Management of Automation Projects
The life cycle of a control project is followed from inception
through to replacement with emphasis on the management aspects
of each stage. The various standards and statutory requirements
are identified and introduced. Topics covered include evaluation,
cost & benefit analysis, design, development, testing, acceptance,
installation, commissioning, system management, routine maintenance,
modifications and improvements: contracts; reimbursable & lump
sum, IChemE Red & Green Books, terms & conditions, partnering:
project management; requirements specification, tendering & supplier
selection, functional specifications, planning, resource allocation:
quality & TQM; ISO9000, quality procedures, the cost of quality,
quality improvement teams: management of safety; legislative framework,
HSE, requirements for hazardous plants, safety auditing: management
of safety related systems; PES guidelines and IEC61508 requirements,
certification & training, verification & testing, security:
management of the environment; EU directives, compliance with Environmental
Agency and Local Authorities, responsibilities under EPA, environmental
auditing, integrated pollution control, monitoring of emissions,
A series of case studies are provided for discussion and structured
||CME 8388 (formerly ACS 688)
First degree or equivalent in an appropriate discipline
||By report on assignment
By 1 x 2 hour examination
To provide an understanding of the issues involved in the management of control and automation projects, from specification right through to decommissioning, whether from a user’s, contractor’s or supplier’s perspective, and to become familiar with good practice.
To appreciate how to do a costs and benefits analysis for an automation project, and how best to present it to management.
To understand a range of techniques relevant to the management of automation projects, and to appreciate how and when to apply them.
To be aware of the life cycle issues relating to control systems and application software.
To develop an ability to make judgements about, and to take responsibility for, technical issues in an industrial context.
To become aware of relevant standards, industry guides and legal requirements.
This is a stand-alone module and has no Prerequisites as such.
Note that there is, by intent, some overlap with the content of the Batch Processing and Automation (CME 8372) and Control Systems Technology (CME 8378) modules.
This module is of one week's full-time intensive study consisting of a series of lectures and case studies. It is followed by an assignment to be carried out in the delegate's own time.
Module delivery is structured around the various phases of the life cycle of a control and automation project. A variety of case studies are used to illustrate the aspects of the management of automation projects. These provide a vehicle for group discussion about issues such as project evaluation, presenting the case, contracts, quality, safety, viability, etc. Reference is made to standards as appropriate but these are not covered in detail per-se.
The assignment is typically based upon a critical appraisal of the contractual basis of a major contract, lumpsum or reinbursible, with which they have been involved.
GAMP: Guide for Validation of Automated Systems in Pharmaceutical Manufacture, Version 4, International Society for Pharmaceutical Engineering (ISPE), Florida, 2002.
IChemE (Red Book): Model Form of Conditions of Contract for Process Plant, Lump Sum Contracts, 4th Edition, Rugby, 2001.
Love J, Process Automation Handbook, Springer Verlag, 2007.
Wright D, An Engineer’s Guide to the Model Forms of Conditions of Contract for Process Plant, 4th Edition, IChemE, Rugby, 2004.
Project life cycle overview: Costs and benefits analysis. Conceptual design. Requirements specification. Tendering. Vendor selection. Functional specification. Software design. System building. Integration and testing. Factory acceptance. Installation. Commissioning. Site acceptance. System management. Maintenance and support. Decommissioning.
Evaluation: Costs and benefits analysis. Capital cost estimating. Factorial methods. Estimation of operating costs. Sources of benefit. Estimation of benefits. Intangible benefits. Fixed and working capital. Inflation.. Cash flow diagrams. Capex versus opex. Discounted cash flow. Rate of return. Pay-back time. Sensitivity analysis.
Contracts: Model forms of conditions of contract. IChemE model conditions. Red (lumpsum), green (reimbursable) and yellow (sub contract) book contract scenarios. Detailed analysis of the Red Book: lump sum contracts and their relation to the law. Overview of reimbursable and sub-contracts. Intellectual property, copyright and patents.
Project management: Planning, organisation and control. Feasibility studies. Conceptual design. User requirements specification. Tendering and vendor selection. Functional, software and test specifications. Techniques for management of large contracts. Critical path planning. Resource allocation. Use of the IChemE guide to effective project cost control. Information: generation, storage, retrieval and transmission. Documentation. Management of installation and commissioning.
Quality and TQM. Evolution of standards. GAMP guidelines. Understanding and interpretation. Specification of quality procedures. Management structures for effective quality control. Total quality management. Identification and measurement of costs and benefits of quality. Self assessment against ‘best in class’. Quality initiatives and improvement teams.
System management: Scheduling of routine maintenance. Optimisation of maintenance. Management of documentation. Management of modifications and risk assessment. Industrial relations and employment law. Improvement mechanisms. Human factors: People as system components and operators. Ownership of systems. Abnormal situation management. Operator support systems. Training and refresher courses. Use of simulators for training.
Enterprise and entrpreneurship: Parties and people. Motivation and psychology. Decision making. Group perspectives. Spotting opportunities. Selling ideas. Championing the cause. Lobbying and influencing. Role of consultants. Competition. Procurement policy. Integration and collaboration. Scope issues. End-user, contractor and supplier relationships.