From concept to commissioning Inside a Typical Control System Journey
Every control system project follows a carefully defined path — from understanding user requirements to final on-site testing. Here’s how inControl turns those steps into reliable, real-world solutions for our customers.
Every project we take on starts with understanding the customer’s process and requirements. From the first sketches to the final sign-off, each stage of the control system design process plays a vital role in ensuring the final solution performs exactly as intended.
In the video, you can see one of our latest control panels — built by our local panel build partner, the only stage of the process we don’t complete in-house.
Step 1: URS → FDS
We begin by reviewing the User Requirement Specification (URS) and translating it into a detailed Functional Design Specification (FDS).
This step defines exactly what the system needs to do — and getting it right is critical. Once the FDS is approved, we have a shared blueprint for delivery.
Step 2: Panel Build + Software Development
While our panel-building partner constructs the hardware, our in-house engineers develop the PLC software and design the HMI & SCADA displays that enables the process to be operated and visualised as intended.
Depending on the project scale, this can take weeks or even months to complete, with both streams progressing in parallel to save time.
Step 3: FAT → SAT
When the build and programming are complete, we conduct a full Factory Acceptance Test (FAT) at our facilities — verifying every component, screen, and line of code.
Once the customer is satisfied, the system is delivered to site for commissioning and SAT (Site Acceptance Test) — the final milestone before handover.
Wrap-Around Additional Integration Services
From helping the customer to define and understand their requirements, to translating that into a finished efficient automated process. Our engineering team works from start to finish of every project. In addition to the key steps above, we also perform; electrical design, network architecture, cyber security, site surveys, site installation, training of your staff and providing an agreed level of support contract if required.
“What makes any project successful is a careful attention to the specification from both ourselves and the customer, ignore this part — and it will come back to bite you at the end of the project”
Ian Clarke, Sales & Marketing Director at inControl Systems.
Project Spotlight: Biogas Tanker Filling System
The control panel shown is part of a system designed to manage the safe and efficient filling of biogas tankers. The setup includes an associated HMI panel for operator access and process control.
With the software complete and panels built, we’re now ready to welcome the customer to our site for Factory Acceptance Testing.
💡 Key Takeaway
From URS to FAT, each stage of the control system design process ensures the customer’s needs are understood, implemented, and verified — before the system ever reaches the factory floor.
If you’re planning a new control system or upgrade, our team can help you get it right from the first design stage.
How inControl Helps Manufacturers Streamline Operations
At inControl, we help manufacturers modernise their plants through smart automation and digital transformation.
Our expertise spans:
- ✅ Control system design and integration
- ✅ PLC, SCADA, and HMI development
- ✅ Industrial networking and OT/IT convergence
- ✅ Project management and site-work
Whether you’re upgrading legacy systems or planning your next automation project, our team can guide you from URS to SAT — delivering safe, efficient, and connected operations.
Learn more about our automation services:
