Norwegian pioneer on software testing

 

In Norway, all units with dynamic positioning systems need to be HIL tested if they are to operate for Statoil for more than two years. DOF, Maersk and Sevan Marine are other clients of Marine Cybernetics. Photo courtesy of Marine Cybernetics.

The Norwegian company Marine Cybernetics is providing testing of computer control systems, known as HIL testing for the offshore sector, as the first company offering this kind of service offshore. Now, the pioneers are looking for an entry into the Brazilian market.

Although Hardware-in-the-loop (HIL) technology is being used frequently in many other industries, Marine Cybernetics was the very first company to offer this kind of service to the offshore and maritime sectors, starting in 2004.

HIL testing is testing of computerized control systems, and in the Brazilian offshore sector, the technology is still not being used. Petrobras has however decided to include HIL testing in the specifications for the 28 drilling rigs that are going to be built for the future pre-salt explorations.

Modern ships and rigs have advanced computer systems for dynamic positioning, power distribution and drilling operations. A large portion of the automation systems on today’s vessels are put into operation without independent testing, a paradox considering that the automation systems often contain safety-critical failure handling functionality.

“Safety critical functions on modern platforms and offshore vessels are continuously being taken over by control systems, and these systems are hardly tested in advance. Few people have the knowledge to do it, although software problems are among the main causes for down time on new drilling rigs nowadays”, explains Trond Martin Augustson, business development manager at Marine Cybernetics do Brasil.

Replica
Software errors in control systems on drilling rigs and offshore vessels lead to delays, non-productive time and also compromise safety. Due to the increasing complexity of the offshore control systems, classification societies like DNV and ABS recommend implementing HIL testing of the dynamic positioning (DP) control systems before vessels leave construction yards.

“This kind of third party testing of software is being used in all advanced control systems, like in the automotive industry, aviation industry and during design of space shuttles. NASA researchers were some of the first to use HIL testing. It is a complex procedure where a kind of virtual reality of the control systems is created, to test if the systems are fit for their intended use. We can check if the different systems are working well together and not causing unexpected errors as they are integrated and configured. We look for hidden bugs and introduce errors if they are detected and the correct measures initiated”, says Trond Martin Augustson.

Marine Cybernetics was established in Brazil in January 2011 and founded back in Norway in 2002. Today the company is located in the offices of Inventure Management in Botafogo, but the drilling tests are being conducted in the lab in Trondheim.

The company is considering building a lab in Brazil, and is currently exploring the possibility for a closer cooperation with local universities, as well as with Petrobras in order to improve and develop the HIL testing philosophy further.

Great news
Since 2004, Marine Cybernetics has provided HIL testing for control system software on drillships, semisubmersibles, jackup rigs, offshore service vessels, construction/diving vessels and shuttle tankers.

“As the systems are developed by several different suppliers, few have a complete overview on how they work together. You’ll always find software errors and no vessel or rig is the same, not even sister ships”, says Trond Martin Augustson.

Marine Cybernetics has been in a close dialogue with Petrobras for years.

“Petrobras has a very competent technical group working on dynamic position and related incidents. In an attempt to avoid incidents, improve safety and to ensure up time, Petrobras decided to include HIL testing in the specifications for the 28 drill ships. This is great news for us”, says Jan  Lomholdt, country manager of Marine Cybernetics do Brasil.

According to Marine Cybernetics there have been several incidents caused by software errors on the Brazilian offshore sector, especially on complex systems consisting of integrated controllers from different vendors. 

“The offshore sector is conservative, but the companies are beginning to see the need for more advanced testing, as they are experiencing lots of incidents, mainly on drilling control systems. The operators of the drilling ships have reported down time of several hours a day, caused by errors in the control systems, and although the industry tends to prefer solving problems as they occur, many companies are beginning to realize that a long-term approach might pay off economically and also improve safety. We are talking about drilling rigs worth billions and still the companies don’t test the systems in advance, like they do in other industries. To test the systems in advance is a cheap investments for the company compared to the cost of hours and even days of down time on these rigs. Errors can also compromise safety”, says Jan Lomholdt.

By Runa Hestmann Tierno, NBCC journalist