We have a set system integration design procedure.

The first stage of this procedure is to create the design documentation to enable the hardware design and software development to progress.

Stage 1: Functional Design Specification (FDS)

Our first priority is to develop an accurate function design specification (FDS) the information in this document is obtained from the user requirement specification (URS) or contract specifications and close liaison with the client’s representative.

The FDS contains all information relating to the control system including details of how each area of the plant is to operate under automatic control (Control philosophy), details of the SCADA system (i.e. screen layouts, navigation charts, alarm handling, trending and reporting) network architecture, and details of any local operator interfaces.

Stage 2: PLC I/O Schedule

When the control philosophy has been approved a PLC input/output schedule (PLC I/O) is created this document details all signals that are available from the plant for monitoring and control by the PLC.

Stage 3: Hardware Design

The PLC input/output schedule is the basis of the hardware requirements; our engineers will use this information to propose a hardware configuration.

This will take into account our client’s requirements in terms of suitability to the application, physical size constraints, unit cost, operating environment, availability of spares and ability to support the proposed system.

Stage 4: Procurement

Once all parties have agreed the hardware to be used be it a sole manufacturer or multi vendor based systems Tycon Automation Ltd run the procurement of hardware alongside the software design.

Stage 5: Software Development

After client approval of the FDS and the PLC I/O the software development can commence. Our first consideration for the development is the user friendliness of the application software i.e. it is important that any engineer can maintain and support it.

This is why we ensure that all code is documented but it also follows a logical structure so that it is process efficient and easily traceable. With this in mind we have developed standard libraries of routines and graphics that have been used for numerous processes.

In addition to this we have worked in conjunction with framework suppliers to various industries, with whom we have assisted in developing customer standard libraries for PLC’s HMI/SCADA and fieldbus monitoring.

The re-use of these libraries combined with our experience in implementing and commissioning them ensures that the most reliable solution is provide whilst also being cost efficient by cutting down on development and commissioning time.

Stage 6: Testing Documentation

On completion of software development there are threes phases of software testing:

• Internal Factory Acceptance Testing (IFAT)
• Client Factory Acceptance Testing (CFAT)
• Site Acceptance Testing (SAT)

An acceptance sheet accompanies all tests performed. Each sheet will cover all aspects of control for each section of the FDS. This provides the client with a log of tests both factory and site and also ensures that all areas of the control philosophy are tested.

Stage 7: Internal Factory Acceptance Testing (IFAT)

Tycon Automation Ltd operate an IFAT philosophy, this ensures total transparency and flawless operation at the CFAT stage. At this stage a mock factory inspection test is carried out with another member of the team scrutinising the effectiveness and efficiency of the coded system

Stage 8: Client Factory Acceptance Testing (CFAT)

We provide the facility to test software by various in house simulation packages. We have the capability to perform hardware and software testing with our own electrical personnel if we provide the MCC or any other MCC manufacturer.

Stage 9: Site Acceptance Testing (SAT)

After completion of the installation our commissioning personnel will test the process in conjunction with the site acceptance test sheet. We follow a staged test procedure, which is as follows:

• Digital PLC I/O test from plant item to PLC.
• Configure Instruments (i.e. set ranges of flow meters, level sensors etc. if required to do so).
• Analogue PLC I/O test signal from instrument to PLC.
• Ensure all network terminations are correct and network is powered and polling.
• Test all SCADA/LOI graphic displays, alarms and set-points.
• Process testing in conjunction with the SAT test sheets.
• Test all SCADA/HMI graphic displays, alarms, set-points, trends and reports.
• Client or representative is invited to witness any or all of the process tests.
• After satisfactory completion of all process tests commissioning completion certificate is signed by commissioning personnel and client or representative.
• Commissioning complete.

Stage 10: System Training

As part of our ongoing commitment to our clients we place operator and maintenance training for a newly commissioned project high on our list of priorities. We understand that successful hand over is essential part of a project. This is why we like to involve our client’s operation personnel in the early stages of the project by means of proposed operating and maintenance procedures and allowing their suggestions to be noted and included where applicable. This means at the time of training all concerned have an understanding of the systems operation. System training is present to small groups by the commissioning personnel who have been on site and have all ready formed a working relationship with site operatives. Trainees are given a copy of the operating instructions that the trainer works through with them. Standard operating procedures are put into practice this gives all trainees hands on experience of the system while the trainer is present after which a Q & A session is held.

Below are just some of the systems that we have had development experience:

Tycon Automation currently employs two Mitsubishi Certified Engineers.