ELECTRICAL CONTROLS ENGINEERING

STANDARD WORKFLOW & OPERATING PROCESS

Department: Engineering / Electrical Controls
Role: Electrical Controls Engineer
Purpose: Establish a repeatable, documented, safe, and scalable method for managing controls engineering work from initial request through design, programming, commissioning, documentation, and long-term support.

1. MISSION OF THE CONTROLS ENGINEERING FUNCTION

The Electrical Controls Engineering function exists to safely improve, maintain, troubleshoot, standardize, and document the electrical automation systems that support production and facility operations.

Every controls project should accomplish five things:

Safety → Reliability → Maintainability → Documentation → Standardization

A successful project is not simply one where the machine works.

A successful project is one where:

• The problem is clearly understood.

• The original system is backed up.

• The change is documented.

• Safety implications are considered.

• PLC/HMI changes are traceable.

• Testing is completed.

• Operations understands the change.

• Maintenance can troubleshoot it later.

• Drawings and documentation match reality.

• A future engineer can understand what was done without relying on the original engineer's memory.

2. THE MASTER CONTROLS ENGINEERING WORKFLOW

Every project should progress through the following lifecycle:

REQUEST → TRIAGE → DISCOVERY → SCOPE → RISK REVIEW → BACKUP → DESIGN → REVIEW → DEVELOPMENT → OFFLINE TEST → INSTALLATION → COMMISSIONING → VALIDATION → DOCUMENTATION → HANDOFF → CLOSEOUT → FOLLOW-UP

Projects may vary in size, but the process remains essentially the same.

3. PHASE 1 — REQUEST / SUPPORT TICKET

Every Controls Engineering request should begin as a documented request.

Avoid performing significant controls work based solely on hallway conversations, text messages, or verbal requests.

Minimum Information Required

Record:

• Project/Ticket Number

• Date Requested

• Requested By

• Department

• Machine/Line/System

• Building/Area

• Problem or Requested Change

• Business Reason

• Production Impact

• Safety Impact

• Desired Completion Date

• Current Machine Condition

• PLC Manufacturer

• PLC Model

• HMI Manufacturer

• HMI Model

• Software Required

• Current Program Version

• Known IP Addresses

• Electrical Drawing Availability

• Estimated Downtime Required

• Photos/Screenshots

• Priority

• Assigned Engineer

• Status

Request Categories

Classify each request as:

• Breakdown / Emergency

• Troubleshooting

• PLC Logic Modification

• HMI Modification

• Electrical Modification

• Hardware Upgrade

• Software Upgrade

• Obsolescence Upgrade

• New Equipment

• Continuous Improvement

• Safety Improvement

• Network / Communications

• Alarm Improvement

• Data Collection / Trending

• Documentation Only

• Preventive Controls Maintenance

4. PHASE 2 — TRIAGE & PRIORITIZATION

Do not treat every request as an emergency.

Use a priority system.

P1 — Critical

Examples:

• Safety risk

• Production completely stopped

• PLC failure

• Major controls failure

• Critical communication failure

Response: Immediate

P2 — High

Examples:

• Major production degradation

• Recurring machine fault

• Reliability problem causing significant downtime

• Important quality issue

Response: Same day / next available opportunity

P3 — Normal Project

Examples:

• Logic modification

• HMI improvement

• Alarm addition

• Sequence improvement

• New sensor

• Process optimization

Response: Planned project

P4 — Improvement / Future Work

Examples:

• Nice-to-have HMI changes

• Visualization improvements

• Future upgrades

• Obsolescence planning

• Documentation cleanup

Response: Backlog / planned engineering work

5. PHASE 3 — DISCOVERY

Before changing anything, understand what the system currently does.

This becomes:

CURRENT STATE

Document:

• What happens now?

• What starts the sequence?

• What stops the sequence?

• What equipment is involved?

• What PLC routine controls it?

• What HMI screen controls it?

• What interlocks exist?

• What permissives exist?

• What timers exist?

• What alarms exist?

• What happens during faults?

• What happens during E-Stop?

• What happens after power loss?

• What happens during communications loss?

• What happens in Manual?

• What happens in Auto?

• What happens during startup?

• What happens during shutdown?

Do not immediately start programming.

Understand the machine first.

6. PHASE 4 — DEFINE THE FUTURE STATE

Document exactly what the system needs to do.

Create a simple sequence of operation.

Example:

1. Operator enables system.

2. PLC verifies safety conditions.

3. PLC verifies required permissives.

4. System enters Ready state.

5. Product is detected.

6. Timer begins.

7. Condition is evaluated.

8. Output activates.

9. Confirmation sensor verifies operation.

10. Failure generates alarm.

11. Operator clears condition.

12. Reset becomes available.

13. System returns to Ready.

This sequence becomes the blueprint for the PLC program.

7. PHASE 5 — ENGINEERING REQUIREMENTS

Determine what will be required.

PLC Requirements

Document:

• Controller

• Firmware

• Programming software

• Program file

• Routine(s)

• Tags/addresses

• Inputs

• Outputs

• Timers

• Counters

• Interlocks

• Permissives

• Alarms

• Communications

HMI Requirements

Document:

• HMI model

• HMI software

• Screen(s) affected

• New buttons

• Indicators

• Numeric entries

• Setpoints

• Alarms

• Navigation

• Security levels

Electrical Requirements

Document:

• Sensors

• Solenoids

• Relays

• Contactors

• Circuit protection

• Power supplies

• I/O modules

• Network equipment

• Terminals

• Enclosures

• Wiring

• Labels

8. PHASE 6 — HARDWARE & SOFTWARE UPGRADE REVIEW

Every project should include an opportunity to identify obsolete or aging equipment.

Create an:

UPGRADE OPPORTUNITY REGISTER

Record:

• Existing Device

• Manufacturer

• Model

• Age

• Firmware

• Obsolescence Status

• Replacement Device

• Estimated Hardware Cost

• Estimated Software Cost

• Engineering Hours

• Installation Hours

• Downtime Required

• Priority

• Risk of Doing Nothing

• Recommended Upgrade Year

This allows small controls projects to become opportunities for long-term capital planning.

9. PHASE 7 — RISK & SAFETY REVIEW

Before programming, ask:

• Can this modification create unexpected motion?

• Does this bypass an existing interlock?

• Does this affect an E-Stop?

• Does this affect guarding?

• Does this affect pressure?

• Does this affect temperature?

• Does this affect chemical flow?

• Does this affect motors?

• Could a valve unexpectedly open?

• Could equipment automatically restart?

• Could product quality be affected?

• Could communications failure create an unsafe condition?

• What happens if the new sensor fails?

• What happens if the PLC loses power?

Controls logic should never casually defeat a safety function.

Safety-related modifications should receive appropriate engineering/EHS review.

10. PHASE 8 — BACKUP BEFORE CHANGE

This should become an absolute department rule:

NO PLC/HMI MODIFICATION WITHOUT A BACKUP.

Before touching the program:

1. Upload PLC program.

2. Save original.

3. Upload HMI program.

4. Save original.

5. Record PLC firmware.

6. Record software version.

7. Record IP addresses.

8. Photograph relevant hardware.

9. Save electrical drawings.

10. Record current machine status.

Use a naming convention such as:

Machine_System_YYYY-MM-DD_PRECHANGE

Example:

Line5_DialOut_2026-10-06_PRECHANGE

Never overwrite the original.

11. PHASE 9 — VERSION CONTROL

Recommended structure:

V1.0 — Original

V1.1 — Minor Modification

V1.2 — Additional Modification

V2.0 — Major Revision

Every revision should have a Change Log.

Record:

• Version

• Date

• Engineer

• Ticket Number

• PLC Routine

• HMI Screen

• Description

• Reason

• Testing Performed

• Approval

12. PHASE 10 — DESIGN BEFORE PROGRAMMING

Before opening Studio 5000, RSLogix 500, TIA Portal, CCW, etc., create the logic concept.

Determine:

Inputs

What tells the system something happened?

Conditions

What must be true?

Interlocks

What prevents operation?

Outputs

What will happen?

Feedback

How does the PLC know it happened?

Faults

What happens if it does not happen?

Recovery

How does the operator recover?

This simple discipline prevents unnecessary online experimentation.

13. PHASE 11 — PLC PROGRAMMING STANDARD

Develop standard routine structures whenever practical.

Example:

00_Main

01_IO_Mapping

02_Mode_Control

03_Sequence_Control

04_Equipment_Control

05_Interlocks

06_Alarm_Triggers

07_Alarm_Status

08_HMI_Interface

09_Data_Logging

10_Diagnostics

Naming should explain function.

Prefer:

Line5_Infeed_PE

over:

Sensor_1

Prefer:

Can_Stop_Command

over:

Output_5

Prefer:

Infeed_Jam_Timer

over:

T4:17

Where legacy platforms require addresses, use detailed descriptions and symbols.

14. PHASE 12 — I/O MAPPING STANDARD

Maintain an I/O database containing:

• Machine

• PLC

• Rack

• Slot

• Channel

• Physical Address

• PLC Tag

• HMI Tag

• Device

• Device Type

• Description

• Voltage

• Normally Open / Normally Closed

• IP Address

• Drawing Reference

• Terminal Number

• Panel

• Status

• Spare / Used

This eventually becomes one of the most valuable Controls Engineering documents in the facility.

15. PHASE 13 — HMI DEVELOPMENT STANDARD

Every HMI modification should consider:

Navigation

Can the operator easily find the screen?

Status

Can the operator tell what the machine is doing?

Commands

Are Start, Stop, Reset, Auto and Manual obvious?

Diagnostics

Can Maintenance identify why equipment will not operate?

Alarms

Does the alarm explain the problem?

Bad alarm:

FAULT 17

Better alarm:

Line 5 Infeed Jam — Photo Eye Blocked > 5 Seconds

Best alarm:

Line 5 Infeed Jam — Clear Product From Infeed Photo Eye and Press Reset

16. PHASE 14 — OFFLINE TESTING

Before downloading:

Verify:

• Logic compiles.

• Tags exist.

• Addresses are correct.

• Timers use correct time bases.

• Outputs cannot conflict.

• Auto logic works.

• Manual logic works.

• Interlocks work.

• Reset logic works.

• Alarm logic works.

• HMI commands work logically.

• Failure conditions have been considered.

17. PHASE 15 — CHANGE PLAN

Before commissioning, document:

What will change?

When will it change?

Who needs to know?

How much downtime is required?

What production conditions are required?

What is the rollback plan?

Where is the previous program?

If the change fails, you should already know exactly how to restore production.

18. PHASE 16 — COMMISSIONING

Use a commissioning checklist.

Test:

• Inputs

• Outputs

• Auto Mode

• Manual Mode

• Start

• Stop

• Reset

• Permissives

• Interlocks

• Timers

• Counters

• Alarms

• HMI indicators

• HMI controls

• Communications

• Power-cycle recovery

• Failure conditions

Never consider:

"The output turned on."

to mean:

"The project works."

Test the entire process.

19. PHASE 17 — VALIDATION WITH OPERATIONS

Have the operator or responsible stakeholder run the machine.

Ask:

• Does this operate as expected?

• Is the HMI understandable?

• Are alarms understandable?

• Is recovery understandable?

• Did we introduce another problem?

• Is anything missing?

Record who validated the modification.

20. PHASE 18 — POST-COMMISSIONING BACKUP

After successful commissioning:

UPLOAD AGAIN.

Save:

Machine_System_YYYY-MM-DD_POSTCHANGE_V1.1

The POSTCHANGE file becomes the new master.

21. PHASE 19 — DOCUMENTATION UPDATE

Update applicable:

• PLC backup

• HMI backup

• I/O list

• Network/IP list

• Electrical drawings

• Device list

• Alarm list

• Change log

• Sequence of operation

• Software inventory

• Hardware inventory

• Project ticket

• Photos

• Troubleshooting instructions

The documentation should represent the machine after the project—not how it looked six months ago.

22. PHASE 20 — PROJECT CLOSEOUT

Do not close a project simply because production is running.

Use a formal:

CONTROLS PROJECT DEFINITION OF DONE

A project is complete when:

☐ Requested change completed
☐ PLC tested
☐ HMI tested
☐ Inputs tested
☐ Outputs tested
☐ Interlocks tested
☐ Alarms tested
☐ Operator validation completed
☐ Final PLC uploaded
☐ Final HMI uploaded
☐ Version number updated
☐ Change log updated
☐ I/O documentation updated
☐ Electrical drawings updated where applicable
☐ Photos attached
☐ Spare parts identified
☐ Training completed if required
☐ Stakeholder notified
☐ Project documentation stored
☐ Follow-up date established

Only then should the ticket become:

CLOSED

23. 24–72 HOUR FOLLOW-UP

For significant changes, return to the equipment after it has operated in production.

Ask Operations and Maintenance:

• Any unexpected faults?

• Any nuisance alarms?

• Any unexpected downtime?

• Any operator confusion?

• Any sequence problems?

• Any sensor issues?

• Any additional improvements?

This catches problems that commissioning may not reveal.

24. EMERGENCY TROUBLESHOOTING WORKFLOW

Emergency troubleshooting requires a shorter process but still needs discipline.

Use:

MAKE SAFE → UNDERSTAND SYMPTOM → CHECK HISTORY → CHECK INPUTS → CHECK CONDITIONS → CHECK INTERLOCKS → CHECK LOGIC → CHECK OUTPUT → CHECK FIELD DEVICE → CORRECT → TEST → DOCUMENT

Avoid changing logic merely because the machine is not working.

First determine whether the PLC is correctly refusing to operate because a field condition is missing.

25. THE CONTROLS ENGINEER TROUBLESHOOTING RULE

Follow the signal.

For a failed output:

FIELD CONDITION

↓

INPUT

↓

PLC INPUT ADDRESS

↓

PROGRAM CONDITION

↓

INTERLOCK/PERMISSIVE

↓

COMMAND

↓

PLC OUTPUT

↓

OUTPUT MODULE

↓

FIELD WIRING

↓

DEVICE

This prevents random troubleshooting.

26. WEEKLY CONTROLS ENGINEERING OPERATING RHYTHM

Because there is currently only one Controls Engineer, time must be intentionally divided.

MONDAY — PLAN

Review:

• Active projects

• Open support tickets

• Production issues

• High-priority items

• Upcoming downtime

• Parts needed

• Vendor dependencies

Establish weekly priorities.

TUESDAY — ENGINEERING

Focus on:

• PLC development

• HMI development

• Electrical design

• Research

• Testing

• Project execution

Protect several uninterrupted engineering hours.

WEDNESDAY — FIELD / RELIABILITY

Walk equipment.

Look for:

• Damaged sensors

• Temporary wiring

• Bypassed devices

• Cabinet issues

• Communication problems

• Obsolete hardware

• Repeated faults

• Poor labeling

• Documentation gaps

THURSDAY — PROJECT EXECUTION

Focus on:

• Installation

• Testing

• Commissioning

• Vendor coordination

• Planned changes

FRIDAY — CLOSEOUT & REVIEW

Before the weekly project review:

Update:

• Completed projects

• Active projects

• Blocked projects

• Upcoming projects

• Parts required

• Manager decisions needed

• Upgrade opportunities

• Risks

• Next week's priorities

Reserve time afterward for documentation and backups.

27. DAILY CONTROLS ENGINEERING ROUTINE

Start each day with approximately 10–15 minutes of planning.

Review:

1. What could stop production today?

2. What project must move forward today?

3. What am I waiting on?

4. What documentation needs updating?

5. What can I complete today?

Avoid allowing email, Teams messages, and small requests to control the entire workday.

28. CREATE A CONTROLS ENGINEERING BACKLOG

Maintain one master backlog.

Suggested fields:

• Ticket

• Project

• Department

• Machine

• Requestor

• Priority

• Safety Impact

• Production Impact

• Estimated Hours

• Status

• Assigned Engineer

• Target Date

• Waiting On

• Hardware Required

• Software Required

• Estimated Cost

• Downtime Required

• Next Action

Suggested statuses:

NEW

DISCOVERY

SCOPING

WAITING FOR APPROVAL

WAITING FOR PARTS

DEVELOPMENT

READY FOR INSTALL

COMMISSIONING

MONITORING

DOCUMENTATION

CLOSED

ON HOLD

29. CONTROLS ASSET DATABASE

Begin documenting every automation asset on site.

For every machine:

• Equipment Name

• Asset Number

• Manufacturer

• PLC Manufacturer

• PLC Model

• Firmware

• PLC IP

• HMI

• HMI IP

• VFDs

• Servo Drives

• Managed Switches

• Remote I/O

• Safety PLC

• Software Required

• Current Program Version

• Last Backup

• Backup Location

• Electrical Drawing Location

• Critical Spare Availability

• Obsolescence Status

Eventually, you should be able to answer:

"What controls equipment do we have?"

without walking the entire plant.

30. NETWORK DOCUMENTATION

Maintain a Controls Network Register.

Document:

• Device

• Machine

• IP Address

• Subnet

• Gateway

• MAC Address

• Manufacturer

• Model

• Firmware

• Switch

• Switch Port

• Protocol

• PLC Connection

• Notes

This becomes extremely valuable during communication failures.

31. CONTROLS BACKUP LIBRARY

Create a structured master directory.

Example:

CONTROLS ENGINEERING

→ PLC Programs
→ HMI Programs
→ Electrical Drawings
→ Network Documentation
→ I/O Maps
→ Projects
→ Support Tickets
→ Standards
→ Templates
→ Vendor Manuals
→ Software
→ Firmware
→ Commissioning
→ Training
→ Obsolescence
→ Archived Programs

Organize PLC/HMI backups by:

AREA → LINE → MACHINE → YEAR → PROJECT

32. STANDARD DOCUMENT LIBRARY

Build reusable templates for:

• Controls Project Request

• Support Ticket

• PLC Change Request

• HMI Change Request

• Controls Project Scope

• Sequence of Operation

• I/O Mapping

• PLC/HMI Tag List

• Alarm List

• Network/IP Register

• Hardware Inventory

• Software Inventory

• Controls Backup Log

• Commissioning Checklist

• FAT Checklist

• SAT Checklist

• Change Log

• Risk Assessment

• Troubleshooting Report

• Incident Report

• Project Closeout

• Upgrade Recommendation

• Controls Obsolescence Report

• Weekly Project Review

The goal is to stop recreating engineering paperwork for every project.

33. KNOWLEDGE ARTICLE SYSTEM

Every time you solve a difficult problem, ask:

"Will someone eventually have to solve this again?"

If yes, create a Knowledge Article.

Examples:

HOW TO — Upload a PanelView Plus Application

HOW TO — Add an Alarm to FactoryTalk View ME

HOW TO — Replace a CompactLogix Controller

HOW TO — Troubleshoot EtherNet/IP Communications

HOW TO — Restore a PLC Program

HOW TO — Add a New PLC Input

HOW TO — Add a New HMI Pushbutton

HOW TO — Commission a New Photo Eye

You are effectively documenting your experience for your future team.

34. CONTROLS ENGINEERING DASHBOARD

Your web application should show at minimum:

OPEN PROJECTS

Number of active controls projects.

SUPPORT TICKETS

Open / Closed / Waiting.

PRIORITY PROJECTS

P1 / P2 / P3 / P4.

PROJECT PIPELINE

Requested → Engineering → Development → Commissioning → Closed.

PLC BACKUP HEALTH

Machines with current backups.

HMI BACKUP HEALTH

Machines with current backups.

DOCUMENTATION HEALTH

Machines with current drawings.

OBSOLESCENCE

Devices requiring replacement.

CONTROLS RISKS

Known single points of failure.

COST AVOIDANCE

Estimated savings created through internal controls work.

DOWNTIME IMPROVEMENT

Problems eliminated or reduced.

35. PERSONAL DEVELOPMENT SYSTEM

Becoming an exceptional Controls Engineer requires more than completing projects.

Develop expertise across six areas.

PLC

Continue mastering:

• Studio 5000

• RSLogix 500

• Siemens TIA Portal

• CCW

• Ladder Logic

• Structured Text

• Function Block

• State machines

• Sequencing

HMI / SCADA

Develop expertise in:

• FactoryTalk View

• PanelView

• Siemens HMI

• C-More

• Alarm management

• Trending

• Data logging

INDUSTRIAL NETWORKING

Become highly competent with:

• EtherNet/IP

• PROFINET

• Modbus TCP

• Modbus RTU

• DeviceNet legacy systems

• Managed switches

• VLAN concepts

• IP addressing

• Wireshark

ELECTRICAL

Continue developing:

• Electrical schematics

• Motor controls

• VFDs

• Servo systems

• Safety circuits

• Relays/contactors

• Instrumentation

• Analog signals

• 24 VDC systems

SOFTWARE

Develop:

• SQL

• Python

• PowerShell

• APIs

• OPC UA

• MQTT

• Industrial databases

• Reporting

LEADERSHIP

Develop:

• Project management

• Documentation

• Vendor management

• Cost estimating

• Capital planning

• Training

• Standards development

• Technical communication

The eventual goal is not simply:

Controls Engineer

but:

Controls Engineer → Senior Controls Engineer → Controls Lead → Controls Engineering Manager / Automation Manager

36. THE "BUS FACTOR" TEST

Ask yourself:

"If I were unavailable tomorrow, could another qualified Controls Engineer understand what I built?"

If the answer is no, documentation is insufficient.

Your systems should not depend entirely on what is stored in your head.

37. THE FUTURE CONTROLS TEAM

When another Controls Engineer eventually joins the company, they should receive:

Controls Engineering Handbook

containing:

1. Department Mission

2. Engineering Workflow

3. Project Management Process

4. Support Ticket Process

5. Programming Standards

6. PLC Standards

7. HMI Standards

8. Alarm Standards

9. Naming Conventions

10. I/O Standards

11. Network Standards

12. Backup Standards

13. Version Control Standards

14. Commissioning Standards

15. Documentation Standards

16. Troubleshooting Standards

17. Safety Expectations

18. Knowledge Articles

19. Plant Controls Asset List

20. Project Closeout Requirements

Instead of telling the new engineer:

"This is how I normally do it."

you will be able to say:

"This is our Controls Engineering Standard."

38. FIRST 90-DAY IMPLEMENTATION PLAN

Do not attempt to build everything simultaneously.

DAYS 1–30 — CONTROL THE WORK

Implement:

• Project numbering

• Support ticket intake

• Priority system

• Project statuses

• Weekly project review

• Pre-change backups

• Post-change backups

• Change logs

• Standard naming convention

• Definition of Done

Goal:

Every controls change becomes traceable.

DAYS 31–60 — CONTROL THE INFORMATION

Build:

• PLC inventory

• HMI inventory

• IP address register

• I/O mapping database

• Software inventory

• Firmware inventory

• Backup database

• Hardware upgrade register

• Obsolescence list

• Standard folder structure

Goal:

Know exactly what automation equipment exists and where its documentation lives.

DAYS 61–90 — BUILD THE DEPARTMENT

Establish:

• PLC programming standards

• HMI standards

• Alarm standards

• Commissioning standards

• FAT/SAT standards

• Troubleshooting procedures

• Knowledge Article library

• Controls Engineering Handbook

• New engineer onboarding checklist

• Controls KPI dashboard

Goal:

Create a repeatable Controls Engineering department that another engineer can immediately join.

39. THE STANDARD

From this point forward:

No undocumented projects.

No unidentified PLC programs.

No downloading without backups.

No permanent undocumented temporary fixes.

No unexplained PLC tags where reasonable naming is possible.

No project closed without final backups.

No controls change without understanding the existing sequence.

No modification without considering failure conditions.

No relying solely on memory.

No completed project without leaving the system easier for the next engineer to understand.

40. THE END GOAL

You are not simply maintaining PLC programs.

You are building the company's Controls Engineering infrastructure.

The objective is to transform:

One Electrical Controls Engineer handling requests

into:

A standardized Controls Engineering function with documented systems, processes, assets, history, and engineering standards.

When additional engineers arrive, they should be joining an established engineering system—not helping create one from scratch.

The process should already exist.

The documentation should already exist.

The standards should already exist.

The project history should already exist.

The asset database should already exist.

The Knowledge Articles should already exist.

And the new engineer should be able to learn the operation through the system you created.

That is how a one-person Controls Engineering role becomes a scalable Controls Engineering department.