Transcript ControlDraw

ControlDraw Overview
Contents
• Background - why ControlDraw was developed
• Process Control Specifications
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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?
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Users
Operational staff
Suppliers
Sales engineers
Programming staff
Tester
Validators
Specification Contents
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Words describing the processes
P&ID’s
Control loops
Interlock logic
Sequences
Recipes
Many lists and tables such as IO Lists
Graphics
Specification Organisation
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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
Requirem ents
Specification
Testing of the URS
Functional
Specification
System
Acceptance
Testing
Testing of the
Functional Spec
Softw are
Integration
Testing
Softw are
Design
Specification
Softw are
Module
Specifications
Code Modules
Softw are
Module
Testing
Review and
Test Modules
Process Control Specification Production
• Typically the requirements are specified with Word, Visio,
Excel, Access
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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
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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
h.origin
Production Information Management -- h
(pim.dat)
h.Production Information Entry Class
h.Report Element Class
h.Batch Report Class
h.Production Information Entry
Absolute time stamp (real time)
Description
Source ID (person, program, etc)
Value
h.Batch History Entry
Batch Id
h.Production Information Recipe Entity
is based on
h.Report Element
h.Batch Report
Report Header
h.Common Information Entry
Logical Vie w
ModelElement
Responsibility
TaggedValue
0..n
Expression
/characteristic
{implicit}
0..1
Type
0..n
0..n
Instance
0..1
0..1
0..n
0..n
+multiplicity : Multiplicity 1..n
TypeExpression
references
+referncedTypes() : List of T ype
0..n
0..n
roles
state instance
actions
0..1
State
0..1
0..n
Behav iorInstance
Primitiv e Type
+details : Uninterpreted
Value
-value : Uninterpreted
Class
UseCase
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
Requirem ents
Specification
Functional
Testing of the URS
Requirements
Specification
Words
Functional
Specification
Procedures
System
Acceptance
Testing
Testing of the
Functional Spec
Graphics
Phase Logic
Softw are
Design
Specification
Control
Modules
System
Database
Softw are
Module
Specifications
Code Modules
Softw are
Integration
Testing
Softw are
Module
Testing
Review and
Test Modules
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
Type
Grafcet / Sequential function charts(SFC)
SAMA Loops
Logic
Ladder
Procedure Function Charts (PFC)
Process Flow
State Transition
System
Flowchart diagrams
Entity Relationship
Typical Use
Sequential Logic,
Modulating Control schemes
On/Off Control, Interlock Logic
On/Off Control, Interlock Logic
S88 Recipe Procedures
Small schematic diagrams of the
controlled plant
State logic for Units, Control
modules etc
Control system network diagrams
Software Design
Systems Analysis, Software Design
Diagrams that Capture the S88 Models
Site diagram
Page 1 in the ControlDraw
model
Plant
Plant
Area
Area
Plant Area diagram
Unit
Common
Resource
Unit
Plant Area diagram
This also has all the Units and
Resource etc
Common Resource diagram
Unit diagram
Unit
Equipment
Procedure
Module
Control
Module
Control
Module
Equipment Module diagram
Control
Module
State 1
State 2
Control Module diagram
Unit Procedure diagram
Phase
Phase
Phase diagram
Phase Step
Condition
Phase Step
Equipment
Module
Process Flow diagrams
Recipes
Control Room
Laboratory
64
Additive Stor age Hoppers 65
FLT2
Additive Warehouse
SH1
Covers Banana, Strawberry and
Controller02
other blends
30 Control
Unit
Module
26
SH2
Fudge DrinkProcedure
65
Covers Chocolate and other blends
Local Display
Stores the palettes of Flav our
additiv es
31
12 13
Additives
12
Solids Processing
BV2
CIP
Supply
Milk Tanker3
Operations
Add Milk Sta rt
Qty
49
LAH
Intermediate
Store Batch Mixing Unit FLT3
14
8
Milk Tanker2
Unit procedure
32
Tracking Database
Batch Mixing Unit
32
AG1
33
LSH
WQ1
36
8
Milk Silos
Batch Mixing Proc es s es
2
Los s-In-Weight
Feeder
Jacket Temperature Batch DB Table
Product
Silos
Batch
2 Controls
Packaging
3 s ilos
69
Bldng Vessel
Liquids Processing
3 s ilos filled during day , cleaned
at night
Additives
Covers Chocobooz e and other
blends
73
Milk Tanker1
SIA
28
Milk Alchoshak
Supply e Procedure
Flavour additives materials are depalletised and
weighed into IBC's
BV1
62
Fruit Drink Procedure
70
FLT1
Control Activity
Model
Tracking Database
3
4
Add Milk Final
Qty
50
5
EM3
Produc t Homogenis ing pipework
CIP Chemicals
CIP_L3
Line CIP for lines from Batc h CIP G eneration
CIP Chemical
Store
Ves sel
to Homogeniser
System
47
15
6
HG 1
Q uarantine
Store
55
CIP
Return
HG 2
Homogenis er
Packaging
Packaging
Store
FLT4
Homog - enis er
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52
CIP for Homogenis er
58
47
FLT5
CIP Supply2
Mix and
53 Heat
66
WT1
Final Product Store
35
LSL
Stores the palettes of final
LAL produc t
CIP_H1
32
Water Treatment
EM4
Plant
Produc t Dis tribution manifold
Steam Resour ces
XV6
56
Add Milk and
Solids
48
Product
Sample
Operation
Transfer
Feed
Outto Batch Ves s el
XV5
34
CIP_V2
34
Batch Ves sel CIP
CIP_L4
58
Line CIP for lines from
Homogenis er to Product Silo
47
CIP Return2
Drain
PS1
PS2
Product Silos
PS3
Pump33
SAMA Loops
DCS Func tions
610 AT 00 05
Field
610 AC 00 05
610 FV 0001
610 FC 0001
AL
610 FT 0001
610 FY 0001A
610 FY 0001B
[not on P&&ID]
610 FAL 0001B
610 FT 0002
Field
610 ALSP 0002
[not on P&&ID]
610 FC 0002
610 FV 0002
610 FZT 0023
610 FZY 0023
610 FZY 0023B
[not on P&&ID]
610 FZT 0024
610 FZAL 0023
610 ALSP 0002
[not on P&&ID]
ESD Func tions
Logic Diagrams
Auto Start
Auto_Inte rlock
Auto_Start
Motor
Auto/Man
Manual Start
Man Start
Man Interlock
Procedure Function Charts S88.02
PFC Start
PFC Allocation
UnitProc
PFC Start
PFC Allocation
Operation
UnitProc
PFC Start
Operation
Operation
Sample
Receiv e
Explicit Transition
Transfer
Operation
Operation
State Transition diagrams
Note
If the unit is acquired this
is the only state where
manual dev ice operation
is permitted.
Shutdown
Abandon
Fail
Stop
Hold Batch
in manual
Start
Batch
Abandon
*
Starting
Unit to
Auto
Stop
Start
Complete
Unit to
Auto
Hold Batch
Available
Released by
Batch *
Hold in
manual
Fail or
Man
Restart
batch *
Acquired
by Batch *
In use
* Co-ordination control
Co-ordination control Func tion,by Recipe Manager
Fail or
Batch
Hold
Unit to
Manual
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
Additiv e Storage Hoppers
• Mapping procedures
into Basic Control
Controller02
SH1
SH2
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Process
Cell
Local Display
11
11
BV1
BV2
Batch Mixing
U nit
Batch Mixing
U nit
7
7
CIP
Supply
Mixing Unit
EM3
Product H omogenis ing pipework
Unit Control
Module
CIP_L3 20
Line CIP f or lines
SIA
f rom Batc
h
Additiv
es
57
63
Vess el to
Operations
HG1
HG2
Milk
Supply
XV1
Valve
Control Module
PLC AV---03
Coolant
Return
SCADA AV---04
PLC Library Code
SetC im D ef inition R ec ord
32
MAN
A/M
AG1
LSH
34
31
XV2
57
TT1
XV3
This applies to the standard block v alv es and is
as sum ed to be the s ame f or the div erter v alv es
Auto/Manual
0 = m anual, 1 =
Auto
Auto
Set
Unit
Autoby
C om
mand F rom U nit State
Matrix TM RO
30
32
Note
Manual C ommand
0 = c lose, 1 =
Open
26
Valv e Driv er
Standard Auto/Manual.
Trav el is timed in eac h
direction. Timeout c aus es
F ail to Open or F ail to C lose
Alarm .
Indiv idual times f or each
direction m ust be prov ided.
f rom
H om ogeniser to
Product Silo
FTO
FTC
F ail to C lose
C IP f or
H om ogeniser
Add Milk and
EM4Solids
46
21
Product D is tribution m anif old
Add Milk Final Qty
Operation
CIP
Return2
48
Mix and Heat
Start
WTSP
51
37
32
Coolant
Supply
23
47
Loss -In-W eight
F eeder
Batch
Vessel
CIP_L4
TC
Line CIP f or lines
Condensate
F ail to Open
CIP
Supply2
WQ1
CIP_H1
Add Milk Start Qty57
23
Steam
Supply
H om og enis er
H om ogeniser
LAH
CIP
Return
XV4
33
LSL
32
WT1
32
Valv e Open
Transfer Out
XV5
F eed to Batch
Vess el
XV6
Max imum Open
Trav el Time
32
Drain
PS3
Pump
Batch Vessel C IP
Actual W eight
Wait f or the weight to be s teady
T_Stable
Weight stable f or
x s econds
Store Tare Wt
Store the weight f or use in batch
calc s
If set to 1 the
Open limit s witch
is ignored
True
DIClosed
ZSC
C losed Limit
Switch
WTPV
Product Silos
CIP_V2
31
OVRO
Ov erride Open =
If set to 1 the
Open limit
s witch
OVRC
is
Ovignored
erride C losed -
PS2
Stabilise
30
TM RC
T_Start
PS1
LAL
O
Max imum C lose
Trav el Time
Target W eight
Sample Operation
DIOpen
ZSO
Open limit s witch
DOSov
Interlock Condition
Sov
Unit
State
Matrix
D um my
Fast Feed
Add milk a f ull rate.
T_WT > WTSP
Weight greater
than Target
Stabilise1
Wait f or the weight to be s teady
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
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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
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Longer tagnames - 32chr
No limit on description text
Text inside symbols
Manual text positioning
Word integrated - RTF files embedded in the models
Symbols
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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
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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
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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
ControlDraw Model
OPC Batch
Interface
XML Batch Data
Exchange Schema
In Projects
• Scope control
– Detailed metrics from the model
– Module provide basis for
• estimates
• project plan
– Highly detailed change tracking
Thanks
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