The Challenge
Ampac Fine Chemicals required an integrated control and reporting platform for a regulated manufacturing process, combining hardware fabrication with software integration under strict lifecycle documentation requirements.
- Need for integrated control, monitoring, and reporting system for manufacturing operations
- Requirement to combine electrical and pneumatic control panels with PLC and HMI systems
- Ensure data collection, reporting, and historian capabilities
- Meet validation and lifecycle documentation requirements for regulated environments
Why These Projects Are More Complex Than They Appear
Delivering a UL-certified, validated control system for a regulated process required coordinating panel fabrication, controls programming, and full lifecycle documentation as one initiative.
Control Panel Fabrication
Fabricate UL 508A certified electrical and pneumatic control panels, including drawings.
PLC Programming
Develop the PLC control program using Rockwell Studio 5000.
HMI Development
Implement the operator interface using AVEVA Edge.
Historian & Reporting
Configure historian and automated reporting through AVEVA Application Server.
System Integration & FAT
Conduct system integration and Factory Acceptance Testing before deployment.
Lifecycle & Validation
Create URS, Risk Assessment, Validation Plan, and Traceability Matrix, and support IQ/OQ/PQ execution.
Technical Approach
The project combined panel fabrication, controls programming, and full lifecycle validation documentation to support a regulated startup.
- Fabricated electrical and pneumatic control panels
- Developed PLC program using Rockwell Studio 5000
- Implemented HMI interface using AVEVA Edge
- Configured historian and automated reporting using AVEVA Application Server
- Conducted system integration and Factory Acceptance Testing (FAT)
- Developed electrical and pneumatic panel drawings
- Created lifecycle and validation documentation including URS, Risk Assessment, Validation Plan, and Traceability Matrix
- Supported IQ/OQ/PQ execution and system startup
Project Execution
The project followed a structured path from initial assessment through commissioning and validation.
- STEP 01
Assessment
- STEP 02
System Design
- STEP 03
Panel Design
- STEP 04
PLC Migration
- STEP 05
FAT Testing
- STEP 06
Validation
Key Takeaway
A regulated manufacturing system is only as reliable as its lifecycle documentation—pairing panel fabrication and controls programming with URS-to-PQ traceability from day one avoids costly rework at startup.