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, contingency planning.

A series of case studies are provided for discussion and structured group work.

Objectives

To understand a range of techniques relevant to the management of control projects, and to appreciate how and when to apply them.

To be aware of the issues relating to system and software management, maintenance and support.

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 and legal requirements, especially in relation to safety.

Phasing

This is a stand-alone module and has no prerequites as such.

Note that there is, by intent, some overlap with the content of modules ACS 672 (Batch Control and Application Software) and ACS 678 (Control Systems Technology).

Study Modes

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.

Coursework

A notional project is tracked through the project life cycle as a vehicle for group discussion about the issues related to project evaluation, contracts, management, quality, safety, environment, etc. Reference is made to standards as appropriate but these are not covered in detail per-se.

Assignments

Delegates are typically required to carry out a critical appraisal of either the management of a control engineering project in which they are/have been involved or the management of the control functions for a plant with which they are familiar.

Recommended Texts

Cox S & Cox T, Safety Systems and People, Butterworth Heinemann,

Safety Performance Measurement, pub by IChemE.

Guidelines for the Documentation of Computer Software for Real-Time and Interactive Systems, 2nd edition, pub by IEE, 1990

Topics include

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. Discounted cash flow. Rate of return. Pay-back time. Sensitivity analysis.

Contracts: Capital investment and exploitation. Reimbursable and lump sum contracts. Terms and conditions for home and overseas contracts. Alliancing and risk sharing contracts. Relationships between suppliers, contractors and operating companies. Purchasing policy and procurement: quality, price and delivery. Intellectual property (protection and exploitation) legislation. Copyright. Costs and benefits of patents. Research and development, including UK and European funded initiatives.

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. Construction site industrial relations.

Quality and TQM. Evolution of standards. 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’. Software Process Improvement and Capability dEtermination (SPICE). Price of non-conformance. 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.

Safety and protection systems: Evolution and interpretation of guidelines and regulations. Definitions of safety related equipment. UK offshore operators guidance. Competent bodies. Competencies of staff to work on safety related equipment. Certification and training. Verification of safety related systems. Legal requirements for testing. Security of systems to hacking, theft, tampering, etc. Firewalls. Least privilege approach to system and file access.

Management of safety: Legislative framework, enactment and enforcement. Factory Inspectorate. Compliance with Health and Safety Executive (HSE). Particular legislative requirements for major hazardous plants. Offshore safety case regulations. Responsibilities under health and safety at work act (HSAW). Safety auditing. Human frailty: personal safety and training. Organisation and control of maintenance and modifications to plant. Documentation: permits to work and safety certificates. Human error. Accident and incident reports. Learning from experience. Safety statistics. Safety committees. Safety representatives. Motivation and incentives. Emergency equipment and procedures. Fire and toxic gas drills. Measurement and control of noise and heat.

Management of the environment: Legislative framework, enactment and enforcement. Compliance with Environmental Agency and Local Authority. The changing nature of legislation. Responsibilities under Environmental Protection Act. Environment management and auditing systems (EMAS). Identification of effluent and vent streams. Implementation of integrated pollution control policies. Monitoring of emissions. Contingency planning for emergencies. Strategies for containment.

Standards etc

Low Voltage Directive.
Machinery Directive.
Electromagnetic Compliance Directive.
Products/Systems/Installations Directive.
IEE regulations.
Seveso Directive.
CIMAH regulations.
COSHH regulations, etc.
ISO 14001 and EMAS.
Design and Construction Regulations (DCR) for offshore work.
Construction, Design and Management (CDM) Regulations (1995).
BS5750 and ISO9001 quality standards.
ISO9003 (Tickit) software standard.
HSE Guidelines on the Safe use of PES.
IEC 61508 standard on reliability for safety systems.
Statutory instrument 913 (June 96) for offshore applications.
IChemE guide to capital cost estimating.
IChemE guide to economic evaluation.
IChemE green and red books for contracts.
IChemE guide to work minimisation.
INCOTERMS for overseas contracts.