Panel Design Training
BY: Muhammad Faizan Aadil
Sr. Design & Application Engineer
M.S. Control System
Key Points
System Architecture
Bill of Material
Electrical Load Calculation
Heat Load Calculation
Panel Design
Q&A
System Architecture
Control System selection
IO count
Network requirement
Fiber and Ethernet network
Third-party interface
[Link]
dy%20Work/Panel%20Design%20Training/Lifua/[Link]
Bill Of Material
[Link]
/Panel%20Design%20Training/Lifua/BOM/[Link]
Electrical Load Calculation
[Link]
/Panel%20Design%20Training/Lifua/ELC/[Link]
[Link]
/Panel%20Design%20Training/Lifua/ELC/[Link]
[Link]
nel%20Design%20Training/Lifua/ELC
D:\CV\20220419-Cover [Link]
Scope of Work – Gateway PLC
New controller and EtherNet/IP communication module (for replacing the existing ControlNet module).
Existing chassis, power supply and the DHRIO Module will be used.
Upgrade of Gateway PLC requires the shutdown.
Scope of Work – SCADA Network
Aveva System Platform 2020 will be used for HMI.
Supervisory layer shall contain;
Application servers X 2
OMI Client X 8 (Number of OMI Clients shall be confirmed by CABGOC)
Historian X 1
PLC EWS X 1
Test server X 1
HMI EWS X 1
Operator Workstations X 3
AMS for SIS X 1 (Hold till further confirmation from CABGOC)
Engineering workstation and APP Servers will be server grade machine. Operator workstations, server grade confirmation
is pending from CABGOC.
GS Mike PLC and HMI Applications and objects shall be used for upgrade. GSM Objects will be verified before using for EK.
Scope of Work – Factory Acceptance Test (FAT)
3 weeks FAT will be conducted in INTECH Dubai Office.
FAT shall include Hardware and software testing of both the packages.
If customer cannot attend the FAT, internal testing records will be shared and considered for
acceptance of equipment
After FAT, shipment will be packed and shipped to Malongo.
Scope of Work – Site Services
Site services will be on day rate basis
Total 3 teams during shutdown in single shift. 2 for PCS and 1 for SIS.
2 teams for SIS hot cutover. This will be carried out in 2 shifts per day.
One Team comprises of one Engineer and One Technician.
Scope of Work – Site Survey
Six Days Site survey is planed after Kick Off
Space verification for proposed panels and JB’s
IOW verification and mark ups
Distance estimation for cabling between panels in CCR
Cable routing from existing to new panels
Scope of Work – Assumption & Clarification
Redundant 24VDC supply for all panels will be provided by CABGOC
Multimode FO cable considered for communication
Due to the prevailing chip shortage, certain industrial control components are also facing longer lead times,
which are beyond INTECH's control and may impact final delivery schedules.
Scope of Work – Exclusions
All civil work
Installation and Erection activities
Cable trays installation
Any Cable laying Outside control panel
Supply & Installation of FO and Ethernet cables outside cabinets
Grounding system engineering outside INTECH supplied cabinets
All type of Construction work
Control room engineering
Panel base construction
Shades for panel
Dismantling of existing panels
Hardware Scope of Supply
Control Logix Hardware for PCS
AADvance Hardware for SIS
Integrated Cabinet and JBs for SIS
Migration Kit for PCS upgrade
Network Cabinet with equipment
Workstation and Servers with monitors and KVM
FO patch panels and ethernet switches
Software Scope of Supply
Studio 5000 for Control Logix Designing
AADvance SIS Workstation 1.1
AVEVA 2020 System Platform with OMI Clients (to be free issued by CABGOC)
E&H AMS for SIS instruments
List of Deliverables
Management Documents Technical Documents
1 CG-211224-MDR-001 Master Document Register 13 CG-211224-SAR System Architecture
14 CG-211224-BOM Bill Of Materials
2 CG-211224-SCH-001 Project Schedule
15 CG-211224-PCS-IOL IO List - PCS
3 CG-211224-PRT-001 Project Progress Report 16 CG-211224-SIS-IOL IO List - SIS
17 CG-211224-PCS-ELC Electrical Load Calculation - PCS
4 CG-211224-PQL-XXX Project Queries List
18 CG-211224-SIS-ELC Electrical Load Calculation - SIS
5 CG-211224-XMT-XXX Project Transmittal 19 CG-211224-SIS-HLC Heat Load Calculation - SIS
6 CG-211224-FPR-001 FAT Procedure 20 CG-21224-PCS-FDS Functional Design Specification - PCS
21 CG-21224-SIS-FDS Functional Design Specification - SIS
7 CG-211224-SPR-001 SAT Procedure
22 CG-211224-PCS-GAD* General Arrangement Drawing - PCS
8 CG-211224-CMP Commissioning Plan 23 CG-211224-SIS-GAD-XXX General Arrangement Drawing - SIS
9 CG-211224-SIS-HCP Hot Cutover Plan - SIS 24 CG-211224-PCS-PDB Power Distribution Drawing - PCS
25 CG-211224-SIS-PDB-XXX Power Distribution Drawing - SIS
10 CG-211224-OPR Operator Manual
26 CG-211224-PCS-IOW* IO Wiring Drawing - PCS
11 CG-211224-SIS-LTP Hot Cutover Loop Transfer Plan 27 CG-211224-SIS-IOW-XXX IO Wiring Drawing - SIS
28 CG-211224-HML HMI List of Screens
12 CG-211224-PQP Project Quality Plan 29 CG-211224-ILD* Instrument Loop Drawings
* Existing Drawings will be updated
INTECH document format and revision philosophy will be followed.
One week review cycle is considered.
Project Interface & Communication – Project Organogram
Director Engineering QHSE Manager Director Project Controls
(Waseem Butt) (Sidra Haroon) (Javed Aslam)
Procurement
Portfolio Manager Factory Manager Manager
(Kashif Ijaz) (Rehan Afghan) (Assad Ahmed)
CABGOC
Project Manager
Project Execution Factory QHSE Logistics
Manager Engineer Supervisor
(Bilal Fraz) (Jeena Kokkodan) (Sohail Raza)
Project Lead
Project Team
Engineer
Interface
(Faizan Aadil)
HMI Application
CAD Engineer Commissioning Material Handler
Development
Engineers
Team
PLC Application Procurement
Development Panel Integration Engineer
Team
Software Design & Hardware Design Procurement / Material
Implementation & Panel Commissioning Handling
Integration
Project Interface & Communication – Project Key Contacts
Preferred mode of communication is Email.
All technical emails to be addressed to:
To: [Link]@[Link]
cc: [Link]@[Link]
[Link]@[Link]
All commercial emails to be addressed to:
To: [Link]@[Link]
cc: [Link]@[Link]
[Link]@[Link]
All schedule/progress related emails to be addressed to:
To: [Link]@[Link]
cc: [Link]@[Link]
[Link]@[Link]
Project Interface & Communication – Communication Plan
Sr. Communication Protocol Frequency
1 Project Schedule Upon Schedule revision
2 Project Progress Report Fort-Nightly
3 Project Query List As required
4 Technical Clarification Meeting Weekly till design is approved
Project Execution – Project Execution Flow
Project Cycle Start
Handover from Sales DDP Delivery of Hardware
Study of Specifications & Kick-
off Meeting Pre-Shut Down Activities
Receiving of Required Engineering
Data and Specs Shut Down Activities
Site Survey (6 days) Hot Cutover SIS
Hand Over
Hardware Design Software Design
As-Built
HW Design approval from SW Design approval from
customer customer
Procurement Software Implementation
JB/Panel Integration
Staging and
Internal Testing
FAT
Project Schedule
Payment Milestones
Sr. Milestones Payment
1 With Purchase Order 30%
2 PO Placement to Major Vendors 20%
3 Ready for FAT in UAE 20%
4 Ready for Site Mobilization 20%
5 After completion of site work 10%
Design Inputs from CABGOC
Existing GA and IOW (Native files)
Cause and Effect
P&ID
Sequence Document (If Any)
PCS & SIS Loop Drawings (Native)
Customer Feedback Process
1. INTECH has established independent QA department which engages customer to obtain
their feedback to derive improvement in projects and processes.
2. Feedback is obtained by QA upon completion of:
1. Design
2. Factory Acceptance Test
3. Training (if applicable)
4. Site services (if applicable)
3. You can share your general feedbacks, complaints or appreciation at
1. feedback@[Link]
Q&A Session
