How we use real world simulation to ensure major project success
The size and complexity of the major projects we work on means that eliminating potential issues before our engineers get to site is a priority. Chris King, our Engineering Manager (Major Projects), explains how our Building Management System (BMS) simulation rig helps us do this, and the other advantages it has for our clients and engineers.
With any major BMS project, one of the most important pre-installation considerations is ensuring that the software the system will run operates correctly. That’s why we have made a significant investment in developing a comprehensive Building Management System (BMS) simulation rig at our Wokingham office.
What is the simulator?
Our simulator consists of examples of all the BMS control equipment we use on major projects. This includes Trend, Tridium and Schneider Electric BMS products as well as the Schneider Electric programmable logic controllers (PLC), which are commonly used on the largest complex projects, such as data centres. This is a clear contrast to the purely digital approach to testing and simulation adopted by some businesses.
All the equipment is powered and networked in the same way it would be when installed in a client’s building, and configured to match the project requirements. If required, we can fully simulate any physical field equipment or devices, such as air handling units (AHU) and pumps. This ensures we can achieve as close to real-world conditions as possible for our software testing. We have also designed it to be expandable and whenever new products are released, we make sure we add them to our test equipment as soon as possible.
What are the benefits?
Our simulator allows us to carry out thorough testing of software and graphical packages using fully simulated inputs and outputs before the equipment is installed and commissioned on site. In the same way as an equipment manufacturer will carry out Factory Acceptance Testing (FAT) before the products are shipped, we can perform a ‘software FAT’.
This is standard practice for us on all major projects for several reasons. Firstly, without a ‘software FAT’, the testing would need to be done after the installation of the equipment. Completing this element in advance reduces the time required for commissioning. Furthermore, it also helps with troubleshooting issues that may occur during installation and commissioning. As the software has been previously tested with the equipment, engineers can immediately rule out one potential cause to help get to the root of the problem more swiftly – reducing time on site still further.
In addition, our testing process can help give clients confidence that the system will operate as intended. A number of our clients choose to attend the testing, in part to see the equipment and software interfaces that they will be using. Whether they are present or not, clients receive documentation detailing the testing.
As a large number of our major projects are located outside of the UK or include teams located in different countries, our simulation equipment is configured for remote use by our global teams. Engineers can log in remotely, load the software for their project and simulate the inputs and outputs in the same way as our UK based engineers can. We have also had overseas clients attend the testing virtually.
Beyond the project and client benefits, the simulator also has a role in staff training. With all the equipment they will use on site fully operational, engineers that are new to ABEC can be trained with the products in a simulated live environment. Furthermore, because we always have the latest equipment installed, it allows our team to quickly become familiar with the new products, which allows them to speak knowledgeably to clients about the products as they have direct experience.
Pre-installation testing of the software is just one of the ways we help ensure a project is successfully delivered on time, within budget and meets all client requirements. Find out more about our approach to major projects here.