As a project engineer in a control systems company, our objective is to prepare and execute a project, provide a automation & control systems as customer requirements. In a project, we are dealing with the some stages on engineering phases:
1) Detail engineering: the objective for this phase is to produce an detail design for a project, support the procurement team and prepare the necessary documents for fabrication. Normally, this phase begin by receiving some documents: initial systems architecture, bill of material, IO list, control narratives, P&ID diagram, Cause & Effect diagram, etc. The first two documents normally will be received from procurement and sales team. The other documents normally will be received from customer or main contractor. The detail engineering can be subdevided into two categories:
a. Hardware: normally involved designing the General Arrangement (GA) drawing for panel, power distribution calculation, power distribution drawing, IO termination list. There would be also a detail bill of material which include the detail quantity of supported materials, such as panels, wires, power supply, trunking, terminal block, etc.
b. Software: software configuration normally based on systems architecture, IO list, IO termination list, P&ID, Cause & Effect Diagram, Shutdown Hierarchy, Control philosophy. The configuration including the Human Machine Interface (HMI) configuration and control logic configuration.
The bill of material (BOM) will be used by procurement team to purchase the required materials. Several aspects that need to be considered are: price, supplier, and delivery date. Several well known supplier are listed below:
- panel from Rittal
- terminal block from Phoenix Contact or Weidmuller,
- power supply from Phoenix Contact or Lambda,
- IS barrier from Pepperl+Fuch,
- circuit breaker or isolator from ABB
Purchase Order (PO) will be sent to the respective suppliers, and upon receiving the materials, the Delivery Older (DO) will be sent by the supplier. In some country, the delivery date shall be taken carefully into consideration because it will effect the project schedule. For example, it might take some days (even weeks and months) to deliver materials to Indonesia, but in contrast, it could take only one day to deliver the materials in Singapore (as almost all suppliers have their office and store in Singapore).
3) Fabrication and Assembly
The fabrication and assembly include:
- Panel fabrication to assembled all material (controller and IO modules, wire, power supply, terminal block, breaker) inside a panel. Normally this phase will be managed by subcontractor in Staging Area.
- Computer and network installation
4) Factory Acceptance Test (FAT) and Integrated Factory Accepatence Test (IFAT)
FAT will be done with the presence of customer to test the systems. Usually it would take some weeks of even months, as it would depend on the system size. Some procedures shall be done during the tests:
- Continuity test
- IO test
- logic test
- System redundancy test
- System power test
During the testing, some deviations might be recognized, and shall be logged as a Punch Lists. Before finishing the FAT, this Puch Lists shall be cleared under the confirmation from customer.
Another term is IFAT, which is basically consist of FAT and additional tests with other third-parties systems.
5) Dissasembly, pakcaging and shipment
After FAT finish, then systems will be shipped out to customer’s site, upon sign-off the handover letter. Dissambly shall be done before shipment and packaging normally will be managed by subcontractor. The shipment then will be proceed.
6) Site Acceptance Test (SAT)
SAT will be done on customer’s site. Basically it will proceed with the same procedures as FAT, but including also some additional tests such as instruments and valves calibration.
7) Start-up and commissioning
After completing the SAT, then the project can continue to start-up and commissioning. Its objective is to make the plant works and start the production.