Step 3: TEST
CONSTRUCTION & INSTALLATION SUPPORT
Delivery and installation of control systems cost-effectively.
During the construction and installation phase of project implementation, Fourstep can provide a turnkey control system built on the following components with a standard 1-year performance warranty:
Develop Control System Test Plan
To reduce rework costs and the risk that our client’s control system software does not work properly, our procedures require a deterministic method for software development and testing. These procedures are based on GAMP standards required in FDA-regulated industries.
Functional Specifications and Detailed Hardware and Software Design Specifications developed during Control System Engineering define exactly how each new Control System must work and will be formally tested. These Specifications are used as a basis for Software development.
Fourstep can provide the following software with a standard 1-year performance warranty:
- Batch Reports
- Historian Configurations
- Custom VB, C++ Programs
- PLC/SCADA Configurations
- SQL Server Database and Reports
- DCS Configurations
Work In Progress Testing
To maximize the safety and the useful lifespan of a manufacturing Control System, it is essential that Control Panels are designed and built properly. Valuable hardware components must not be exposed to hazardous currents, heat, vibration, moisture, dust, or flammable gas.
Fourstep designs control panels in compliance with relevant codes. Fourstep utilizes an in-house UL Listed panel shop for panel assembly and only works with UL Listed panel shops when outside panel construction is required. Our panel shop auditing and panel quality control process provide true 3rd party quality control while minimizing cost.
Fourstep can provide the following types of UL Listed control panels with a standard 1-year performance warranty:
- Class 1, Division 2 rated for flammable or explosive environments
- Remote Instrument Enclosures
- VFD and MCC Enclosures
- Field Termination Enclosures
- Remote IO Enclosures
- PLC/DCS Enclosures
Factory Acceptance Testing
Instrumentation is the “eyes and ears” of a Control System. Improperly specified instrumentation can cause unsafe and unreliable manufacturing performance.
Fourstep professionals have extensive experience in the industries we serve and know what devices you need for optimal performance. We are not obligated to specify any particular manufacturer’s instrument, so our clients are sure to have the optimal instrument for the job.
To prevent costly project delays and rework, we utilize the following procurement steps:
- Purchase Instrumentation Utilizing Customer Approved Datasheets
- Receive Instrument and Verify Part Numbers Match Datasheets
- Bench Check Instrument to Verify Proper Function
- Transmit Instrumentation to Client Site for Mechanical Installation Where Applicable
- Transmit Instrumentation to Panel Fabrication Site Where Applicable
Fourstep can provide the following types of instrumentation with a standard 1-year performance warranty where applicable:
- Analytical Measurement
- Pressure Measurement
- Temperature Measurement
- Flow Measurement
- Weight Measurement
- Modulating Control Valves
- On/Off Control Valves
- Pressure Safety Valves
- Proximity Switches
- Variable Frequency Drives (VFDs)
- Servo Motors and Controllers
Site Acceptance Testing
Site Acceptance Testing (SAT) is performed at the client site after installation is complete. We encourage our clients to witness and participate in this test phase as much as possible because it improves results and provides client training.
This is an excellent opportunity to get any final client requests included before the final installation. A thorough SAT is essential because modifications are considerably more difficult after installation is complete.
Startup
Startup occurs after SAT is completed and Control System functionality is proven. During startup, Fourstep programmers and Control System Engineers work with the client to run the equipment for the first time.
Control System loop tuning, recipe development, and client training are all objectives of Startup. Fourstep programmers and Control System Engineers are uniquely qualified to hand manufacturing systems over to Client production. This is because we understand how mechanical, electrical, instrumentation and software work together with your process to manufacture your product.
Validation
Validation is a legal requirement for our Life Science customers. It is also a requirement for Safety Instrumented Systems (SIS).
Our goal for this phase of project implementation is to streamline the Validation process by executing the SAT as a “dry-run” of Validation Installation Qualification (IQ) and Operational Qualification (OQ).
To achieve this goal, we work to get client Validation and Engineering approval of our Test Plan, FAT, and SAT documentation. This way our FAT and SAT test forms can evolve into IOQ test forms needed for Validation.