ControlDraw Overview Contents

• Background - why ControlDraw was developed

• Process Control Specifications– Who writes them?

– Who are they for?

– What’s in them?

– How are they produced?

– Problems

• ControlDraw Overview– High Level, not training

Process Control Specifications

• Who writes them?– Purchasers, Contractors, Suppliers

– Process Control engineers

• Who are they for?– Users

– Operational staff

– Suppliers

– Sales engineers

– Programming staff

– Tester

– Validators

Specification Contents

• Words describing the processes

• P&ID’s

• Control loops

• Interlock logic

• Sequences

• Recipes

• Many lists and tables such as IO Lists

• Graphics

Specification Organisation

• Varying degrees of structure

• Break down into Process areas

• Break down into functional types

• Typicals and Specifics

• S88.01 models and terminology

• Object based

Life Cycles

• Imported from IT industry

• GAMP, IEE, etc have adapted to process

• Good model for documents

• Provide a ‘chronological’ structure

• Not realistic as a time series– Requirements and design

often iterate

User Requirements Specification Testing of the URS

Functional Specification Testing of the

Functional Spec

Software Design

Specification

Software Module

Specifications

Review and Test Modules

Code Modules

Software Module Testing

Software Integration

Testing

System Acceptance

Testing

Process Control Specification Production

• Typically the requirements are specified with Word, Visio, Excel, Access– Problems!

– Too many files, clumsy and inadequate version control.

– Inconsistencies abound due to absence of consistency checking

– Proliferation of documents increases QA and validation effort.

– Lack of process control focused integration in spite of OLE etc

– Hard to find things

CASE Tools, UML etc

• Solve some problems

• Create others

• They do not ‘understand’ Process Control

• Alienate some users

• DCS/PLC tools are too product specific

• Can work, acceptance growing

• Capable of code generation– Focused on C(++)

– Standardised languages

– But Process Control languages are still proprietary

h.Production Information Entry

Absolute time stamp (real time)DescriptionSource ID (person, program, etc)Value

h.Batch History Entry

Batch Id

h.Common Information Entry

Production Information Management -- h(pim.dat)

h.Batch Report

Report Header

h.Batch Report Classh.Production Information Entry Class

h.Report Element

h.Report Element Class

h.origin

h.Production Information Recipe Entity

is based on

I cannot use this to agree process functionality

Logical View

Type

+multiplicity : Multiplicity

TypeExpression

+referncedTypes() : List of Type

Primitive Type

+details : Uninterpreted

Value

-value : Uninterpreted

ModelElement Responsibility TaggedValue

Expression

Class UseCase

State

BehaviorInstance

1..n

0..n

references

{implicit}

0..1

0..n

/characteristic

Instance0..n

0..1

0..n

0..1

0..1

0..n

actions

0..1

0..n

state instance

0..n

0..n

roles

Functional Requirements Specification

• A comprehensive statement of exactly what the system needs to do.

• Includes all control and operational requirements.

• Can be Independent of the actual technology.

• But reflects the capabilities of the actual system.

• Develops throughout the project life cycle.

• Should be testable.

• And validatable

Requirements and Functional Specifications

• Must clearly express the requirement in ways that all users (not just control specialists) can understand

• Be easily amended so they can be iterated toward an agreed basis.

• Ultimately include all of the information needed during the programming and test phases.

• Should be an Open electronic document

The FRS applies throughout the Life Cycle

User Requirements Specification Testing of the URS

Functional Specification Testing of the

Functional Spec

Software Design

Specification

Software Module

Specifications

Review and Test Modules

Code Modules

Software Module Testing

Software Integration

Testing

System Acceptance

Testing

Functional RequirementsSpecification

Words

Control Modules

Phase Logic

Procedures

Graphics

System Database

ControlDraw Overview

• Modelling software for specification and documentation of Process Control Systems.

• A diagram processor.– Easy to understand diagrams for end users to review

– Hundreds of diagrams related to each other through hierarchical links and data tables

• A database– All of the model is kept in one Access file.

– Can include All tabular data

• A simulation tool– Capability to test control strategies being developed

ControlDraw- Diagrams

• Drag and drop drawings

• A library of process control symbols

• Diagrams connected hierarchically– S88 Models.

• Typicals and Instances– For example a typical for each type of PID Control loop and a

link in the model to each occurrence

Diagrams

• Many types of diagrams

Diagrams that Capture the S88 Models

Common Resource diagram

Control Module diagram

Equipment Module diagram

Phase diagram

Plant Area diagram

Site diagramPage 1 in the ControlDraw

model

Unit diagram

Unit Procedure diagram

Common Resource

Control Module

Phase

Plant Area

Unit

Unit Procedure

Plant Area

Unit

Equipment Module

Control Module

Control Module

Equipment Module

Plant Area diagram

This also has all the Units and Resource etc

PhaseState 2

State 1

Phase Step

ConditionPhase Step

Process Flow diagrams

FLT2Additive Warehouse

Stores the palettes of Flavour additives

13 Solids Processing

Flavour additives materials are depalletised and weighed into IBC's 73

Intermediate Store 14

Milk Silos

3 silos filled during day, cleaned at night 2

CIP Chemical Store15

CIP Generation System 6

Liquids Processing

Batch Mixing Processes3

FLT1

FLT3

Packaging Bldng

5

Packaging Store 52

FLT4FLT5

Product Silos

3 silos4

Fruit Drink ProcedureCovers Banana, Strawberry and

other blends30

Fudge Drink ProcedureCovers Chocolate and other blends

31

Alchoshake ProcedureCovers Chocobooze and other

blends32

Recipes

Quarantine Store 66

Final Product StoreStores the palettes of final

product

Product

Additives

CIP Chemicals

Packaging

Milk Tanker2

Milk Tanker1

Milk Tanker3

Water Treatment Plant

Control Activity Model 62

Control Room64

Laboratory65

Steam Resources

Tracking Database

70

8

SH1

12

SH2

12

BV2

Batch Mixing Unit

8

CIP Supply

HG2

Homog - eniser

5858

CIP Return

EM3

Product Homogenising pipework55

EM4

Product Distribution manifold56

CIP Supply2

CIP Return2

Controller02

26

CIP_L3Line CIP for lines from Batch

Vessel to Homogeniser47

CIP_H1CIP for Homogeniser

47

CIP_L4Line CIP for lines from

Homogeniser to Product Silo47

Product Silos

Additive Storage Hoppers

Local Display

Tracking Database

Batch DB Table

69

BV1

Batch Mixing Unit

HG1

Homogeniser

PS3PS1 PS2

Batch Vessel

AG133

XV534

Pump33

Milk Supply

WT135

Additives

WQ1

Loss-In-Weight Feeder36

Jacket Temperature Controls2

Drain

CIP_V2Batch Vessel CIP

58

Transfer OutFeed to Batch Vessel

Add Milk Start Qty49

Mix and Heat53

Add Milk and Solids48

Sample Operation

Add Milk Final Qty50

LSL

LSH

LAH

32

LAL32

XV6

34

Unit procedureOperations

65 SIA28

Unit Control Module

SAMA Loops

610 FT 0001

610 FC 0001AL

610 AC 0005610 AT 0005

610 FV 0001

610 FY 0001A

610 FT 0002610 FAL 0001B

610 FY 0001B[not on P&&ID]

610 ALSP 0002[not on P&&ID]

610 FC 0002 610 FV 0002

DCS Functions

Field

Field

610 FZT 0023

610 FZT 0024

610 FZY 0023

610 FZAL 0023

610 FZY 0023B[not on P&&ID]

610 ALSP 0002[not on P&&ID]

ESD Functions

Logic Diagrams

Manual Start

Auto Start

Auto_Interlock

Auto_Start

Auto/Man

Motor

Man Start

Man Interlock

Procedure Function Charts S88.02

UnitProc

Operation

Operation

Sample

Explicit Transition

Transfer

Operation

Receive

Operation

PFC Allocation

PFC Allocation

PFC Start

PFC Start

PFC Start

Operation

UnitProc

State Transition diagrams

Shutdown

Start

Starting

StopFail

Abandon

Available

Hold in manual

Fail or Man

Unit to Auto

Start Complete

Stop

In use

Hold Batch

Fail or Batch Hold

Restart batch *

Acquired by Batch *

Released by Batch *

Batch Abandon

*

Hold Batch in manual

Unit to Manual

Unit to Auto

* Co-ordination control

Co-ordination control Function,by Recipe Manager

NoteIf the unit is acquired this is the only state where

manual device operation is permitted.

ControlDraw Database

• ControlDraw model is an Access database

• Extensive user defined lists obtainable– Data for Object typicals

– Data for Object Instances

– IO Lists, module lists, Instruments etc

– Recipes

7

BV1Batch Mixing Unit

EM3Product Homogenising pipework

CIP Supply

7

BV2Batch Mixing Unit

11

SH2

11

SH1

ControlDraw State Matrices

• Mapping procedures into Basic Control

TMROMaximum Open Travel Time

ZSCClosed Limit Switch

ZSOOpen limit switch

NoteThis applies to the standard block valves and is assumed to be the same for the diverter valves

OValve Open

OVRCOverride Closed - If set to 1 the Open limit switch is ignored

OVROOverride Open = If set to 1 the Open limit switch is ignored

Interlock Condition

DIOpen

DIClosed

DOSov

TMRCMaximum Close Travel Time

FTCFail to Close

FTOFail to Open

Valve DriverStandard Auto/Manual.

Travel is timed in each direction. Timeout causes Fail to Open or Fail to Close Alarm.Individual times for each direction must be provided.

MANManual Command0 = close, 1 = Open

AutoAuto Command - From Unit State Matrix

A/MAuto/Manual0 = manual, 1 = AutoSet by Unit

Process Cell

Mixing Unit

OperationValve Control Module

Operations

CIP_V2Batch Vessel CIP

26

SIA

63

Unit Control Module

32

XV6

30

LAL

30

LAH

LSH

LSL

48

Add Milk Final Qty

Sample Operation

46

Add Milk and Solids

51

Mix and Heat

47

Add Milk Start Qty

Transfer OutFeed to Batch Vessel

Drain

37

TC

34 WQ1

Loss-In-WeightFeeder

32

XV3

32

XV1

32

XV2

32

XV4

Additives

TT1

33 WT1

Milk Supply

31 Pump

32 XV5

31

AG1

Batch Vessel

WTPVActual Weight

WTSPTarget Weight

T_WT > WTSPWeight greater

than Target

Fast Feed

Add milk a full rate.

TrueDummy

Store Tare WtStore the weight for use in batch

calcs

T_StableWeight stable for

x seconds

Stabilise

Wait for the weight to be steady

T_Start

Start

Unit State Matrix

ControlDraw 1

• Developed 1994 to 1998

• Publicly available freeware

• Used on several projects to define physical and procedural control for DCS, PLC/SCADA and MES including– Fresenius Kabi Sweden

• Large Human Parentals project, covering formulation, filling, CIP, SIP etc

– Novo Nordisk Denmark

• Insulin plants with dispensing, formulation, filling

– And more

ControlDraw2

• VB6 and Access97

• 6000+ hrs already spent on version 2

• Latest Component technology– Fast C++ modules bought in for diagram and data handling

• Low risk even though new product– All diagrams and data can be copied into Visio, Word, Excel,

Access etc

ControlDraw2

• Complete Specification generator

• Testers include several S88 specialists

• In use on new projects since early 2000

New In CD2

• Improved– Connections!

– Text

– Symbols

– Database

– Matrices

– Version Management

• New– Simulation

• Future!

Connections!

• Much Easier, all done on the diagram– Move connect points

– Add new connections

– Manual and other routings

• Unlimited– 1 Output can connect to any number of inputs

– Any number of connections per symbol

• Data flows through them - when in Run mode

Text

• Longer tagnames - 32chr

• No limit on description text

• Text inside symbols

• Manual text positioning

• Word integrated - RTF files embedded in the models

Symbols

• Shapes and fill colours

• More pictures

• Pictures embedded in model

• More palette functions– Collections

– Special symbols

• Dynamic appearance

• New Link types– Not just parent, can now have extensions and jumps

Database

• Integrated - The CD2 model is an Access 97 DB file

• All the model is in the DB

• Customisable - add your own fields for each class

• Provides for Expert users to extend functionality themselves through Access

Matrices

• Are tables in the Database

• Interact with the simulation

• Track Tagname changes

Document and Version Management

• Publish

• Issue and Backup

• Compare

• Export to Word/HTML

Simulation

• Symbols can be dynamically animated to show state or value

• Data flows through connections - – connections animated

– eg process material flows through pipes

• Symbols can contain VBS program

• Simple drag and drop scripting

• Canned scripts in symbols library

Prospects

• XML– Export a model as XML

– Possibility of vendors being able to import, eg BatchML

XML Batch Data Exchange Schema

OPC Batch Interface

ControlDraw Model

In Projects

• Scope control – Detailed metrics from the model

– Module provide basis for

• estimates

• project plan

– Highly detailed change tracking

http:\\www.controldraw.co.uk

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