It would be impossible to operate a modern rig or installation without highly integrated software control systems. On any given rig, we can find multiple interdependent control systems responsible for the coordinated operation of the machines required to safely drill, complete and produce a well. Unfortunately, we often experience problems with the delivered quality and reliability of these systems when they exhibit unacceptable defect levels that cause operational problems.
The delivered quality and reliability of any control system is directly related to the effectiveness of the acceptance test milestones that occur during the later stages of a control system development project. Figure 1 is a typical system lifecycle, and the acceptance test milestones (M4 and M5) usually include factory acceptance test (FAT), site acceptance test (SAT), site integration test (SIT), commissioning, sea trials and rig acceptance.
Effective execution of the acceptance test milestones simply means that for each milestone, roles and responsibilities are defined, requirements are stated and the test methodology selected for each milestone can demonstrate that the requirements are met.
One critical expectation that needs to be set early, and reinforced at every test milestone is that the test is an outgoing quality guarantee, not an incoming defect screen. In other words, the vendor is responsible for guaranteeing outgoing quality, rather than the customer being responsible to screen for incoming defects. This simple, yet powerful change in mindset can radically improve the effectiveness of the testing and the quality of the delivered system.
Over the next several issues of the Athens Group Services newsletter, we will be exploring each of the test lifecycle milestones. Starting with Factory Acceptance Testing (FAT), we’ll describe the best ways to ensure that the acceptance test milestones focused on system quality are aligned with the singular goal of delivering a fit for purpose control system, ready to operate.
For more information please contact us.