Real-time digital twin prototype for cyber-physical analysis of anomalies in PV–PEM–BESS systems for green hydrogen production

The deployment of hybrid green hydrogen systems faces challenges due to complex integration and exposure to cyber threats. The lack of secure testbeds to replicate severe anomalies limits the analysis of fault propagation without endangering physical assets. Consequently, it is necessary to develop a testbed to replicate anomalies in the operation of a green hydrogen generation system to facilitate its physical implementation. This article presents the development of a real-time Digital Twin Prototype (DTP) testbed for green hydrogen production systems integrating photovoltaic (PV) generation, a proton exchange membrane water electrolyzer (PEMWE), and a battery energy storage system (BESS), structured with a DC bus and a supercapacitor. The platform is implemented using Hardware In the Loop (HIL) to emulate system dynamics, enabling the safe testing of cyber-physical anomalies such as False Data Injection Attacks (FDIA) and DC bus short circuits. Historical weather data, including irradiance and temperature from a real-site weather station, are streamed to the HIL-based model via User Datagram Protocol (UDP) communication, replicating realistic operating conditions. A cost-effective real-time monitoring architecture is established using a low-cost Single Board Computer (SBC), with data logged in InfluxDB and visualized through Grafana. Results are analysed through flowcharts depicting failure propagation, offering insights into system resilience and control performance. The testbed facilitates the validation of anomaly detection techniques and Energy Management Systems (EMS), while minimizing the need for physical prototyping. This approach enhances operational safety and accelerates development efficiency in renewable hydrogen infrastructures.