How can you optimize control system performance through testing?

Control systems are essential for efficient and reliable operation of power plants and grids. However, designing and implementing a control system is not enough to ensure optimal performance. You also need to test and validate your control system to verify its functionality, robustness, and compliance with standards and regulations. In this article, you will learn how you can optimize your control system performance through testing, using some practical tips and best practices.

1 Define your testing objectives and criteria

Before you start testing your control system, you need to have a clear idea of what you want to achieve and how you will measure it. Your testing objectives and criteria should be aligned with your control system requirements, specifications, and expected outcomes. For example, you may want to test your control system for stability, accuracy, response time, fault tolerance, security, or interoperability. You should also define your testing methods, tools, data sources, and scenarios, as well as your acceptance and rejection thresholds.

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2 Choose the right testing environment and platform

The testing environment and platform you use can have a significant impact on your control system performance. Ideally, you want to test your control system in a realistic and representative environment that simulates the actual operating conditions and load profiles of your power system. However, this may not always be feasible or cost-effective, especially for large-scale or complex systems. In that case, you can use alternative testing environments and platforms, such as hardware-in-the-loop (HIL), software-in-the-loop (SIL), or model-in-the-loop (MIL), that can emulate the physical components and dynamics of your power system.

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3 Implement a systematic testing process and documentation

Testing your control system is not a one-time activity, but a continuous and iterative process that involves planning, execution, analysis, and improvement. You should follow a systematic testing process that covers all the relevant aspects of your control system, such as design, configuration, integration, verification, validation, and optimization. You should also document your testing process and results, using standard formats and templates, to ensure traceability, transparency, and accountability. Documentation can help you identify and resolve issues, track changes, and report outcomes.

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Adam Goodwin, MBA, ICD.D

Ops Executive | Board Director with expertise from energy to service, developing strategic improvement and energy transitions.
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Many commissioning tracking software databases (Omega 365, WinPCS, etc.) will help keep track of the equipment, testing methods, and test results. Most programs can enforce gated stages to prevent failure caused by skipping steps and avoid wasted time from redundancy.

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4 Use automation and simulation tools

Testing your control system manually can be time-consuming, error-prone, and inconsistent. You can save time and resources, improve accuracy and reliability, and enhance scalability and repeatability by using automation and simulation tools. Automation tools can help you perform tasks such as data collection, test execution, result analysis, and report generation, without human intervention. Simulation tools can help you create and run scenarios that mimic the behavior and interactions of your power system and control system under different conditions and events.

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5 Incorporate feedback and improvement loops

Testing your control system is not only a way to check its performance, but also a way to improve it. You should incorporate feedback and improvement loops in your testing process, to ensure that you learn from your testing results and apply corrective or preventive actions. Feedback and improvement loops can help you detect and eliminate errors, enhance functionality and efficiency, and optimize performance and quality. You should also communicate and collaborate with your stakeholders, such as customers, regulators, operators, and suppliers, to obtain and incorporate their feedback and expectations.

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Adam Goodwin, MBA, ICD.D

Ops Executive | Board Director with expertise from energy to service, developing strategic improvement and energy transitions.
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Utilizing AI tools from the previous testing to run multiple analyses of the results will speed up the process and may find improvements that we wouldn't catch otherwise.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Sherif A.

Technical Program Manager @ Schneider Electric | Master's Degree, Industrial Automation
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Consider doing the testing on multiple phases and do not wait all the way till the system is shipped to the plant. For example, test logic configurations very early and using simulated hardware if needed, the test on target hardware before shipping to site. Then finally do your last site acceptance test to confirm all the criteria are met before the system goes online.

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Adam Goodwin, MBA, ICD.D

Ops Executive | Board Director with expertise from energy to service, developing strategic improvement and energy transitions.
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Refer back to and improve upon your FAILURE MODE AND EFFECTS ANALYSIS (FMEA) to ensure you walk through all the "what if?" scenarios and have a plan if the failures occur during testing. This is particularly helpful when online commissioning is going on.

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How can you optimize control system performance through testing?

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5

6

1 Define your testing objectives and criteria

2 Choose the right testing environment and platform

3 Implement a systematic testing process and documentation

4 Use automation and simulation tools

5 Incorporate feedback and improvement loops

6 Here’s what else to consider

Power Engineering

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How can you optimize control system performance through testing?

1

2

3

4

5

6

1 Define your testing objectives and criteria

2 Choose the right testing environment and platform

3 Implement a systematic testing process and documentation

4 Use automation and simulation tools

5 Incorporate feedback and improvement loops

6 Here’s what else to consider

Power Engineering

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