Nuclear tooling and automation projects often involve tight schedules, complex integrations, and limited flexibility once work reaches site. Many teams want greater confidence in controls behavior before installation begins, especially when new systems must align with existing infrastructure.
Virtual commissioning helps teams test and refine system performance earlier in the project. Using a digital twin of the system, teams can integrate controls software, simulate system behavior, and evaluate how equipment is expected to perform under real operating conditions. This early validation can help uncover issues sooner, support clearer decision-making, and improve readiness for Factory Acceptance Testing and Site Acceptance Testing.
The Challenges We Address with Virtual Commissioning
Understanding the common barriers that affect project timelines and integration success.
Late Discovery of Controls and Interface Issues
When validation happens late in the process, teams often face rework and schedule pressure. Virtual commissioning brings integration and debugging forward, where adjustments are easier to manage.
Integration Complexity Across Disciplines
Controls, mechanical, electrical, and safety teams each bring a different perspective. A shared virtual model allows teams to align on how the full system is expected to behave.
Unclear Readiness for FAT and SAT
Project milestones rely on a smooth transition from build to installation. Early validation can help teams confirm readiness with more confidence before formal testing begins.
System Upgrades that Must Integrate with Existing Controls
Upgrades often involve both existing and new PLCs. Virtual environments allow teams to evaluate these interfaces before physical commissioning begins.
On-Site Troubleshooting that Drives Downtime and Risk Exposure
Troubleshooting during installation can add pressure and extend timelines. Earlier simulation and testing can reduce the amount of adjustment required on site.
Our Solution
A structured virtual commissioning process that brings system validation forward.
1. Build a digital twin of the existing equipment and system.
2. Apply planned changes to the virtual model to represent the future-state configuration.
3. Integrate the new equipment logic and controls software into the virtual environment.
4. Interface PLCs with HMIs and virtual machines to validate behavior before installation.
5. Run simulations to verify interactions, movements, and fault handling across the integrated system.
Key Benefits
The advantages of partnering with us.
Reduce Lead Time
Software integration and debugging tasks move earlier into the project through offline development and testing.
Improve Quality Control of System Behavior
System components, including HMIs and PLCs, can be evaluated together within a single environment.
Support Upgrades and Integration
New stations or tooling changes can be reviewed alongside existing systems, including interactions between PLCs.
Concurrent Schedule Support
Virtual commissioning supports parallel work streams so teams validate integration and identify design issues while equipment build work continues, supporting smoother transition from FAT to SAT.
Communication and Validation Across Teams
A shared model, combined with real control logic, allows teams to align on system behavior throughout the project lifecycle.
System-Level Stress Testing in a Virtual Environment
Simulated operating scenarios help identify potential failure points and inform maintenance planning before installation.
Applications
Real-world use cases across industries.
Refurbishment and Life-Extension Tooling Upgrades
Teams can validate new tooling logic and interfaces before outage work begins, helping improve testing readiness.
Operations and Maintenance System Upgrades
Validate upgrades that require new controllers or new PLC interfaces while maintaining compatibility with existing controls and HMI behavior.
SMR and New Build Programs
Teams can assess controls logic and system interactions before installation plans are finalized, reducing integration uncertainty.
Decommissioning and Waste Handling Systems
Sequencing, interlocks, and error handling can be evaluated in advance, supporting safer deployment in constrained environments.
Reduce Integration Risk Before Site Work Begins.
Connect with ATS Nuclear Energy Solutions to discuss how virtual commissioning may support your project scope, testing readiness, and integration planning.