1

ControlDraw Ltd

• 10 years successful operation• Providers of Software plus expert consulting• Clients and users around the world• Lends money to banks

• www.controldraw.co.uk

2

Francis LoveringControlDraw Ltd

24 years with EPCTechnical manager Automation group

10 years ControlDraw LtdActive and Award winner in World Batch Forum

fl@controldraw.co.uk

3

(How) Do you?

• Ensure Automation Systems meet End User needs– Must haves, wishes etc– Manage User approvals

• Manage automation projects– Design before programming!– Track progress– Manage changes

• Ensure Specifications are accurate

• Define the Modularisation of a system– S88 etc

4

ControlDraw Introduction

• Software for Specifying and Designing Automation systems• Hierarchical and Graphical Object models• Discrete, S88 batch and Continuous control• High definition Specifications for the entire Life Cycle• Improves User understanding • Improves Project Management• Reduces errors• Accelerates development

5

ControlDraw Description

• Uses a Hierarchical and Graphical object modelling approach• Appropriate Diagrams for all modules• Includes State oriented objects and methods• Includes simulation, verification and more• A ControlDraw model is database

– Tables automatically generated from the contents of diagrams– Advanced data population

6

Advantage of graphical specifications

• (Good) Diagrams are much less ambiguous than text

• User understanding is improved– New Users may need a few hours of training– Then User approval is more meaningful– And traceable

7

Graphical Objects

• Diagrams show the Objects in a process

• Diagram Symbols can be much more than pictorial, they can be S88 Objects corresponding to the S88 entities– Recipe Procedures, Units

Equipment modules, Control Modules etc

8

Hierarchical

• Objects can contain objects, by linking an object to a Child Diagram

• This is recursive so allowing hierarchies that match the S88 Physical and Procedural Models

Process Cell 2 diagram

Common Resource diagram

Control Module diagram

Equipment Module diagram

Process Cell 1 diagram

Site diagramPage 1 in the ControlDraw model

Unit diagram

Phase SFC diagram

CommonResource

Plant Area

Unit

Unit Operations

Plant Area

Unit

EquipmentModule

ControlModule

ControlModule

EquipmentModule

State 2

State 1

&

Step

ConditionStep

Condition

Start

End

Condition

Recipe ProcedureDiagrams

Recipe Procedure

State Matrix

9

Object properties

• Class– Extended S88 types

• Eg Unit, EM, CM

– Data structure for instance data

• Data – Symbols can contain data– This can cascade down

the hierarchy (inheritance)

em 07Outlet

Equipment Module

Symbol Class

Equipment

TT02

33

ScaleMinScaleMaxEngUnits

0150

DegC

Measurement Analog

Symbol Data

Data stored in a symbol

Child Page Link

Show the number of the diagram that is linked to the symbol

10

Object Instances

• ControlDraw scans a model to create records for all object instances

• Each Class has configurable database tables • These can match PLC and DCS structures

11

Diagrams

• Process Cells

Material B

un216A

CIP return

Mixing

Material B

un216B

Material B andMaterial A Supply

un205A Material A

un215A

Material A,

un215BMaterial

BDelivery

cr216X

Material A

CIP return

CIP Return Pump

cr215Z

Matrl C

un138B

MaterialA

Delivery

cr215X

CIP return

Matrl CSupply

cr138Y Matrl CDelivery

cr138X

CIP Return Pumps

cr216Z CIP Return Pumps

cr138Z

Matrl C

un138A

CIP Supply

Storage A or Bmixs Receive Store Deliver

7 7 2 3 3

9

17

13

5

11

15

17 17

13

48

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Diagrams

• Units,

CIP

Storage

Delivery

Filling

Phases

Storage Tank

Material Supply

LT001ContentsTT001

Material Delivery Line

Storage Tank Mainem01

CIP Supply

CIP Return

JT001

em02

P&ID reference

Passive

Stop

Hold

Ready toDeliver

Ready toCIP

Delivering CIPFilling

Storing Discharge CIP Drain

IF to UnitIF to Supply Unit

IF to CIP Unit

Interface Objects

un StorageTankReady to Fill

36 Operation

39 Operation

40 Operation

38 Operation

3

27

Measurement Analog

27

Measurement Analog

6

5 Equipment Module

Passive

Hold

Ready to Fill

Filling

Storing

Ready to DeliverDelivering

Discharge

Ready to CIPCIP

CIP Drain

Off

Off

Ready to Fill

Filling

Storing

Ready toDeliverDelivering

Discharge

Ready toCIPCIP

CIP Drain

Process Material

Off

Off

Off

Run

Run

Run

Run

Off

Off

Off

Off

18

27

Measurement Analog

19 Equipment Module

Document Reference

State

State

State

State State

State State State

State State State

Control Module Control Module

Control Module

em01 em02

State

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Diagrams

• Equipment Modules

CV216

29

FT001

To Sterliser

CIP return header

CIP return header

FQIC001 25

V903

19

CIP SupplyForward

Unit A Unit B

CIP SupplyNext

Set StateSimulation

P01

23

Ready toDeliver

CIP

Off

EM States

Ready toCIP

Active asSource 44

Active asDestination 44

Delivering CIP Drain

V902

21

307AV252 V904

21

V931

21

em Material A/B Delivery

Off

Ready to Deliver

Delivering

Ready to CIP

CIP

CIP Drain

V902

Thru

Thru

Thru

Divert

Divert

Thru

V903

Closed

Closed

Closed

Open

Open

Open

P01

Stop

Stop

Run

Stop

Stop

Stop

FQIC001

Out OR

Out OR

Auto

Out OR

Out OR

Out OR

CV216

Close

L Clamp

Controlled

Open

Open

Open

V904

Thru

Thru

Thru

Divert

Divert

Thru

V931

Thru

Thru

Thru

Divert

Divert

Thru

Active as Source

Off

Off

Enable

Off

Off

Off

Active asDestinationOff

Off

Off

Off

Enable

Off

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Diagrams

• SFC – Sequential Function Charts – for Phases and

Operation (Equipment Procedural Entities) step 03

Destination "Ready" signal Set

Init

EM State confirmed

Source "Active" signalSetread from Feed Stock Supply Unit EM

Temp. OK

step 02Set to Ready

to Fill

parameter achievedORSource "Ready" signal Reset

step 04

Set to Filling

End

step 05Destination "Ready" signal Reset

Source "Ready" signalResetread from Feed Stock Supply Unit Operation

step 08"Can not start f illingtemperature too high "

Temp not OK

Source "Ready" signal Setread from Feed Stock Supply Unit Operation

step 01

Store currentWeight

Confirm

EM State confirmed

step 07

Set to Storing

epFill_Weight

Material A = 90% volumeMaterial B = 90% volume

Matrl C = 90% volumeMatrl C = 90% volume

epFill_Temp

Material A = 55 degMaterial B = 55 deg

Matrl C = 55 degMatrl C = N/A

rpStore_TempMaterial A = 5 - 10 degCMatrl C = 5 - 10 degCMaterial B = N/AMatrl C = N/A

step 06

Store curent w eight and calculateamount of material added

True

BL_Received_Qty Batch Log Total Received

rpStore_Time_MaxMaterial A = 48 hoursMaterial B = N/AMatrl C = N/AMatrl C = N/A

Note

Set to Storingadd a timer CM

- start of f illing until empty- time since last f illed (for

Matrl C /Matrl C)

Set State

Set to Hold

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Diagrams

• PFC –Procedure Function Charts– For Recipe Procedures,

Recipe Unit Procedures, Recipe Operations

Filling

Acquire Vessel

Operator selects destination - asssumed std MES function.MES should not allow filling of a vessel that is currently delivering dow nstream.Or that does not have room for the batch load

MixDelivery

Acquire Mix Unit

Release Mix Unit

Note

MES w ill manage "hygenic states" and therefore should not acquire a "non clean" unit

Delivery

Vessel Not Empty

Stop

Stop

Release Vessel215A/B

Vessel EmptyNote

MES must run a CIPrecipe procedure once vessel is empty

Batchmakeup

Discharge

38 41

40

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Diagrams

• SAMA, Logic – For Control

ModulesPID Algorithm

Out = K* 1/Td etcPV

To Do Customise messages,

in thexxxx p

Difference

Local Set Point

Loc/Rem

Local / Remote

Auto/Manual

Auto/Man

Manual Output

Indicate

OutTo Analog output or cascade secondary

29

K

TI

TD

FromTransmitter

sngOverideValue is Zero unless

parent show sotherw ise

Overide

blnOveride

B > A

Set/ResetConfiguration Values

Level

Stop Level

Start Level

Enable: On/Off

B > A

On/OffCycling

NoteInclude hi and low limits on enterer values and eg check start level < stop level

Note

Energy saving / Cooling Pump CtrNote This Valve is numberered216 in

56

34

32

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States and state matrices

• All objects in a model can have States• These can be related to each other.• An SFC action can set the state of an object• A State Matrix can be built relating for example Equipment

Module to Control Module states

em Material B / C Supply Main

Off

Ready to DeliverDelivering

Ready to CIPCIP

CIP Drain

V902

Thru

Thru

Thru

Divert

Divert

Thru

V202

Close

Open

Open

Close

Close

Close

V203

Through

Through

Through

Mix

Mix

Mix

P01

Stop

Stop

Enabled

Stop

Enabled

Stop

V204

Closed

Open

Open

Open

Open

Open

V901

Thru

Thru

Thru

Divert

Divert

Thru

V931

Closed

Closed

Closed

Open

Open

Open

V903

Thru

Thru

Thru

Divert

Divert

Thru

Active asSourceOff

Off

Enable

Off

Off

Off

Active asDestinationOff

Off

Off

Off

Enable

Off

Lamp

Off

Flashing

Steady

Flashing

Steady

Flashing

18

Simulation

• Many Diagrams types can be put into simulation mode

• Test Control Strategies

19

S88 Procedure to Equipment Linking

• The Recipes can be linked to the equipment by referencing Recipe Procedural elements to Equipment Procedural elements

Unit Diagram with Unit PhasesThe phases are Equipment Procedural Elements

Recipe Equipment Link

The Phases in the Procedure are linked to their Equipment phases in the Unit

Unit Procedure Diagram

20

Build libraries of modules.

• Diagrams can be re-used in multiple models • Reference model contains the shared diagrams• Reference model also defines the classes• Diagrams can be made polymorphic so the one

diagram can cover a number of similar modules

21

Version Controls

• Everything in a model has a version number:– Diagrams– Classes– Matrices – Data

• Compare facilities provide details on all changes

22

Comparison with P&ID CAD systems• Products like SmartPlant and Comos have some capability• But only a small portion of the scope of ControlDraw models

Wiring

InstrumentSpecifications

Complex ControlLoops

Recipe Procedures

Simple ControlLoops

Control modulesEquipment control

Equipment modules

Equipment phases

Exception handlingRecipe Formula

Recipe operations

Recipe phases

UnitsUnit procedures

CAD scope

ControlDraw model scope

IO List

23

What can a Project manager get out of ControlDraw?

• High quality System Independent Specifications– Provide traceable estimates– Can be for implementation in-house or externally by a third

party– With design control retained even when using third party

• Proposal Models– Estimates– Initial client approval

• Project Control– Continual Scope Measurement– Change Tracking– Built in features such as Diagram Review Status help

24

What expertise must my engineers have?

• Not all need the same level• Some might just do the simpler things

– P&ID based tasks for example to take a P&ID and make a ControlDraw diagram

• Experts can then develop the model– It is possible to quickly make major changes and even

restructure models without losing the value of the work already done

• CD includes Model Review and Advisor functions– To check for consistent models and much more

25

The ControlDraw Reviewer

• View, navigate, and print the contents of a ControlDraw model

• Make comments on the diagrams and matrices• Make compare reports that show all changes

between model versions• Extract all data from models• Can be used for online documentation

26

Opportunities

• Get in at the beginning of projects– Develop System independent models– Focussed on end user requirements

• in the recession– Clients may scale back or postpone projects– But often they keep a small front end going

27

QuotationScope model

Client URSdocuments

Order Scopemodel

Issue Proposalto client

Client Orderdocuments

Functional Design model

Client Review

Pre-order activities

Management ReviewLessons Learned so far.Decide w hether to Continue

Test Specs

Standards

DataExport

Module listScada Tag List

IO ListParameter lis

Systemprototype

Testing

DataImport

System development

Review andApproval

Internal and Client

Model for Code

DataExport

DataExport

DeliverableSystem

Design activities

DataCompare

DataImport

DataExport

DataCompare

TestResults

Document generated from model

DeliverableSystem

Tests

DataExport

DataImport

Update to Client requirements

Development

Slice f or prototy pe

Trial Data Trial Data

Can be staged release

Design changes

Data changes

System Development One Page

28

Concluding

• The more you do with ControlDraw, the more you can get out of it

• Examine all the documents you produce outside CD– Can they be done With CD?– If not then maybe improvements to ControlDraw can be

made