controldraw introduction
DESCRIPTION
Do you manage automation projects?TRANSCRIPT
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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
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Francis LoveringControlDraw Ltd
24 years with EPCTechnical manager Automation group
10 years ControlDraw LtdActive and Award winner in World Batch Forum
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(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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Measurement Analog
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Measurement Analog
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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
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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
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FT001
To Sterliser
CIP return header
CIP return header
FQIC001 25
V903
19
CIP SupplyForward
Unit A Unit B
CIP SupplyNext
Set StateSimulation
P01
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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
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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
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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
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Simulation
• Many Diagrams types can be put into simulation mode
• Test Control Strategies
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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
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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
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Version Controls
• Everything in a model has a version number:– Diagrams– Classes– Matrices – Data
• Compare facilities provide details on all changes
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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
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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
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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
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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
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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
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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
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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