HIL testing: Assurance of Maritime and Offshore Control Systems

Errors in control system software or integration issues between systems can quickly lead to non-productive time, equipment damage, or even accidents. Hardware-in-the-Loop (HIL) testing is an efficient and proven method for identifying such issues early. Instead of connecting the control system to actual equipment on the vessel or unit, it is connected to a HIL simulator—a digital twin of the relevant systems.

The control system is treated as a black box, meaning no access to or disclosure of proprietary code is required. However, a functional description of the system, along with detailed knowledge of it’s I/O and the equipment it controls, is essential to define a meaningful test scope.

This approach enables systematic and comprehensive testing of control system functionality and failure handling—without any risk to people, equipment, or the environment. Testing is conducted in a safe environment at an early stage, positively impacting the project schedule by identifying and resolving software weaknesses before they affect the critical path.

Through HIL testing, we help ensure the functionality and safety of your control systems. Our experts provide deep insights into system design and functionality, fostering transparency and dialogue between equipment manufacturers, yards, owners, and charterers.

HIL testing can also be used in incident investigations to identify the root causes of failures.

HIL Testing for a Wide Range of Control Systems

With over 20 years of experience, our experts have conducted HIL testing across a broad spectrum of control systems, including:

• Dynamic Positioning (DP)
• Power Management Systems (PMS)
• Steering, Propulsion, and Thruster Control Systems
• Integrated Automation Systems (IAS)
• Vessel Management Systems (VMS)
• Drilling Systems (e.g., drawworks, top drives, mud pumps, pipe rackers, zone management)
• Automated Drilling Control (ADC)
• Blowout Preventers (BOP)
• Managed Pressure Drilling (MPD)
• Cranes and Specialized Lifting Systems (including motion-compensated)
• Jacking, Fixation, and Skidding Systems
• Motion-Compensated Subsea Installation Systems
• Hydraulic Manifold Systems (e.g., choke & kill panels)
• Exhaust Gas Cleaning (EGC)
• Emergency Shutdown (ESD)
• Fire and Gas (F&G)
• Ballast Systems
• Integration Testing across Systems and Vendors

Benefits of HIL Testing with DNV

Partnering with DNV for HIL testing offers numerous advantages:

• Enhanced safety and robustness of control systems
• Fewer software issues during commissioning and operation
• Early validation of user interfaces
• Comprehensive alarm system testing for correct behavior and prioritization
• Compliance with owner specifications and functional requirements
• Early detection of design flaws and verification of failure handling
• Independent third-party verification of control system software
• Improved schedule control through early-stage testing

Let’s Talk

Contact us to learn how DNV can help you minimize risks and avoid costly issues caused by software and control system failures.