Deployment Checklist

Phase 1: Pre-Deployment

Complete these items before any on-site work begins.

Project Planning

• Define project scope and target reactor(s)
• Identify key stakeholders (operations, engineering, IT, safety)
• Establish success criteria and KPIs
• Complete Management of Change (MOC) process
• Schedule deployment windows with operations

Technical Assessment

• Document current control system architecture
• Identify PLC model and firmware version
• Map all relevant I/O points and tags
• Review existing PID tuning parameters
• Collect 3-6 months of historical process data
• Document safety system interfaces

Infrastructure Requirements

• Verify network connectivity to control system
• Allocate IP addresses for Acaysia devices
• Confirm firewall rules and network segmentation
• Provision rack space and power for edge device
• Establish secure remote access (if required)

Documentation

• Obtain P&IDs for target process
• Collect equipment datasheets (reactors, heat exchangers)
• Review operating procedures
• Document alarm setpoints and safety limits

Phase 2: Installation

Physical installation of Acaysia hardware.

Hardware Installation

• Mount Acaysia edge device in control room/MCC
• Connect power (verify UPS backup if required)
• Connect Ethernet to control network
• Verify LED status indicators
• Label all connections per plant standards

Network Configuration

• Configure static IP address
• Verify connectivity to PLC (ping test)
• Verify connectivity to Acaysia cloud (if applicable)
• Test DNS resolution
• Configure NTP time synchronization

Initial Software Setup

• Complete initial device registration
• Apply latest firmware updates
• Configure system credentials
• Set up user accounts with appropriate roles
• Configure backup schedule

Phase 3: Configuration

Configure Acaysia for your specific process.

Communication Setup

• Configure OPC UA or EtherNet/IP connection
• Map all required PLC tags
• Verify read access to process variables
• Verify write access to control outputs (in safe mode)
• Test communication failover behavior

Process Model Configuration

• Input reactor specifications (volume, heat transfer area)
• Configure reaction parameters (if known)
• Set operating ranges for all variables
• Import historical data for model training
• Validate initial model predictions

Safety Configuration

• Configure output limits (min/max/rate)
• Set up watchdog timer parameters
• Configure fallback PID setpoints
• Define alarm thresholds
• Test manual override functionality
• Verify SIS status integration (read-only)

Integration

• Configure HMI/SCADA integration
• Set up alarm routing
• Configure historian data export
• Set up email/SMS notifications

Phase 4: Shadow Mode

Acaysia observes and learns without affecting control.

Shadow Mode Activation

• Confirm all configuration is complete
• Enable Shadow Mode in Acaysia dashboard
• Verify data collection is active
• Notify operations team of shadow mode start

Model Training (Minimum 2-4 weeks)

• Collect data across normal operating range
• Include grade changes and transitions
• Include startup and shutdown sequences
• Document any process upsets or anomalies
• Monitor model accuracy metrics daily

Shadow Mode Validation

• Compare Acaysia predictions vs. actual outcomes
• Review recommended control actions
• Validate constraint handling
• Achieve model accuracy targets (>95% prediction accuracy)
• Document findings and tuning adjustments

Shadow Mode Exit Criteria

• Model accuracy meets acceptance criteria
• No unexplained anomalies in recommendations
• Operations team comfortable with system behavior
• Safety review completed and approved

Phase 5: Advisory Mode

Acaysia provides recommendations; operators execute.

Advisory Mode Activation

• Brief all shifts on advisory mode operation
• Enable Advisory Mode in dashboard
• Configure recommendation display on HMI
• Establish feedback mechanism for operators

Advisory Mode Operation (Minimum 2-4 weeks)

• Track recommendation acceptance rate
• Document operator feedback on each shift
• Refine recommendations based on feedback
• Measure theoretical performance improvement
• Address any operator concerns or questions

Advisory Mode Exit Criteria

• Recommendation acceptance rate >80%
• Operators confident in recommendation quality
• Demonstrated performance benefit
• No safety concerns raised
• Operations and engineering approval for closed-loop

Phase 6: Closed-Loop Control

Acaysia takes direct control of specified outputs.

Pre-Activation

• Final safety review meeting
• Confirm operator training complete
• Verify all failsafe mechanisms tested
• Schedule activation during low-risk period
• Ensure engineering support available

Closed-Loop Activation

• Notify operations of mode change
• Enable closed-loop control in dashboard
• Monitor closely for first 24-48 hours
• Document any manual interventions
• Collect operator feedback

Performance Monitoring

• Track KPIs vs. baseline
• Monitor safety metrics
• Review any fallback events
• Document process improvements
• Calculate ROI metrics

Phase 7: Post-Deployment

Ongoing support and optimization.

Documentation

• Update P&IDs with Acaysia integration
• Document final configuration
• Create operating procedures for Acaysia
• Update emergency procedures
• Archive all deployment documentation

Training

• Complete training for all operators
• Train maintenance staff on hardware
• Document escalation procedures
• Establish refresh training schedule

Ongoing Operations

• Establish regular performance review meetings
• Set up automated reporting
• Schedule quarterly safety reviews
• Plan for software updates
• Identify expansion opportunities