Facility Digital Twin
We model the facility's electrical network (transformers, cables, panels, loads) in ETAP, monitor it in real time with live data from power analysers, meters and SCADA, and tie it to a laser-scan-based 3D facility model. AI-assisted deviation and load analysis and pre-investment scenarios all run on the same model. Supply, installation and commissioning of the measurement, communication and monitoring infrastructure is included as turnkey delivery (EPC).
Which questions does this model answer?
A digital twin supports decisions only to the extent it matches how the facility really behaves, which is why the model is checked against measurements and keeps being compared with live data.
Is the facility behaving the way the model predicts?
Analyser and SCADA data are continuously compared with the loading and voltage the model calculates; a warning is raised when the deviation exceeds a defined threshold.
Can I see the facility in 3D and read live values on the equipment?
Transformers, panels and main loads are shown at their locations in the 3D facility model; live measurements and warnings are read on the relevant equipment.
Is unusual behaviour spotted early?
AI-assisted methods flag unusual patterns in load and power quality data; each flag becomes an engineering review.
Can the existing transformer and lines carry the new load?
For load growth or a new line or transformer, loading, voltage drop and losses are compared on the model.
What happens when PV or storage is added?
Generation, consumption and power flow at the connection point are examined on the same model together with live load data.
Are fault levels and protection settings still suitable?
After network changes, short-circuit levels are recalculated; the results feed into the short-circuit, protection coordination and arc flash studies.
Can I cut cost by shifting load on price and forecasts?
Load and price forecasts are assessed together with flexible loads and storage; the shifting schedule is optimized in the EMS work.
Required data
The model is built from existing documents and measurements; missing measurement points are identified during the survey and brought into the infrastructure scope.
- Current single-line diagram and panel/load list
- Transformer nameplate data and cable cross-section and length information
- Historical consumption data (15-minute or hourly; at least 12 months where possible)
- Existing measurement sources: power analysers, multifunction meters, SCADA or an energy monitoring system (with protocol and access details)
- Laser scan (point cloud) for the 3D model; existing drawings and layout plan for comparison if available
- Existing PV, storage and compensation information; planned changes
Work steps
The steps are sequential: the output of each is the input of the next.
01
Data collection and validation
Diagrams, equipment data and measurement series are collected; inconsistencies and gaps are flagged.
02
Building the network model
Transformers, cables, panels and main loads are modelled on the single line in ETAP; sources and connection points are defined.
03
Calibration against measurements
Loading and voltage values calculated by the model are compared with measurements; deviations are resolved or recorded as limitations.
04
Measurement infrastructure and live connection (EPC)
Missing analysers, meters and communication infrastructure are supplied, installed and commissioned; analyser and SCADA data are connected to the model and warning thresholds are defined.
05
3D facility model
The facility is laser scanned and modelled in 3D from the point cloud; the model is tied to the single-line model, and equipment locations and live values are combined in the 3D view.
06
AI-assisted analysis
Deviation and anomaly detection and short-term load forecasting run on live data; an engineer reviews the results.
07
Scenarios and load shifting
Load growth, a new transformer, PV and storage are compared on the same model together with price- and forecast-based load shifting.
08
Reporting and acceptance
Results are delivered under document control with their assumptions and deviations; the installed infrastructure is commissioned with acceptance tests.
Reference framework
The frameworks below are used as references. This is a reference framework, not a certificate or accreditation claim.
- IEC 60909
- Short-circuit currents in three-phase a.c. systems
- IEC 60076-7
- Loading guide for mineral-oil-immersed power transformers
- ISO 50006
- Measuring energy performance using energy baselines and energy performance indicators
- IEC 62443
- Cybersecurity framework for industrial automation and control systems
Calculation software: ETAP
Delivered outputs
- ETAP network model scope and assumptions
- Calibration results and deviations
- Installed measurement and communication infrastructure, with commissioning and acceptance test records
- Live monitoring view and definition of warning thresholds
- Laser-scan-based 3D facility model tied to live values
- Report on deviation, anomaly and load forecast results
- Scenario comparison (loading, voltage, losses, short-circuit levels, load shifting)
- Statement of assumptions and limitations
- Document control record (prepared / checked / approved, revision)
Scope and limits
- The infrastructure scope (which analyser and which communication at which point) is settled after the survey based on the facility's existing state; existing devices are reused where possible.
- The AI outputs of the digital twin are engineering review support and do not replace relays or protection systems. Automatic commands are applied only within the EMS scope, on request, and within the authority and constraints defined with the facility.
- The level of detail of the 3D model depends on the laser scan coverage and resolution; electrical calculations come from the ETAP model, not the 3D model.
- Live monitoring quality depends on the continuity of the data feed; the model must be updated when the facility changes.
A live, measurement-calibrated model for your facility
Let us review your diagrams, measurement sources and goals together and settle the scope.
Request a technical pre-assessment