Overview

The implementation work process includes four main activities:

1. Creating the implementation modules
2. Testing the automated procedures
3. Creating documentation and training materials
4. Installation and commissioning of automated procedures

Success requires that all applicable personnel receive training on procedure automation concepts, development toolkits, testing requirements, programming guidelines, and documentation requirements before implementation begins.

Creating Implementation Modules

Design documents must be formally approved by all identified stakeholders before any implementation work begins. This approval catches potential problems while they are still easy and inexpensive to fix on paper rather than in the field.

Toolkit components streamline development by incorporating proven engineering practices, reducing custom application code, and delivering: reduced costs through faster development, greater consistency, improved quality, better documentation, and enhanced traceability.

Implementation scope covers: control algorithm code, engineer interface tools, operator interface (HMI), version control across all software components, alarm management, data historians, and communication drivers. Testing occurs at two levels: individual automated procedure testing and integrated system testing.

Test Environment Implementation

The test environment can be developed in parallel with control system module programming to reduce overall timeline. Test environment types based on available resources:

• No simulation: Actual hardware with loop-back testing
• Low fidelity simulation: Simplified models capturing basic process behavior
• High fidelity simulation: Detailed mathematical models closely mirroring real-world behavior including nonlinearities, delays, and disturbances

When simulation is used, a Model Acceptance Test (MAT) verifies that the simulation accurately represents real-world process behavior before it is used for control strategy testing.

Documentation and Training

Documentation and training materials must be produced as part of the implementation work process — not as an afterthought. They draw from three sources: procedure specifications, design documents, and the actual implemented system as built.

Training relevant operations personnel before acceptance testing allows them to participate more effectively in FAT and commissioning activities and reduces the learning curve during critical project phases.

Acceptance Test Execution

Three formal testing phases per ANSI/ISA-62381-2011:

• FAT (Factory Acceptance Test) — testing at vendor facility before shipment; includes exception handling validation under both normal and upset conditions
• SAT (Site Acceptance Test) — validates communication with plant BPCS and integration with peripherals at the actual plant site
• SIT (Site Integration Test) — validates integration with the overall control program; parts can be done in parallel with FAT and SAT

Commissioning

Commissioning is performed or overseen by the operating organization (end user) and includes verification that automated procedures work correctly according to project requirements and specifications. Project team members — control engineers, programmers, system integrators — must be available during commissioning to provide technical support and troubleshoot issues.

Procedure Audit

A procedure audit following project completion evaluates whether the original business case has been met. It examines management systems and work processes, compares automation work processes against the procedure automation philosophy, and generates actionable feedback to the Procedure Automation Strategy work process for continuous improvement.