Project Background
Client: BHP
Date: May 2021 – May 2024
Location: GTE Offices – Perth, Western Australia
BHP needed a solution to test and validate key control systems and industrial network equipment before deployment in a live production environment. The challenge included verifying SCADA servers, PLC hardware and network switches, as well as simulating staged upgrades over time. GTE was tasked with ensuring seamless integration, preventing compatibility issues and avoiding production disruptions.
Challenges
GTE faced the challenge of thoroughly testing and validating all critical control systems and network equipment for BHP. The complexity of the project was amplified by the need to replicate the exact conditions of the site environment in a controlled, off-site setting. We needed a solution that could anticipate and mitigate risks associated with extended shutdowns or hardware failures.
Approach and Solution
Specialised Test Lab Facility
We responded by designing and building a dedicated test lab in our Perth office. This facility mirrored the hardware and software configurations that would be deployed on-site, allowing us to conduct thorough testing of each device’s configuration, compatibility and integration. By creating an identical working environment, we ensured that all aspects could be fully tested, including those involving obsolete or end-of-life hardware.
Minimising Risks with Strategic Planning
Our approach included purchasing end-of-life equipment to test and de-risk the migration strategies, ensuring that any potential design flaws, software bugs or host incompatibility issues were identified and resolved well before site commissioning. The test lab’s capacity to simulate real-world conditions was critical in reducing risks and avoiding costly delays during time-sensitive shutdown windows.
Results and Impact
Over 60 BHP equipment installs tested and de-risked in GTE’s Perth lab, ensuring seamless integration, preventing extended shutdowns and achieving zero downtime over 3 years.
Significant Risk Reduction
Through our test lab facilities, we provided BHP with a significant reduction in project risks. Our rigorous testing process identified and addressed potential issues before they could impact on-site operations, ensuring all equipment was fully compatible and ready for deployment.
Operational Continuity and Long-Term Benefits
The test lab played a pivotal role in preventing extended shutdowns and minimising downtime. Over a period of 3 years, GTE’s facility was instrumental in testing and staging upgrades for over 60 shutdowns at BHP WAIO, ensuring seamless transitions and operational continuity. This proactive approach also included reviewing the functionality of new end-of-life replacements, ensuring that all hardware and systems were fit for purpose for the next 10 to 15 years.
Conclusion
GTE’s Industrial OT Test Lab Facilities have proven to be an invaluable resource for BHP, providing a controlled environment where critical systems can be tested and validated before deployment. Our work demonstrated a commitment to precision, risk management and long-term reliability. As we continue to refine our approach, our capacity to foresee potential challenges and address them proactively allows us to remain a trusted partner for BHP and other Tier 1 companies.
