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
 https://intechprocessautomation-my.sharepoint.com/personal/faizan_aadil_intechww_com/Documents/Stu
dy%20Work/Panel%20Design%20Training/Lifua/CG-211224-SAR.pdf
 Bill Of Material

 https://intechprocessautomation-my.sharepoint.com/personal/faizan_aadil_intechww_com/Documents/Study%20Work
/Panel%20Design%20Training/Lifua/BOM/LFA-STS-ICS-LST-IPA-00002-00.xlsx
 Electrical Load Calculation

 https://intechprocessautomation-my.sharepoint.com/personal/faizan_aadil_intechww_com/Documents/Study%20Work
/Panel%20Design%20Training/Lifua/ELC/LFA-STS-ICS-CAL-IPA-00002-00.xlsx
 https://intechprocessautomation-my.sharepoint.com/personal/faizan_aadil_intechww_com/Documents/Study%20Work
/Panel%20Design%20Training/Lifua/ELC/LFA-STS-ICS-CAL-IPA-00001-00.xlsx

https://intechprocessautomation-my.sharepoint.com/personal/faizan_aadil_intechww_com/Documents/Study%20Work/Pa
nel%20Design%20Training/Lifua/ELC
 D:\CV\20220419-Cover Letter.docx
 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: Faizan.Aadil@intechww.com
cc: Bilal.Fraz@intechww.com
Kashif.Ijaz@intechww.com

 All commercial emails to be addressed to:

To: Kashif.Ijaz@intechww.com
cc: Bilal.Fraz@intechww.com
sarfraz.ajmal@intechww.com

 All schedule/progress related emails to be addressed to:

To: Bilal.Fraz@intechww.com
cc: Kashif.Ijaz@intechww.com
Faizan.Aadil@intechww.com
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@intechww.com
Q&A Session