Case study: Control design of an anaerobic digestion system using simulation-based synchronization

One of the problems for development of industrial controls programs is the availability of the actual equipment to be controlled. Availability of the equipment may be due to project timing, cost issues, and even location. By using a simulation tool, integrated with the control programming environment, the control engineer can test the control program functionality to reduce the amount of time required to commission and deploy the system. Dependent upon the complexity of the system and simulation, diagnostic programs can be developed and tested. Additionally, as new control system capabilities are developed, the corresponding simulation model can be adapted to test those new capabilities. In this paper, we describe the development, use, and validation of an integrated control and simulation tool for an anaerobic digester lab system. Results of the validation tests are discussed, as well as the methods used to develop and deploy the control program. Finally, future work is described to use the capabilities of the control and simulation tool as a formal validation step in the control system design and commissioning.