SFE's TYPICAL CONTROL SYSTEM PROJECT EXECUTION CYCLE
Engineering Activities :: Design review and documentation
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Control System Architecture and Design
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System Loading calculations such as Controller (CPU) loading and communication network loading as applicable
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System Power Consumption and Heat Dissipation calculations (subsequently useful for power supply design on site and also for site-planning of air-conditioning where required)
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Cabinet sizing and design
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Generation of typical cabinet layout drawings
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Generation of I/O Termination and typical Wiring diagrams, loop drawings
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Graphics design for plant operations and maintenance � develop color and symbol philosophy, navigation philosophy, animation and alarming philosophy
Engineering of physical Inputs and outputs
- Input/Output, Tag database generation
- Design of System I/O Cards and channel allocation
- Design of system address allocation for tags
Programming and Software development (off-line)
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System Software development: Define system modules and assign racks/slots, communication cables etc
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Control software development: Programming controllers and developing ladder logic, Batch recipes etc as applicable to application
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SCADA/HMI Software development and configuration
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Alarm configuration
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Historical Trends and Reports configuration
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Configuration of data transfer to/from third-party systems if applicable
Hardware Engineering and System Integration
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Fabrication and wiring of panels and cabinets
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System rack and Module assembly, integration and power-up
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Load System software and upgrade to latest revisions required
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Load application software developed offline
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Establish system network and communication (I/O Cards � CPU � Communication modules/cables � Operator screens/SCADA)
System and software Testing
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If applicable, check integrity of wiring in panels by simulation of field signals and corresponding updates to the system health displays
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Check control software and displays by simulation of field inputs/outputs
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Check program and application software for correct operation of control schemes, interlocks and logics by simulating normalized conditions (by applying �forces� on I/O)
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Check displays for proper representation of plant equipment, pipelines etc and for corresponding dynamic links and data updates with the simulated inputs
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Verify operator alarm notification to be in accordance with the plant requirement
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Verify proper data collection and retention on the historical database and for proper data displayed on trends
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Generate sample reports such as Shift Logs, Daily Logs, Production reports etc as applicable by the requirement specifications
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Document test results and rectify errors found while testing
Factory Acceptance Testing (FAT)
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Repeat the above tests and obtain System Acceptance by client for a DEFECTLESS system
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Documentation of Modifications that need to be made to the control system after the FAT prior to testing at Site
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Prepare System for shipment with necessary documentation to identify different cabinets, packages etc.
Documentation of Modifications that need to be made to the control system after the FAT prior to testing at Site
Installation, Testing On-Site and Plant Start-up / Commissioning
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Installation of System cabinets and cables as per recommended procedures and project documentation
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Power-up of system on site
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Repeat tests conducted during FAT on site with actual signals (SAT)
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Engineers� stand-by support during pre-commissioning, commissioning and startup of plant
You may choose to breakdown your job and apply SFE capabilities to any portions per your convenience