What is the difference between FAT and SAT?
FAT tests the control logic and screens in the workshop against the functional specification. SAT repeats the agreed functions on site with the real process and field devices.
Engineering
Industrial & Building Automation (PLC, SCADA)
Control philosophy, PLC and SCADA engineering, instrumentation and drives, with controllers, panels and field devices supplied and commissioned by Powersense.
01Overview
Supply and engineering from one team
Powersense supplies the controllers, HMI and SCADA software, drives, instruments and panels, and engineers the system around them: from the I/O list and control philosophy to programming, factory acceptance testing and commissioning on site.
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02Scope and process
Engineering scope and deliverables
- 01
Requirements and control philosophy
The process description, operating modes, interlocks and alarm philosophy are agreed and written into a functional design specification.
DeliverableFunctional design specification, alarm list - 02
I/O list and system architecture
Signals, field buses and network topology are defined, and controllers are sized for I/O count, scan time and redundancy requirements.
DeliverableI/O list, system architecture drawing - 03
Instrumentation and drive selection
Sensors, actuators, drives and soft starters are selected for the process range, accuracy and motor duty. Machine electrical equipment follows EN 60204-1.
DeliverableInstrument schedule, drive and motor datasheets - 04
Panel design and build
Control panels are drawn, built and wired as verified assemblies to IEC 61439, with hazardous-area equipment selected under IEC 60079-14 where required.
DeliverableSchematics, panel layouts, routine test records - 05
PLC and SCADA programming
Control logic is written in the IEC 61131-3 languages. SCADA screens, trends, alarms and reports are built and tested in the workshop (FAT).
DeliverableSource code, SCADA project, FAT report - 06
Commissioning and cybersecurity
Site acceptance tests (SAT), operator training and handover are completed. Network segmentation and access rules follow the principles of IEC 62443.
DeliverableSAT report, as-built software, operator manual
03Standards
International standards applied
These standards form the technical basis for design and equipment selection. The exact set is confirmed for each project against the national regulations in force.
- IEC 61131-3Programmable controllers: programming languages (ladder, function block, structured text, sequential function chart).
- IEC 62443Security for industrial automation and control systems: network segmentation and access control.
- EN 60204-1Safety of machinery: electrical equipment of machines.
- IEC 61439-1Low-voltage switchgear and controlgear assemblies: general rules and design verification.
- ISA-5.1Instrumentation symbols and identification for P&IDs and loop diagrams.
- IEC 60079-14Explosive atmospheres: design, selection and erection of electrical installations.
04Products
Products we supply
- PLCs and distributed controllers
- HMI panels and SCADA software
- Field instruments and sensors
- AC drives and soft starters
- Network analysers and energy meters
- Automation panels built and wired in-house
05Project types
Typical project types
- Wastewater and water treatment
- Pumping stations
- Manufacturing and process lines
- Energy monitoring and distribution
- Building technical services
- Machines with explosion-protected motors
06Technical notes
Technical notes and FAQ
Can energy and process data be used for analysis?
Yes. Where the devices support them, meters and analysers report to the SCADA over open protocols such as Modbus or OPC UA, and the data can be exported for energy management under ISO 50001.
07Keep exploring
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