What are some best practices for testing control systems in water treatment?

In my view, simulation tools can be utilized more effectively in the validation of control systems. Despite the high level of accuracy demonstrated by simulation tools, there is a reluctance to adopt them more broadly for validation due to a lack of trust. Currently used for design and initial validation, they could be employed more effectively to reduce HIL testing and validation in test facilities. To do so, it’s essential to build confidence in these tools across all involved parties, such as the systems engineering team, validation team, and system safety team. A back-to-back comparison between simulation results and HIL testing or results from actual test facilities could serve as a means to gradually build this trust.

First understand the associated risks... Define the system… 1 Define the system needs 2 Define the system 3 Decompose the system 4 Perturb system 5 Develop and define risk criteria 6 Design adverse progressions 7 Define risks with minimal controls 8 Design controls to enable acceptable levels of risk 9 Rank risks and address high to low risks 10 Develop and design system monitoring: early detection, isolation, correction, contingency and recovery 11 Continually validate and verify risk controls 12 Monitor the system and revise analyses due to system dynamics.... Such testing is risk-based and part of validation and verification of risk controls... If simulation tools are applied such tools require validation and verification...

Certainly look into NASA's System Engineering document. Structured tests are used to verify and validate system requirements to ensure the system operations and requirements are met. NASA's system engineering methodologies are the best in the industry and will apply to many different types of IT, processing, and product systems.

Involving end users and operations in the testing of control systems is mandatory. Usually Engineers are not operating the equipment in W/WW plants on a daily basis, are as familiar with regulatory guidelines, or logging as much data manually. That being said, Operations Management has to be an intermediary. Collaborative efforts between skilled trades professionals and engineering professionals can become complex for no reason. Operations management has to take control. The testing could be to eliminate a hazardous problem or innovative due to obsolete technology no longer supported by the OEM. Operations has to participate and in a substantial documented way because they are required to have a license to work at these facilities.