems are ready before going live with rigorous pre-commissioning testing. Catch issues early, reduce regulatory risk, and streamline your R2 commissioning phase.
- Test the control system of the plant (PQM, PPC, SCADA, Inverter Controller ect.)
- Pre-test equipment against R2 test plan without regulatory overhead to de-risk project and catch issues early
- Streamline commissioning of plant in R2 phase
Equipment Maturity Assessment
Validate the performance and compliance of your equipment against Australian NER, WEM, and TNSP-specific requirements. Give new market entrants the confidence they need before deployment.
- Validate performance of new entrants to market
- Test hardware against Australian NER, WEM rules and other standard TNSP-specific requirements
Hardware & Model Development
Accelerate your development cycle with rapid control prototyping, custom testbench support, and firmware upgrade testing. We work directly with OEMs and asset owners to get hardware performing at its best.
- provide support to OEMs to test equipment on custom testbench
- Rapid control prototyping and testing
- Firmware upgrade testing for OEMs for asset owners/operators
Testing Support & Consulting
Leverage our expertise to review HIL test plans, coordinate testing, and resolve high-risk issues fast. We provide the technical assurance you need to meet industry standards with confidence.
- Review or support of other OEM HIL test plans against industry standards
- Provide HIL testing coordination & assessment
- Issue replication & testing for high-risk problems
HIL Testing for Power System Security & Grid Stability
Ensure that grid-connected generation control systems adequately maintain a stable grid and respond predictably to events. EPEC’s HIL platform lets you perform upgrades without using the live grid as a testbed — reducing risk and protecting your connection approvals.
Grid Stability Assurance
High-fidelity EMT models test control system response to disturbances and grid events — including PSCAD representations of generator, plant, and surrounding network.
Safe Firmware & Upgrade Testing
Validate firmware upgrades and control changes in a closed-loop simulation environment — without using the live grid as a testbed or risking connection compliance.
Ongoing Digital Twin
Maintain the HIL setup as a live digital twin — available at any time to fault find, test new firmware, and support R2 commissioning troubleshooting.
Software (EMT Model)
High-fidelity PSCAD model of the generator, plant, and surrounding network — including disturbance scenarios.
Hardware Under Test
Actual site equipment — PPC, PQ meters, and SCADA — connected as they would be in the field.
Real-Time Interface (OPAL-RT)
Executes the electrical model in real time, enabling closed-loop validation under realistic operating conditions.
De-Risking Projects
De-Risking Renewable Energy Projects Before Site
Reduce the potential for costly delays and encourage practices that result in faster commercial output of large renewable generation projects. EPEC undertakes risk assessments with clients to identify which equipment to include in the HIL environment and which remains in the model.
Avoid Costly Site Delays
Catch integration issues, control conflicts, and compliance gaps in the lab — before expensive site mobilisation and before issues reduce confidence in the project.
Alternate Compliance Pathways
Unlock alternate pathways to demonstrate compliance to AEMO and NSPs — using HIL test results as evidence in lieu of or alongside field testing.
Targeted Risk Assessment
EPEC works with your team to identify which equipment genuinely needs HIL testing versus what can remain in the simulation model — optimising cost and scope.
Why test before site?
Reduce commissioning risk
Issues resolved in the lab cost a fraction of those discovered during site commissioning or post-energisation.
Faster commercial operation
Pre-validated hardware accelerates site commissioning timelines and reduces the likelihood of connection delays with AEMO or the NSP.
Protect your connection approval
Avoid post-energisation issues that reduce regulator confidence in the project and risk delaying or revoking connection registration.
Real-Time Testing
Real-Time HIL Testing Platform for Control System Validation
Our platform integrates your actual control systems — including PPC, PQ meters, and SCADA — with a Real-Time Simulator (RTS). This allows the hardware to interact with a high-fidelity model of the electrical network as if it were connected to the real grid, validating performance in a safe, controlled environment.
Our Standard Approach
01
Project Scoping
- Assessment of design to determine risk and equipment to be tested
- Liaison with OEMs to obtain equipment, models and setup support
02
Testing & Rectification
- Equipment is tested against the agreed test plan
- Performance issues, abnormalities, and integration problems are identified and raised with the OEM
03
Compliance
- Results benchmarked against R1 model — compliance report provided
- Validated equipment dispatched from HIL lab to site with a transition plan
- Digital twin retained on site to support R2 commissioning troubleshooting
HIL Testing for Power System Security & Grid Stability
Ensure that grid-connected generation control systems adequately maintain a stable grid and respond predictably to events. EPEC's HIL platform lets you perform upgrades without using the live grid as a testbed — reducing risk and protecting your connection approvals.
Grid Stability Assurance
High-fidelity EMT models test control system response to disturbances and grid events — including PSCAD representations of generator, plant, and surrounding network.
Safe Firmware & Upgrade Testing
Validate firmware upgrades and control changes in a closed-loop simulation environment — without using the live grid as a testbed or risking connection compliance.
Ongoing Digital Twin
Maintain the HIL setup as a live digital twin — available at any time to fault find, test new firmware, and support R2 commissioning troubleshooting.
How it works:
- Software (EMT Model): High-fidelity PSCAD model of the generator, plant, and surrounding network — including disturbance scenarios.
- Hardware Under Test: Actual site equipment — PPC, PQ meters, and SCADA — connected as they would be in the field.
- Real-Time Interface (Opal-RT): Executes the electrical model in real time, enabling closed-loop validation under realistic operating conditions.
De-Risking Renewable Energy Projects Before Site
Reduce the potential for costly delays and encourage practices that result in faster commercial output of large renewable generation projects. EPEC undertakes risk assessments with clients to identify which equipment to include in the HIL environment and which remains in the model.
Avoid Costly Site Delays
Catch integration issues, control conflicts, and compliance gaps in the lab — before expensive site mobilisation and before issues reduce confidence in the project.
Alternate Compliance Pathways
Unlock alternate pathways to demonstrate compliance to AEMO and NSPs — using HIL test results as evidence in lieu of or alongside field testing.
Targeted Risk Assessment
EPEC works with your team to identify which equipment genuinely needs HIL testing versus what can remain in the simulation model — optimising cost and scope.
Why test before site?
- Reduce commissioning risk: Issues resolved in the lab cost a fraction of those discovered during site commissioning or post-energisation.
- Faster commercial operation: Pre-validated hardware accelerates site commissioning timelines and reduces the likelihood of connection delays with AEMO or the NSP.
- Protect your connection approval: Avoid post-energisation issues that reduce regulator confidence in the project and risk delaying or revoking connection registration.
Real-Time HIL Testing Platform for Control System Validation
Our platform integrates your actual control systems — including PPC, PQ meters, and SCADA — with a Real-Time Simulator (RTS). This allows the hardware to interact with a high-fidelity model of the electrical network as if it were connected to the real grid, validating performance in a safe, controlled environment.
Our Standard Approach
01 — Project Scoping
- Assessment of design to determine risk and equipment to be tested
- Liaison with OEMs to obtain equipment, models and setup support
02 — Testing & Rectification
- Equipment is tested against the agreed test plan
- Performance issues, abnormalities, and integration problems are identified and raised with the OEM
03 — Compliance
- Results benchmarked against R1 model — compliance report provided
- Validated equipment dispatched from HIL lab to site with a transition plan
- Digital twin retained on site to support R2 commissioning troubleshooting
