Solutions

ICA Engineering delivers a team of technical specialists that is ready to provide expert level PLC/HMI programming, panel design, systems integration, project management services, customized software development, and site-system gap analysis.

We pride ourselves on offering solutions that result in reduction of errors and improved product quality. Our team has successfully managed capital projects in areas such as food and beverage manufacturing, wastewater filtering, waste recycling, pharmaceutical, biotechnology, packaging, materials handling and power plant solutions throughout the Mid-Atlantic region and beyond.

Our services include:

Batch Processing

Development and improvement of batch distillation & reaction procedures. Development of S88-compliant models for control and automation of batch processes.

Commissioning

On-site commissioning of PLC, SCADA and custom client applications such as Allen-Bradley and GE logic, Wonderware InTouch and Archestra, Intellution FIX32/iFix, GE Proficy HMI/Historian, and Visual Basic. Troubleshooting the operation of PLC, and SCADA applications. Performance of Site Acceptance Tests and commissioning.

Electrical Design

Design and specification of AC and DC circuits for control panels. Design of electrical drawings.

Support & Troubleshooting

On-site investigation and diagnoses of process, controller, SCADA, field instrumentation and I/O to isolate and eliminate system and process defects. Troubleshooting the operation of PLC, and SCADA applications. Legacy systems serviced. Service contracts available.

Validation

Development of client Computer System Validation (CSV) documents using customer’s System Development Life-Cycle (SDLC) methodology. On-site validation/testing of hardware and applications. Execution of system validation protocols.

Requirements Analysis

Collaboration with clients to establish functional and detailed design requirements for electrical hardware design, PLC and SCADA control systems. Assessment and evaluation of control and automation systems against regulatory requirements (i.e., FDA) to development of appropriate remediation plans.

Process Design

Development of process flow diagrams (PFD) and piping and instrumentation (P&ID) drawings.

Instrumentation

Selection and sizing of instrumentation and signal conditioning, including temperature, pressure, flow, etc. Creation of process instrumentation specifications, including temperature, pressure, pH, flow, and weight. Instrument loop checks.

Manuals & Training

Development of operations & maintenance training programs, and conducting operator and maintenance training classes in the use and service of PLC & SCADA systems.

Documentation & Drawings

System development life cycle documentation including: User/Functional requirement specifications (UFRS), Functional/Detailed Design Specifications (FDS/DDS), operations manuals, User SOPs, training manuals and system validation documentation (i.e., requirements traceability matrix, test protocols – IQ/OQ, validation summary report). Development of power, motor, PLC I/O drawings, and P&ID drawings with AutoCAD.

Networking

Design and configuration of Industrial Ethernet, ControlNet, DeviceNet, Data Highway plus (DH+), Profibus and MODBUS networks.

Image credit: (Piqsels @ Creative Commons)