Phase 1: Automation Plan
Existing system operating procedures
Highest potential automation areas
Hardware/software block diagrams
Field Hardware and sensor requirements
Operational documents requirements
System implementation plan and schedule
System development, integration, assembly & testing requirements
Phased pricing summary
Return on investment analysis
Phase 2: Project Kick-Off Meeting
Review scope of work and clarity integrator and client responsibilities
Establish a mail and transmittal system
Set up a drawing list
Obtain a set of safety requirements
Obtain reference drawings and data
Establish project reporting methods
Introduce key integrator and client personnel with overall project responsibilities
Develop a preliminary outline for format of final report
(Also, weekly project meetings attended by all system integrator personnel on project and monthly status review meetings.)
Phase 3: Field Survey
Integrator project team reviews current system, including:
Screen and report requirements
Man machine interface
Sequence of operation
Current process overview
Phase 4: Functional Description
(States functional requirements for project.)
Reference request for proposal Involves customer input
Upon final client approval is basis for design document
1. Machine identifier
2. Rack identifier
3. Input card identifier
4. Signal type
5. Terminal numbers
6. Signal identifier
Phase 5: Detailed Description
(Provides implementation method for each requirement in the functional description.)
Controls, regulates and directs progress of system development
Measures technical conformance
Maintains project schedule
Delineates internal structure of system (i.e., data dictionaries, flow charts, logic pseudo code)
Client reviews design progress on regular basis and must approve final document before project can proceed
Phase 6: Acceptance Test Plan & Procedure
(Developed after approval of Phase 4, Functional Description. This document explains how to test hardware and software to demonstrate conformance to system specifications. A detailed list of actions and expected results that satisfy all requirements.)
Test No. 1: Factory Acceptance Test (at S.I... facility)
Complete system staging
Comprehensive test to demonstrate all hardware and software for the project
Test No. 2: Field Acceptance Test (after system installation)
Phase 7: System Development
Write software specifications per the Functional Description. Specifications will consist of data flow diagrams, block schematics (for PLC programming), data dictionary and mini-space (an English language description of the software functions). The specifications will provide enough information for a software engineer to write programming specifications.
Software specifications must be reviewed and approved by client before coding is started. Any changes after client review will be regarded as major additions to the contract.
Programming specifications will be pseudo code version of the final program, specific to operating system, language and hardware. Review of programming specifications will be made prior to final code and implementation.
Graphics configuration: Application of control and feedback features to the screens as defined in the Functional Description.
Coding of controls according to the software and program specifications
Verification of existing customer drawings against actual field conditions. Develop demolition drawings to show sequence and conditions applicable to the removal of existing equipment.
Develop system schematics showing terminal numbering, equipment type, etc.
Develop diagrams to show wiring installation, terminal connections, conduit routing and cable type, etc. These will normally be done according to customer's standard cable schedule format.
Develop diagrams for the necessary enclosures and panels for equipment mounting. Drawings will be suitable for bidding and construction by a third party supplier.
Specifications to inform the vendor of the requirements necessary in the manufacture of the panels, i.e. type of enclosure (NEMA 4, etc.), weld instructions, finish, materials, etc.
Release panel drawings for bid, or according to the procedure for the project (preferred vendor, etc.), and manufacture.
Designate delivery time of panels and enclosures
Phase 8: System Integration Task
After completion of software development and hardware/software interfaces, system hardware and software are integrated.
During integration, power is applied to all hardware and burn-in program operates for 100 hours. Purchased hardware and all system peripherals are inspected and tested to verify that all software and hardware function according to manufacturers' specifications.
Hardware and software are functionally tested and software is modified, as necessary, to assure software modules and hardware elements function as one system
Phase 9: Factory Acceptance Test
Performed at system integrator test facility.
Complete system staged and comprehensive mock-up test performed to demonstrate all hardware and software.
Daily review of scheduled tests and test results. If necessary, integrator engineers correct any errors discovered and perform regression tests to show correct system performance.
Client and integrator jointly develop a "punch" list of items, if any, which require further action and/or correction before shipment.
Phase 10: Support Services
Client must approve Factory Acceptance
Test before shipment
All equipment packed in manufacturers' packing boxes
All items in shipment marked separately with shipping labels and clearly marked with special handling instructions Industry standard shipping materials and methods utilized to avoid damage to fragile items
Proper shipping papers and packing slips prepared
Physical audit and inventory of all deliverables performed and data given to client before delivery
Physical audit and inventory data repeated by integrator after shipment Shipment sent using commercial carriers approved in advance
Close contact maintained with carrier to verify that shipment is received promptly and in good condition
Integrator's field installation engineer(s) will supervise all installation by others and will have the following responsibilities:
Documentation package interpretation, distribution and maintenance
System testing prior to commissioning
Assist in system training sessions
Work closely with client to respect the schedules and other demands on client personnel during installation
One integrator engineer will be designated to schedule and coordinate all start-up activities with client
Engineer will work closely with client to respect schedules and other demands on client personnel during start-up
Same engineers who were responsible for designing the system will be responsible for the system start-up
Field Acceptance Test
Training - Management Training Program
Lecture seminar for executives and managers
Present general features and functions** of the system
Techniques for effective management monitoring and control of the system
Discuss possible future development of the system
Answer participant questions**
Computer Training Program
For system managers & engineers
Theory of system operation
Hardware configuration/system components
Software concepts and structure
System interface and data communications
System preventative maintenance
Operator Training Program
Combination lecture/seminars and hands-on training for dispatchers and supervisors
Focused on individual job assignments
Maintenance Training Program
Combination lecture/seminars and hands-on training for supervisory and maintenance personnel
Instructions on how to maintain, trouble-shoot and adjust system equipment
Phase 11: Documentation
Complete set of manuals of all hardware and standard software products incorporated in the system.
Operational documentation for normal use of the system.
Start-up and maintenance documentation for recovery operations.
Design documentation specifying overall system structure.