From Concept to Commissioning: A Lifecycle Approach to Control System Design

By Lon Johannes, PE | Senior Discipline Engineer, Instrumentation and Control System Engineering

In today’s fast-paced industrial landscape, precision, reliability, and efficiency are essential. At the heart of these demands lies a well-designed instrumentation and control system. At Coffman Engineers, we take a lifecycle approach to control system design, supporting each phase – from concept to commissioning – with technical rigor and practical insight.

Understanding the Vision: Concept and Consultation

Every project begins with a clear understanding of the client’s goals. We collaborate closely with stakeholders to define system requirements, performance expectations, and operational constraints. Whether it’s a greenfield project or a retrofit, we assess sites, review existing infrastructure, and explore opportunities for optimization.

This early engagement helps shape solutions that align with your business objectives, regulatory requirements, and budget. It’s not just about technology, it’s about designing systems that work for people.

Engineering the Solution: Design and Development

With requirements defined, our engineers design systems that balance innovation and practicality. This includes:

• Selecting instrumentation based on process variables, environmental conditions, and accuracy
• Designing control architecture (PLC, DCS, or hybrid systems)
• Network and communication planning for data flow and system integration
• Incorporating safety and redundancy features to meet industry standards and reduce risk
• Safeguarding critical infrastructure by addressing OT cybersecurity through industry standards such as ISA/IEC 62443, NIST SP 800-82, and NERC CIP, focusing on secure architecture, access control, network segmentation, and threat detection

We use advanced simulation tools and CAD software to model system behavior, validate control logic, and identify potential issues before implementation. This proactive approach reduces costly revisions and keeps projects on schedule.

Bringing It to Life: Installation and Integration

Once designs are finalized, we move into the implementation phase – translating plans into action. We can assist or manage the procurement of control system components to help with compatibility and timely delivery. Our team handles PLC programming, designs intuitive HMI graphics, and configures SCADA servers to build a responsive and user-friendly control system.

We work closely with your contractors and internal teams to support seamless integration, verifying that all devices, controllers, and interfaces communicate effectively. The result is a fully integrated, tested, and reliable system that supports efficient operations and meets your performance goals.

Driving Performance: Commissioning and Support

Commissioning is where design becomes reality. We follow a structured process to confirm every control system component performs as intended. This includes loop checks for wiring and calibration, functional testing of logic and alarms, and a controlled startup to fine-tune performance. Once the system is online, we provide training, documentation, and ongoing support for smooth operation and long-term reliability.

Control System Upgrade for Natural Gas Production Facility

At the Armstrong Natural Gas Production Facility, Coffman led a control system upgrade, delivering a secure, modern architecture with PLCs, SCADA integration, and intuitive HMI graphics. The team validated system behavior through simulation and modeling, supported installation, and achieved reliable performance through close contractor collaboration. The upgraded system aligned with Armstrong’s operational goals and regulatory standards, enhancing both reliability and safety at the facility.

Why Coffman Engineers?

The lifecycle approach reflects our commitment to quality and collaboration. With decades of experience across industries like oil and gas, manufacturing, water treatment, and energy, we bring deep technical expertise and a client-focused mindset to every project. Our focus is to provide a well-designed control system and be your strategic partner every step of the way. Contact us if we can be of assistance.

Additional reading: The Value of Commissioning