As the energy landscape evolves, so too must the tools we use to design, optimise and futureproof our infrastructure. Among the most transformative of these tools is the Digital Twin – a virtual replica of a physical system that allows us to simulate, analyse and improve performance with high levels of precision.
Having worked with Digital Twin for a number of years, Energy Projects Development Manager, John Fonseka, shares insight into how this technology works, and the benefits it can bring.
From Site to Simulation: Building the Digital Twin
Creating a Digital Twin is not a one-click process. At the heart of this transformation is the six-stage process outlined in the diagram below. Vital Energi's methodology complements this by conducting extensive site and BMS surveys, ensuring the Digital Twin is built on a foundation of accurate and comprehensive data.
It begins with a detailed on-site asset survey and energy data analysis to understand how a site’s energy generation and distribution system is currently designed and operating. This foundational step ensures that the virtual model reflects the real-world conditions accurately, capturing the nuances of legacy systems, operational constraints and energy flows.
Sandbox for Innovation
Once the Digital Twin is built, it becomes a sandbox for innovation. Engineers can test concepts, simulate performance under different scenarios and identify inefficiencies that would be difficult to detect otherwise. This is where the real value emerges – not just in visualising the system but in understanding it deeply enough to optimise it. We use this sandbox to stress-test proposed modifications under various conditions, such as partial loads and adverse weather, to optimise system performance before implementation.
The process continues with performance analysis and options appraisal. Here, carbon, cost and comfort are weighed to determine the most effective solutions. Whether it's adjusting flow temperatures, reconfiguring control strategies or integrating new technologies, the Digital Twin provides a safe and insightful environment to explore possibilities before committing to physical changes. The calibrated Digital Twin enables us to generate techno-economic studies to accurately quantify the feasibility of integrating low carbon technologies like heat pumps.
Beyond Optimisation: Managing Future Uncertainty
But the journey does not end with optimising an existing installation or installing an optimised design. The Digital Twin evolves alongside the system it represents. Through real-time data monitoring and analysis, it ensures that efficiencies are maintained and improvements are sustained. It becomes a living model with human intervention – one that adapts, learns and guides decision-making over time.
This approach is particularly valuable in complex environments like healthcare estates, where infrastructure varies widely in age and condition, and operational continuity is non-negotiable. In such settings, the ability to simulate upgrades and assess their impact without disrupting services is a game-changer. It allows teams to plan phased interventions, align technical solutions with funding opportunities and ensure that new systems meet both performance and resilience requirements.
Digital Twins also support a more holistic view of energy strategy. By integrating energy conservation measures (ECMs) such as BMS upgrades, distribution system improvements, solar PV and fabric improvements into the model, teams can assess how these elements interact and contribute to long-term sustainability. This helps avoid the pitfall of implementing impressive but costly solutions that are difficult to operate efficiently. This process enhances this optioneering strategy by incorporating dynamic simulation capabilities into measurement and verification, delivering more meaningful and actionable data.
Achieving Success
Ultimately, the success of Digital Twin initiatives depends on the quality of information used to populate the model. Collaboration is key – from design engineers and energy consultants to estates teams and finance directors, everyone must be aligned on the strategy. The process is creative, collaborative and complete – bringing together data, expertise and vision to shape energy systems that are not only efficient but resilient and future-ready.
A Mindset Shift
Digital Twins are not just a technical innovation; they are a mindset shift. They invite us to think differently about how we manage energy, how we plan for change and how we build and commission systems that serve us better. In doing so, they turn ambition into action – and potential into performance. Vital Energi embodies this mindset by transforming ambition into action through a rigorous, data-driven approach that bridges uncertainty and solution.
Imagine a building not just as bricks and mortar, but as a living, breathing entity – one that can be mirrored, studied and optimised in a virtual reality. This is the promise of the Digital Twin: a dynamic replica of physical infrastructure that allows us to see not only what is, but what could be.
Real-World Impact
Digital Twin is not just theory or a buzzword or a shiny new toy to win a sales opportunity. At Bridlington Hospital, the deployment of Hysopt’s Digital Twin technology led to a leap in energy efficiency. Without changing a single piece of hardware, the system’s heat utilisation improved from 83.4% to 98.5% by optimising the operation – a testament to the power of simulation and optimisation. The same virtual model enabled the team to fine-tune return temperatures, unlocking the full potential of low-carbon heat pumps.
Digital Twins at Vital
At Vital Energi, we use two Digital Twin platforms for hydronic and hydraulic applications: Hysopt for HVAC system design and optimisation, and MATLAB for product design and performance modelling. These tools are not only used to predict and influence outcomes before they become reality, but they also serve as training platforms, enabling engineers to explore advanced concepts and test designs with no strings attached.
Digital Twins are redefining how we approach energy systems, turning buildings from static structures into dynamic, responsive environments. They are the blueprint of energy transformation where inefficiencies are exposed, options are appraised and futureproofing without ‘oversizing’ becomes a reality.
If only I had a pound every time I mentioned ‘Digital Twin’ in this article, I would not be a millionaire, I will be £19 richer!
