How a Control System Project Runs at TDL
These are the steps of a TDL control system project, from the first site survey to support after hand-over. Each step links to projects where it was part of TDL's scope; which steps a project needs depends on that scope.
Step by step
1 – Site survey
The existing system, programs, documents and site access are checked before the proposal. The site survey checklist lists what to prepare.
2 – Backup and audit
A backup of the machines before any change, and an audit of the existing control systems and networks.
3 – Design
Functional design specification (FDS), electrical and panel design, power load calculation, network design and a method statement for the site work.
4 – Supply
Controllers, I/O, drives, HMIs and panel components supplied with the system.
5 – Panel fabrication
Control panel fabrication, including a flameproof and dust-protected local control panel for Zone 1/2 and Zone 21/22.
6 – Programming
PLC, HMI and SCADA programming or migration, tested before the plant stops.
7 – Factory acceptance test (FAT)
The system is tested with the client before shipment, following a written FAT procedure, and the results are recorded in a FAT report.
8 – Installation and start-up
Installation at site, often inside a planned line shutdown, then start-up.
9 – Site testing and commissioning
Signal checks from the field to the control room, site testing and commissioning.
10 – Training and hand-over
Operator training and the hand-over documents: I/O list, cause and effect matrix where there is a safety system, FAT and SAT procedures and reports, as-built drawings, PLC, HMI and SCADA program backups, and operation and maintenance (O&M) documents.
11 – Support after hand-over
Technical support after hand-over, and yearly maintenance with scheduled preventive maintenance.
Related services
PLC & Control System Migration
Allen-Bradley
PLC-5 , SLC 500 and MicroLogix, GE Fanuc, Siemens S5 and HIMA systems upgraded to ControlLogix and CompactLogix; ControlNet and DeviceNet to EtherNet/IP; older HMI/SCADA (RSView32, Citect, PanelView) to FactoryTalk View and PanelView Plus 7. Drive upgrades: DC drives to PowerFlex DC, legacy servo drives to Kinetix. Site survey, code conversion, FAT/SAT and planned cut-over, onshore and on offshore platforms.Control Panel Engineering
Control and marshalling panels: design, schematics, fabrication, wiring and factory acceptance testing before shipment. Ex-rated enclosures for hazardous areas.
Breakdown Support & Lifecycle Services
Line down? TDL troubleshoots on site or remotely, fixes programs and supplies replacement Allen-Bradley parts to get production running again. Also commissioning, preventive maintenance, PLC backup and version control (FactoryTalk AssetCentre), vibration monitoring and training on Rockwell Automation and AVEVA software.
Frequently Asked Questions
Is the program tested before the plant stops?
Yes, where the project allows it. At Crown Da Nang the body maker program was tested before the shutdown, and the system was installed and started up during the line 1 shutdown.
Does the client take part in the FAT?
In the project references the FAT is done with the client before shipment, for example for the hazardous-area heater panel at Phu My Gas Distribution Station.
What is handed over at the end?
The hand-over documents: the FDS, I/O list, cause and effect matrix where there is a safety system, FAT and SAT procedures and reports, as-built drawings, PLC, HMI and SCADA program backups and O&M documents, with operator training where it is in scope and technical support after hand-over.
Starting a control system project?
Speak directly with our engineers. Send your RFQ, scope of work or drawings: the engineers who program and commission the systems read them and reply, from the first review of the existing system to the proposed solution.
Email sales@tdl-ia.com.vn Request a site survey Hotline · Urgent breakdown support