The hansaconsult quality simulation testing replaces traditional methods of directly setting up parts or the whole system on-site and then connecting lamps and switches to simulate the inputs and outputs from the plant. The local setting and switching by the test engineer is satisfactory for testing very simple functions, however, it is difficult to test complex functions or to test two functions at the same time. For instance, for testing the hydrant leak detection function, the operator may need to simulate the behaviour of possibly twenty valves at the same time, together with a pump, pressure measurements, etc. Furthermore, any testing after the control system has been installed, have to be carried out at the real plant.
The high performance simulation for testing control systems of fuel plants is carried out by the unique fuel simulator KLEOPATRA® by hansaconsult. The simulation procedure involves setting up the SCADA and PLC parts of the Control System and simulating the operation of the hard-wired control panels, the instrumentation and the plant.
The simulation software runs on a PC, which is connected to the Control System’s PLCs. Hence, the Control System can be operated as if connected to the real plant which enables a comprehensive simultaneous testing of many functions. The simultaneous testing is important to detect system conflicts.
The KLEOPATRA® simulation testing is provided by hansaconsult in the development stage, on-site for testing any changes of the Control System (simply by disconnecting the PLCs from the plant and connecting them to the simulation PC) or for training purposes as an excellent, and very realistic, training tool for the operators during the training lessons.