Testing the Heathrow Terminal 5 Baggage Handling...

Testing the Heathrow Terminal 5 Baggage Handling

System

Huub van der Wouden & Roger Derksen,

Transfer Solutions, The Netherlands

Th5

T

Testing the Heathrow

Terminal 5 Baggage

Handling System

Huub van der Wouden

Roger Derksen

Transfer Solutions

Vanderlande Industries

Presentation objectives (and side effects)

• To give you a flavour of the complexities of testing

a large system

• To give you a basic idea of how a baggage handling

system works

• To explain emulation testing, and its core position

in our test strategy

• To share our experiences with the use of emulation

3EuroSTAR 2007, Stockholm, 6-12-2007

London Heathrow T5 – Intro


T5 – Terminal

30 million

passengers a year

(Heathrow 90 M)

70.000 Bags

a day

Biggest free standing

UK building;

396 x 176 x 40 meterOpens March 27, 2008;

2nd satellite added 2011

T5 site 260 hectares;

as big as Hyde park


EuroSTAR 2007, Stockholm, 6-12-2007 6

T5 – Project

Cost:

6.5 billion euro

Broken down into

more than

100 sub-projects

(€ 45m-225m each)

On peak:

6000 people

working on T5

It will take approx.

37 million man-hours

to build T5

Construction

started 2002

The baggage handling system - functions


VIDEOB~1.MPG

The baggage handling system -

architecture

Logistics management Routes, destinations

Service management Flights, bags, services

Transport Management Transportation, flow control

Physical equipmentRaw conveyor,

Bagtrax, Cranes …


How to test?

• Largest threat to timely delivery:

construction delays

– Building

– Power, network, basic utilities

– Physical baggage handling system

• Site integration time often reduced – airport

opening date is fixed - “no time left”

• The ultimate risk mitigation strategy: start

early!


Component Testing

Integrated FAT

Factory Test Activities

Component FAT

Integration Testing

Unit Testing

Interface Testing

Unit Integration

Low Level Integration

High Level Integration

Commissioning (= LLC Component Testing)

Site Test Activities

Integration and System Testing

I/O Testing

Interface Testing

Software Configuration

Customer

Acceptance

Integrated SAT

Component SAT

Customer

Acceptance

Customer

Acceptance

Customer

Acceptance

Test process


Testing with emulation

• Emulation models – intelligent stubs that

model dynamic aspects of reality:

– Low-level emulation: model physical aspects

– High-level emulation: model physical aspects

plus part of controls

• Automod® simulation software


Low-level emulation & testingLow-level emulation

• Replaces physical equipment

• Interfaces with PLC

• Same electrical inputs/outputs

PLC

PC running emulation model

Conveyor area 1251


Component Testing

Integrated FAT


Component

FAT

Integration Testing

Unit

Testing

Interface

Testing

Unit

Integration

Low Level

Integration

High Level

Integration

Low-level emulation & testingTesting using individual models

• Testing individual PLC software

• Static vs. dynamic functions

• Examples:

– Error handling and recovery

– Tracking bags

– Merge algorithms

– Interfaces to other components

Logistics management Routes,

destinations

Service management Flights, bags,

services

Transport ManagementTransportation,

flow control


Bagtrax, Cranes


Low-level emulation & testingTesting using integrated models

PLC

PC running emulation model

PLC PLC

High Level Controls

Conv Bagtrax Conv

Logistics Manager

Service Manager



Component Testing

Integrated FAT


Component

FAT

Integration Testing

Unit

Testing

Interface

Testing

Unit

Integration

Low Level

Integration

High Level

Integration


destinations


services


flow control


Bagtrax, Cranes


• Testing integrated system

behaviour

• Miniature baggage handling

system

• Several inputs & outputs

• Horizontal (PLC) integration

• Vertical integration (PLC – High

level controls)


Example

Bagtrax®

High speed

transport

Unloading quay

(Transfer bag input)Build lateral

(Make up)


High-level emulation & testingHigh-level emulation

PLC

High Level Controls

Real-life situation

PLC

Equipment

Low-level emulation

PLC

High Level Controls

PLC

High-level emulation

High Level Controls


High-level emulation & testingHigh-level emulation

• Replace physical equipment

and PLC controls

• One model for entire transport

layer

• Realistic configuration

• Emulation of subsystems (incl.

controls software)

• Demo

High Level Controls


destinations


services


flow control


Bagtrax, Cranes


High-level emulation & testing

Subsystem Testing

• Test subsystems in isolation

• Example Early Bagstore

– Capacity of the store

– Flow control algorithms

– Error handling


High-level emulation & testing

Component Integration Testing

• Integrate all relevant HLC

components

• What is tested:

– Interfaces

– Business rules

– Time transitions

– Operational scenarios

– Performance

Component Testing

Integrated FAT


Component

FAT

Integration Testing

Unit

Testing

Interface

Testing

Unit

Integration

Low Level

Integration

High Level

Integration


destinations


services


flow control


Bagtrax, Cranes


What remains: site testing

• Operational scenarios

• Operator positions

• Volume testing

Commissioning (= LLC Component Testing)

Site Test Activities

Integration and System Testing

I/O

Testing

Interface

Testing

Software

Configuration

Integrated

SAT

Component

SAT

• Integration

equipment – low

level controls

• System behaviour

with real baggage

Transport Management

Physical equipment

Logistics management

Service management

Transport Management

Physical equipment


Use of emulation - advantages

• Software more mature and robust - many problems found before going to site

• Integration testing at lower cost and with better control over environment

• Very realistic testing independent of availability of physical system

• Early start is possible!


Use of emulation - beware

• Effort to build models and test environments is considerable

– But reuse potential is high

• Models are complex software

– High level of quality required

– Models need validation


Questions?


Testing the Heathrow Terminal 5 Baggage Handling...

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