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Why Commission Twice When Once Is Enough?

Virtual commissioning eliminates the expensive field debugging phase entirely

Day 47 of commissioning, and the DCS finally talks to the safety system, except the startup sequence now deadlocks in ways the P&IDs never predicted. Contractors are on standby, production is delayed, and engineers are flying in from three countries to debug logic that could have been validated months earlier in a virtual environment.

This pattern repeats across greenfield projects because traditional commissioning forces all integration validation to happen after equipment is installed, when field labor is mobilized and every delay has direct financial impact.

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What Changed

Virtual commissioning runs real control code against dynamic process models with actual operator interfaces before construction finishes. The integrated system gets tested, broken, and debugged during engineering, not during field commissioning.

The difference:

  • 75% less time finding out whether your systems actually work together
  • Zero equipment damage from bad logic
  • Operators who’ve already broken everything virtually before they touch real valves

What's Inside

Virtual Commissioning and Beyond: Accelerating Greenfield Plant Readiness Through Digital Twin Technology walks through the practical implementation of virtual commissioning, from business case to lifecycle handover:

  • Why commissioning fails the same way on different projects
  • The five-layer architecture that makes virtual testing actually work
  • ROI math: 20-25% project cost reduction, months saved, risks eliminated
  • How the digital twin becomes your permanent training and testing platform
  • Implementation roadmap from companies who’ve already done this

If your next startup has 7-figure consequences for every week of delay, this white paper walks through how virtual commissioning actually gets implemented—not the theory, the practice.