Digital Twins for Power Infrastructure
By Jacob Kerley, PE, Director, Transmission, and Paulo Cortez, MBA, MEng, Supervisor, Transmission
For one utility, our team completed a three-year utility-scale transmission modeling program that captured 4,750+ line miles, modeled 684 circuits, and created more than 50,000 Method 4 structures. The result was a full digital twin of their transmission system, built from LiDAR capture, record validation, PLS-CADD modeling, engineering review, and PLS-GRID deployment.
Rather than serving as a static record, the model became a living source of information designed to support long-term asset management and future project work, including pole replacement planning, clearance analysis and mitigation, and justification for line rebuilds.
The Opportunity
Transmission systems evolve over decades. Field conditions change, structures are replaced, lines are reconducted, and distribution underbuild is added. Additionally, records may be updated in various formats, stored in different places, or sometimes not updated at all.
For utilities, this can incur risk. When engineering teams work with incomplete information, routine projects may require additional field verification, schedule adjustments, or rework. For larger programs, the lack of a single, trusted system model can make it harder to prioritize improvements, evaluate constraints, and respond quickly when conditions change.
The goal of this program was to consolidate the utility’s transmission records, field conditions, and engineering models into a single source of truth. Our role combined aerial LiDAR collection, ortho imagery, survey verification, PLS-CADD Method 4 modeling, plan and profile drawings, clearance violation identification and reporting, and clearance mitigation support.
The Vision
The vision was to create a single source of truth: consolidated records, standardized PLS-CADD models, and data that the utility could trust across its system. The solution? A digital twin.
A digital twin is a virtual model of real-world infrastructure. In this context, it goes beyond a 3D image or a GIS database, serving as an engineering-ready model that reflects actual field conditions, structural configurations, conductor positions, terrain, crossings, and supporting records.
To get there, we combined several capabilities into one workflow:
- LiDAR acquisition: aerial laser scanning used to capture accurate terrain, structure, and conductor data.
- Ortho imagery and oblique photos: high-resolution images that support visual validation of alignments, structures, and surrounding conditions.
- Records validation: review and reconciliation of historical structure data, drawings, and archive records.
- PLS-CADD modeling: transmission line modeling used to support design, clearance analysis, sag and tension calculations, and engineering decisions.
PLS-GRID deployment: a centralized model management environment that helps keep models organized, versioned, accessible, and ready for ongoing use.
Challenges and Solutions
Dated and Inconsistent Records
The team encountered gaps in legacy records, the result of decades of system changes, often the result of storm response work, where speed is important. To address this, they went on-site and reviewed physical records to fill these gaps where they existed.
Complex Structure Modeling
For a system that has been around for 100 years, not every structure fits neatly into a standard framing. Lattice towers and non-standard geometries required further modeling and engineering review. Our team used framing drawings, staking information, and aerial imagery to build Method 4 structures that matched LiDAR capture.
In practical terms, Method 4 modeling allows the structure to be represented with more detailed geometry and framing information, giving engineers a more detailed basis for analysis of assets.
Distribution Underbuild and Crossings
Transmission corridors often include distribution circuits, communication lines, and dense crossing conditions. In this program, the distribution underbuild was modeled using available utility data, including voltage, conductor, and neutral-wire information. Wires were graphically sagged to match LiDAR data, while engineering calculations supported accurate wire-temperature and sag conditions.
Multi-year Data Management
A program of this scale requires more than strong field data. It also requires disciplined model management. Our transmission engineering professionals used PLS-GRID to support check-in/check-out workflows, revision history, change logs, folder organization, model uploads, and record document integration.
That structure helped keep every model in one place, fully versioned and ready for future updates.
Innovation in Action
The value of a digital twin is realized when asset management can look across the entire grid system, and confidently identify what that system needs and where it needs it.
Our integrated workflow moved from raw LiDAR import to fully documented, analysis-ready models through setup, structure building, refinement, analysis, and final documentation. This included creating terrain models, aligning ground points, building and adjusting structures, stringing wires, snapping attachment points, defining circuits and phases, adding structure comments and photos, and modeling crossing wires.
The team also used IEEE 738 thermal calculations to support a proper sagging of wires. In simple terms, IEEE 738 helps estimate conductor temperature based on weather, loading, and environmental conditions, thereby supporting more accurate sag and clearance analysis.
From there, the models supported clearance reports, thermal rating reports, and system-wide analysis against applicable utility and NESC clearance requirements.
Services Delivered
We proudly provided a comprehensive set of services:
- Transmission Engineering
- Distribution Engineering
- Geospatial and Remote Sensing Services
- Aerial LiDAR Collection
- Survey Verification
- PLS-CADD Modeling
- PLS-GRID Integration and Model Management
- Plan and Profile Drawing Creation
- Clearance Identification and Reporting
- Clearance Mitigation Support
- Geotechnical Services
- Permitting Services
Civil/Site Design Services
The Outcome
The program delivered a full transmission digital twin within PLS-GRID, with accurate models and relevant asset information designed for asset strategy. It supported clearance analysis, pole replacement and rebuild planning, river crossing analysis, and long-term asset management.
For the utility, the long-term value lay not only in the model itself but also in its ability to serve as a trusted foundation for future work. As the system evolves and internal/external engineers continue to create updates in PLS-CADD, the digital twin serves as a living, evolving picture of the grid. It also provides a reliable foundation for storm response planning and other system-wide analyses as new needs emerge.
A reliable digital twin can help utilities:
- Plan infrastructure improvements with better information
- Support pole replacement and reconductor programs
- Evaluate crossings and clearance constraints
- Accelerate new project work
- Support storm response planning and system resilience
- Maintain consistent records as the system evolves
Prepare for capital planning, system expansion, and load growth
Looking Ahead
Utility-scale digital twins are achievable today, but success depends on more than LiDAR alone. It takes field validation, record reconciliation, engineering judgment, disciplined modeling, and a practical plan to keep data current.
For utilities, developers, and partners navigating grid modernization, the opportunity is clear: better data supports better decisions.
Our Power team brings the surveying, geospatial, transmission engineering, distribution engineering, and model management capabilities needed to help turn complex infrastructure systems into usable, maintainable digital twins.
Contact our Power team to learn more about how Westwood’s capabilities can support your next project.
