Control Systems That Work
Complex Infrastructure, Delivered
Our Automation Owners Project Management (OPM) is an entirely new approach to Process Automation. We believe it is more than just writing code-it is a continuum of deliverables, dovetailed together to provide a transparent, accessible, and reliable Process Control System (PCS).
It is a modular, scalable system to create a framework around all aspects of Process Automation. From Conceptual Process Control System (PCS) design, to Process and Instrument Diagrams (P&ID’s), to DeltaV/PCS coding, to commissioning and qualification of the Automation System, OPM is the playbook to manage and deliver outstanding results. By creating and following this framework, automation projects, and managers, are no longer “in the dark”. By following these detailed guidelines, change orders will be minimized, schedules kept intact, and end-of-project surprises eliminated.
How We Do It
By carefully documenting each and every phase in the Automation Plan, we have developed a reliable and repeatable procedure for Process Automation. All project deliverables are tracked, from development to approval, and kept in one place. No more building from the wrong P&ID revisions. No more using outdated or incorrect module libraries. No more excuses!
When it comes to getting consensus and approval on designs, every stakeholder is on the same page. Everyone knows if there are problems, and what to do about them if they occur.
After the design is finalized, we ensure that everyone on the team is aligned. As documents are developed and approved, they become part of the project archive and are made available to everyone. Any changes that are made are coordinated with the team to ensure ongoing efficient project execution.
Oversight Throughout the Project
Before the PCS coding begins, our framework precisely defines how the system will operate and function. This means Quality Assurance (QA) can verify and approve process parameters, operations, messaging, and alarming.
We then ensure the applicable standards are enforced, such as IEC 61131, ANSI/ISA S88 and S95. Proper libraries and knowledge repositories are utilized in accordance with design documents and protocols. No Black Box development here. All aspects of code generation follow the carefully defined framework, as developed by our Process Automation Subject Matter Experts (SMEs). Simply put, this means you’re running the project, not the Systems Integrator.
Prior to Acceptance Testing, we model controller code to ensure proper data handling procedures are met, recipes and phases download, and networks meet communication standards. We also ensure data flows upward from controllers, through PCS and Historian to the Manufacturing Execution System (MES) layer, and above, in accordance with S95 model and Detailed Design Specifications (DDS).
Our objective is the same as yours: Deliver a robust Process Control System that is collaborative, transparent, and without surprises.
Our Automation OPM Consulting Services
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[accordion-item title=”Conceptual Design”]We work with your Process Visionaries to document a PCS that delivers precisely what is required to manufacture product.[/accordion-item]
[accordion-item title=”Develop Control Strategy”]Our Automation SMEs have extensive experience developing and executing PCS strategy in Biotechnology and other processing technologies. They know where the challenges are, and how to deliver a robust system that serves all stakeholders.[/accordion-item]
[accordion-item title=”ASTM E2500 Consulting”]Our Automation SMEs leverage our extensive experience to design, manage, and deliver a scientific and risk-based approach to Process Automation.[/accordion-item]
[accordion-item title=”Preliminary Automation Budget”]Based on Conceptual Design, we can provide you with a Preliminary Automation Budget. Your team can decide up front what to include, or add later, based on hard numbers.[/accordion-item]
[accordion-item title=”Design Review”]Our Automation Engineers review your documents to ensure each is aligned with project goals. P&IDs are finalized earlier in the process. Process Flow Diagrams (PFDs) drawings accurately portray real-world conditions. Instrument lists are accurate and DDSs are approved early enough to be utilized by everyone on the team.[/accordion-item]
[accordion-item title=”QA Documentation”]Our QA SMEs can write, or simply review your URS, FRS and FS documents. By closely correlating Process Automation to QA, system testing and approval can occur much sooner in the schedule, eliminating bottlenecks down the road.[/accordion-item]
[accordion-item title=”Automation Master Plan”]Our Process Automation SMEs can develop a comprehensive Automation Master Plan that encompasses every aspect of your project, so there are no surprises at the end. You will know how every component of the PCS functions, and precisely how it interacts with the entire system. Want to add MES down the road? Your Automation Master Plan has that, and more covered. We can detail your complete Automation Product Lifecycle.[/accordion-item]
[accordion-item title=”RFP Development and Preparation”]We can provide you with an Request For Proposal (RFP) document that reflects state-of-the-art in terms of content and technology. Our SME’s have the expertise to deliver a solution that Systems Integrators can be held to. No more proposals that are all over the map.[/accordion-item]
[accordion-item title=”Vendor Selection and Review”]We know them all. The good, the bad, and exactly what their comparative advantages are. And we know the change order game, and how to stop it from ruining your project. We can create their schedules and milestones, then manage deliverables. We can review source code, and hold them accountable for milestones, and budget.[/accordion-item]
[accordion-item title=”Automation Validation Plan”]We wrote the book on Computer System Validation. We know how to write Automation Validation Plans, and we know how to execute them. A properly-written plan can significantly reduce the effort required to successfully deliver your project within budget and schedule.[/accordion-item]
[accordion-item title=”FAT/SAT Documentation and Execution”]Our Automation SME’s can write and execute both SAT, and FAT documents. We verify that your equipment was built, and performs to your specifications. We can accurately document software discrepancies long before it becomes an emergency on your factory floor. At SAT, we verify software is ready for production operations, not just recycled FAT. We hold the Systems Integrator responsible for delivering the software performance agreed to in the RFP, and subsequent contract.[/accordion-item]
[accordion-item title=”Calibration Plan”]Our Automation Team can develop, and execute a comprehensive Calibration Plan that will ensure reliable data from your field instrumentation. Couple this with our Maintenance and Reliability offering, and you have a complete Life Cycle Plan for field instrumentation in your facility.[/accordion-item]
[accordion-item title=”C&Q”]We built our reputation on Commissioning and Qualification. This is a core service for us, and we deliver outstanding results. When we execute C&Q on your automation systems, you can be sure it will perform precisely as designed, and you can begin production as rapidly as possible.[/accordion-item]
[accordion-item title=”Turn Over Package”]We can provide the services to complete your turn-over packages from vendors. We will ensure that “as builts” are complete and accurate, and ready for archive. We will verify that software is properly documented, commented, and available for ongoing maintenance.[/accordion-item] [/accordion]
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