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

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

I cannot use this to agree process functionality

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 Functional Requirements Specification 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

Process Flow diagrams

SAMA Loops

Logic Diagrams

Procedure Function Charts S88.02

State Transition diagrams

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

ControlDraw State Matrices Mapping procedures into Basic Control Process Cell Mixing Unit OperationValve Control Module 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 Access 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

Thanks