It's been over 16 years (as of 2024) since I was first involved in a real automation project. I remember it was at an oil refinery, where they were in the process of upgrading and modernizing the automation of two process furnaces.
Participating and seeing how this project was developed and what documents or steps were being taken to make it a reality was "pure happiness" for me; it was the first time I saw "real" engineering in industrial automation.
To date, I've probably reviewed around 100 projects (of all sizes, from many suppliers, engineering firms, and/or automation manufacturers) and designed a few dozen myself. After all that, the learning has been exponential.
In this article, I want to show you the main documents that are typically seen (or are very important) when you embark on proposing the basic engineering design for a project. There is a lot of variety, but these are my recommendations.
Basic engineering in industrial automation projects is a crucial step that lays the foundation for project success. I will explain the essential and recommended documents for conducting efficient and effective basic engineering, providing a clear roadmap for professionals who need to perform design work.
I will not go into detail about each document; the idea is to list them and give a brief definition of each.
Let's begin!
1. Customer Requirement Specifications (Detailed Scope)
The first step in any automation project is to clearly understand what the client needs (whether internal or external). This document should include at least:
- Project objectives: What does the client hope to achieve with automation?
- RestrictionsAny limitations in terms of budget, time, or resources.
- Success criteriaHow will the success of the project be measured?
- Specific needsDetails on functional and non-functional requirements.
2. Block Diagram and/or Control Architecture
These diagrams provide an overview of how the control system will be structured or how this system will be modified as an architecture:
- Block Diagram: It shows the main components and their interactions.
- Control Architecture: Detail the structure of the control system, including controllers, networks, and other key elements. This should be done at a high and/or conceptual level.
3. PFD Diagrams (Process Flow Diagram)
These diagrams are essential for understanding and documenting the processes and equipment involved. Process Flow Diagrams are graphical representations that show the overall flow of an industrial process. These diagrams are used to visualize and document the main processes within a plant or system, highlighting the relationships between the different equipment and stages of the process.
4. P&ID Diagrams (Piping and Instrumentation Diagram)
It is a detailed document that shows the technical design of an industrial process system, including piping, equipment, and control instruments. This diagram is fundamental for the design, operation, and maintenance of complex industrial systems.
It facilitates communication between engineers, operators, maintenance technicians, and other professionals involved, ensuring that everyone understands the design and operation of the system.
5. List of Instruments and I/O (Input/Output) List
Documenting the instruments and input/output signals of your PLC/DCS is fundamental, although at this conceptual stage it is a first approximation to project requirements and costs (later, with the detailed engineering, there will surely be points to refine).
- List of Instruments: It includes all the instruments used in the project, with specifications and locations.
- I/O Listing: Detailed recording of all input and output signals, essential for configuring the PLC/DCS and other controllers.
6. General Technical Standards and SDS (Functional Design Specification)
These are the standards and specifications that will guide the design and implementation. These documents may relate to specifications for control systems, instrumentation, networks and communications, information systems, etc.
- General Technical Standards: General technical standards and guidelines to be followed for the project at a technical level.
- FDS (Functional Design Specification)It details the functional requirements of the system, covering both hardware and software. This again applies to any PLC/DCS/SCADA system, etc.
7. Philosophy or Narrative of Control
A control narrative or philosophy in automation is a detailed document that describes how the automatic control system should "behave" in an industrial process or automation project. This document is essential to ensure that all aspects of the control system are well-defined, clear, and consistent, thus facilitating implementation, configuration in PLC/DCS/SCADA, etc., commissioning, and start-up.
Bonus: 8. Integration Plan with Existing Equipment
A critical aspect of automation projects is ensuring that new systems integrate seamlessly with existing equipment; this document should include points such as:
- Compatibility: Compatibility assessment and integration strategies.
- Interoperability: Ensure that the new systems work seamlessly with the existing equipment.
- Minimizing Interruptions: Planning to minimize disruptions to operations during integration.
Finally, I provide you with some additional documents that are generally not technical and that can feed into your basic engineering as needed:
Project Schedule
A preliminary plan detailing the project phases and key milestones. This timeline should be realistic and consider all stages of the project, from planning to implementation.
Risk Analysis (Risk Assessment)
Identification and initial assessment of potential risks associated with the project:
- Technical risks: Potential problems with technologies or integrations.
- Project risks: Deadlines, budgets and resources.
- Mitigation strategies: Plans to reduce or manage these risks.
Networking and Communications Specifications
Initial details regarding the network configuration and communication protocols required for the project.
Conclusion
Conducting thorough and well-documented basic engineering is essential for the success of any industrial automation project. These documents provide a solid foundation that facilitates project planning, design, and execution, ensuring that customer expectations are met and risks are minimized.
I know that some documents might be missing, or perhaps many more are needed; it will depend on the scope of the project, the level of detail you want in your design, and perhaps also the time and money you're willing to invest. But what I can assure you is that if you at least include these documents in your basic engineering, you'll look like a true professional who knows what they're doing, and above all, you'll be ensuring a proper design for your system from the very beginning.
I encourage you to add to the article with your experience by writing in the comments. You probably have other "documents" that you'd like to include on this list, or other perspectives to share. I'm looking forward to reading your comments!“
Finally, if you'd like me to continue writing about each document, providing details and going deeper, let me know in the comments.
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