P5 - CDL CCM and CM Libraries

Complex Control Module (CCM) and Control Module Libraries
Author

CTRL Designer LLC

Published

2024.02.01

1 Introduction

CTRL Designer LLC (CDL) is a leading provider of SBC state-based control (procedural control) based on ISA106 solutions to the process industries.

Its software portfolio and work processes help process control engineers develop an overall process control design and convert it automatically to the selected control system code. These solutions allow users to make faster and smarter decisions to improve safety, reliability, efficiency, and sustainability.

The products are divided into phases:

  • P1- Industrial Plant Assessment™ (IPA)
  • P2- Level of Automation (LoA) [Service]
  • P3- Operating Trends for Excel™
  • P4- Standard Operating Procedure Analyzer™
  • P5-URS-to-FRS-Builder-for-Excel™
  • P6-FRS-Engine-for-Excel™
  • P7-ACM-Engine-for-Excel™

1.1 CDL Folders

The CDL Package is constructed from the following Folders:

The top folder is called CDL-Product which contains

  • Project
  • Tools

1.1.1 Project Folder

The CDL Project folder contains:

  • CDL-PmName-Project-YYYY
    • PmName is the plant name such as VRT
    • Project is Optional
    • YYYY is the start year is is optional
  • Example is CDL-VRT-2023

In this chapter the CM, CCM and CCM-CM Builder library is documented, the document is divided into three parts:

  • Control Module - CM Library
  • Complex Control Module - CCM Library
  • CCM-CM-Builder

The Project folder contains:

  • P1-IPA-Industrial-Plant-Assessment
  • P2-LofA-Level-Of-Automation
  • P3-OT-Operational-Trends
  • P4-SOP-Standard-Operating-Procedure
  • P5-URS-User-Requirement-Specification
  • P6-FRS-Functional-Requirement-Specification
  • P7-ACM-Automatic-Code-Maker

Each represent a PHASE of the project.

1.1.2 Tools Folder

The CDL Tools folder contains:

  • A-Documentation
  • B-Templates
  • C-CM-CCM-Libraries
  • D-Engines
  • E-Issues

The C-CM-CCM-Libraries folder contains

  • CCm-Library.xlsx
  • Cm-Library.xlsx

The D-Engines folder contains

  • CDL-P5-CCmLibrary-Builder-for-Excel.xlsm Engine

2 Control Module (CM) Library

2.1 Introduction

The control system receives inputs (AI,DI, Operator Commands) and using its predefined procedures (Code) calculate the outputs (AO, DO, Step and Alarm).

The CDL CM Library contains the following generic CM Modules.

Index Name Description
1 CmAiSelector Analog Input Selector
2 CmAlarm Alarm
3 CmAlarmDev Deviation Alarm
4 CmAnalogCalc Analog Calculator
5 CmAnalogIn Analog Input (AI)
6 CmAnalogOut Analog Output
7 CmAnalogOutA Analog Output A
8 CmAnalogOutB Analog Output B
9 CmAnalyzerIn Analyzer Input
10 CmBigSmall Big Small Valves
11 CmCalc Calculator
12 CmCalcDigital Calculator Digital
13 CmCalcRateOfChange Calculator Rate of Change
14 CmCalcSum Calculator Sum
15 CmDigitalIn Digital Input (DI)
16 CmDigitalOut Digital Output (DO)
17 CmDivider Divider
18 CmDoStatus Digital Output Status
19 CmFlwEst Flow Estimator
20 CmPID PID
21 CmPIDAO PID + AO
22 CmPIDC PID Cascade >> PID
23 CmPIDS PID >> Selector
24 CmPIDR PID Ratio
25 CmSelectorAC AC Selector
26 CmSelectorAO AO Selector
27 CmSelectorDO DO Selector
28 Spliter Spliter
29 CmStep Step
30 CmTemplate Template
31 CmTransition Transition

2.2 CmAnalogIn CM Modules

The following CM are shown below:

  • CmAnalogIn

    • General Information
    • LLL - Low Low Low Alarm Information
    • LL - Low Low Alarm Information
    • L - Low Alarm Information
    • H - High Alarm Information
    • HH - High High Alarm Information
    • HHH - High High High Alarm Information
    • Err - Error Alarm Information

2.2.1 CmAnalogIn - General Information

Index Parent-Element CM-Name Name Initial
1 AI CmAnalogIn CMVersion 2020-11-08 HW Version
2 AI CmAnalogIn CMType CmAnalog
3 AI CmAnalogIn GenName [To Be Added]
4 AI CmAnalogIn GenDescription [To Be Added]
5 AI CmAnalogIn InstanceName [To Be Added]
6 AI CmAnalogIn InstanceDescription [To Be Added]
7 AI CmAnalogIn AI [To Be Added]
8 AI CmAnalogIn Normal [To Be Added]
9 AI CmAnalogIn Minimum [To Be Added]
10 AI CmAnalogIn Maximum [To Be Added]
11 AI CmAnalogIn FilterTime 0
12 AI CmAnalogIn Input [To Be Added]
13 AI CmAnalogIn OutPut [To Be Added]
14 AI CmAnalogIn EnableLogic [To Be Added]
15 AI CmAnalogIn CommandLogic [To Be Added]
16 AI CmAnalogIn AiLockForce FALSE
17 AI CmAnalogIn ConsequencesOfInaction [To Be Added]
18 AI CmAnalogIn TimeToResponse [To Be Added]

2.2.2 LLL - Low Low Low Alarm Information

Index Parent-Element CM-Name Name Initial
19 AI CmAnalogIn LLLAlmConfig [V]True,False
20 AI CmAnalogIn LLLAlmEnableLogic [To Be Added]
21 AI CmAnalogIn LLLAlmSeverity [V]Low,Medium,High,Critical
22 AI CmAnalogIn LLLAlmSetpoint [To Be Added]
23 AI CmAnalogIn LLLAlmHysteresis [To Be Added]
24 AI CmAnalogIn LLLAlmDelayTon [To Be Added]
25 AI CmAnalogIn LLLAlmDelayToff [To Be Added]
26 AI CmAnalogIn LLLAlmManReset [To Be Added]

2.2.3 LL -Low Low Alarm Information

Index Parent-Element CM-Name Name Initial
27 AI CmAnalogIn LLAlmConfig [V]True,False
28 AI CmAnalogIn LLAlmEnableLogic [To Be Added]
29 AI CmAnalogIn LLAlmSeverity [V]Low,Medium,High,Critical
30 AI CmAnalogIn LLAlmSetpoint [To Be Added]
31 AI CmAnalogIn LLAlmHysteresis [To Be Added]
32 AI CmAnalogIn LLAlmDelayTon [To Be Added]
33 AI CmAnalogIn LLAlmDelayToff [To Be Added]
34 AI CmAnalogIn LLAlmManReset [To Be Added]

2.2.4 L - Low Alarm Information

Index Parent-Element CM-Name Name Initial
35 AI CmAnalogIn LAlmConfig [V]True,False
36 AI CmAnalogIn LAlmEnableLogic [To Be Added]
37 AI CmAnalogIn LAlmSeverity [V]Low,Medium,High,Critical
38 AI CmAnalogIn LAlmSetpoint [To Be Added]
39 AI CmAnalogIn LAlmHysteresis [To Be Added]
40 AI CmAnalogIn LAlmDelayTon [To Be Added]
41 AI CmAnalogIn LAlmDelayToff [To Be Added]
42 AI CmAnalogIn LAlmManReset [To Be Added]

2.2.5 H - High Alarm Information

Index Parent-Element CM-Name Name Initial
43 AI CmAnalogIn HAlmConfig [V]True,False
44 AI CmAnalogIn HAlmEnableLogic [To Be Added]
45 AI CmAnalogIn HAlmSeverity [V]Low,Medium,High,Critical
46 AI CmAnalogIn HAlmSetpoint [To Be Added]
47 AI CmAnalogIn HAlmHysteresis [To Be Added]
48 AI CmAnalogIn HAlmDelayTon [To Be Added]
49 AI CmAnalogIn HAlmDelayToff [To Be Added]
50 AI CmAnalogIn HAlmManReset [To Be Added]

2.2.6 HH - High High Alarm Information

Index Parent-Element CM-Name Name Initial
51 AI CmAnalogIn HHAlmConfig [V]True,False
52 AI CmAnalogIn HHAlmEnableLogic [To Be Added]
53 AI CmAnalogIn HHAlmSeverity [V]Low,Medium,High,Critical
54 AI CmAnalogIn HHAlmSetpoint [To Be Added]
55 AI CmAnalogIn HHAlmHysteresis [To Be Added]
56 AI CmAnalogIn HHAlmDelayTon [To Be Added]
57 AI CmAnalogIn HHAlmDelayToff [To Be Added]
58 AI CmAnalogIn HHAlmManReset [To Be Added]

2.2.7 HHH - High High High Alarm Information

Index Parent-Element CM-Name Name Initial
59 AI CmAnalogIn HHHAlmConfig [V]True,False
60 AI CmAnalogIn HHHAlmEnableLogic [To Be Added]
61 AI CmAnalogIn HHHAlmSeverity [V]Low,Medium,High,Critical
62 AI CmAnalogIn HHHAlmSetpoint [To Be Added]
63 AI CmAnalogIn HHHAlmHysteresis [To Be Added]
64 AI CmAnalogIn HHHAlmDelayTon [To Be Added]
65 AI CmAnalogIn HHHAlmDelayToff [To Be Added]
66 AI CmAnalogIn HHHAlmManReset [To Be Added]

2.2.8 Err - Error Alarm Information

Index Parent-Element CM-Name Name Initial
67 AI CmAnalogIn ErrAlmConfig [V]True,False
68 AI CmAnalogIn ErrAlmEnableLogic [To Be Added]
69 AI CmAnalogIn ErrAlmSeverity [V]Low,Medium,High,Critical

2.3 CmPIDAO - CM Module

The following CM are shown below:

  • CmPIDAO
    • General Information
    • AO ### General Information
Index Parent-Element CM-Name Name Initial
Index Parent-Element CM-Name Name Initial-Value
1 Pid CmPIDAO CMVersion 2020-11-08 HW Version
2 Pid CmPIDAO CMType CmController
3 Pid CmPIDAO GenName [To Be Added]
4 Pid CmPIDAO GenDescription [To Be Added]
5 Pid CmPIDAO InstanceName [To Be Added]
6 Pid CmPIDAO InstanceDescription [To Be Added]
7 Pid CmPIDAO AC [To Be Added]
8 Pid CmPIDAO Normal [To Be Added]
9 Pid CmPIDAO Minimum [To Be Added]
10 Pid CmPIDAO Maximum [To Be Added]
11 Pid CmPIDAO Input [To Be Added]
12 Pid CmPIDAO OutPut [To Be Added]
13 Pid CmPIDAO EnableLogic [To Be Added]
14 Pid CmPIDAO CommandLogic [To Be Added]
15 Pid CmPIDAO ManualModeLogic [To Be Added]
16 Pid CmPIDAO ManualModeTrack [V]True,False
17 Pid CmPIDAO AutoModeLogic [To Be Added]
18 Pid CmPIDAO AutoModeSpTrack [V]True,False
19 Pid CmPIDAO AutoModeSpValue [To Be Added]
20 Pid CmPIDAO CascadeModeLogic [To Be Added]
21 Pid CmPIDAO DevConfig [V]True,False
22 Pid CmPIDAO Gain 1
23 Pid CmPIDAO Ti 5
24 Pid CmPIDAO Td 0
25 Pid CmPIDAO Direct [V]True,False
26 Pid CmPIDAO OutMaxLimit [To Be Added]
27 Pid CmPIDAO OutMinLimit [To Be Added]
28 Pid CmPIDAO Sp [To Be Added]
29 Pid CmPIDAO SpMax [To Be Added]
30 Pid CmPIDAO SpMin [To Be Added]
31 Pid CmPIDAO SpRampRate [To Be Added]
32 Pid CmPIDAO OutputResponseOnFailure [V]Freeze,Through,Predetermined
31 Pid CmPIDAO CoFreezeValue [To Be Added]
33 Pid CmPIDAO DevConfigPos [To Be Added]
34 Pid CmPIDAO DevConfigNeg [To Be Added]

2.3.1 CmPIDAO - AO Information

Index Parent-Element CM-Name Name Initial
35 AO CmAnalogOut DevAlmConfig [V]True,False
36 AO CmAnalogOut DevAlmEnableLogic [To Be Added]
37 AO CmAnalogOut DevAlmSeverity [V]Low,Medium,High,Critical
38 AO CmAnalogOut DevAlmSetpoint [To Be Added]
39 AO CmAnalogOut DevAlmHysteresis [To Be Added]
40 AO CmAnalogOut DevAlmDelayTon [To Be Added]
41 AO CmAnalogOut DevAlmDelayToff [To Be Added]
42 AO CmAnalogOut DevAlmManReset [To Be Added]

3 Complex Control Module (CCM) Library

3.1 Introduction

The CDL is designed to be object oriented. Therefor the CCM object is constructed from one to many CM. In case of pump motor example, Each DO can have zero to six DIs and one optional DO.

Therefore the control strategy for a plant is analogous to jungle, each tree has a AO or DO as a root and the control code constructed by CM are their leaf. A Um can be represented as collection of trees.

For example DO for a pump motor can have the following structure

Index CM-Name Cm-Type
1 DiFBRun CmDigitalIn
2 DiFBStop CmDigitalIn
3 DiReady CmDigitalIn
4 AiPower CmAnalogIn
5 AiTemp CmAnalogIn
6 DoStop CmDigitalOut
7 DO CmDigitalOut

Assuming that UM has tree pumps, it can be represented shown below.

The Pump CCM is constructed from the DO (Root-Tag) CM and all six associated DI CMs and one DO as shown below.

Where

  • N: is index number of CCM library

  • CM-Name: is the CCM Name of the object

  • Class: Is the Class Name

  • Element: Element Name in CCM

  • Generic Name: The Element Name + | + CmName

The yellow color signify the optional CM and green color represent tn Root-Tag

or

3.2 Strategy

a The CDL strategy to develop code is deigned bottom up, start from the ROOT

  1. Identify the Root-Tags
  • AO Analog Output
  • DO Digital Output

  1. Select control strategy for each Root-Tags from CCM Library for the Root-Tag

  2. Select IO Tag from {B1-IO} sheet for each of optional CM

3.3 CCM Module List

The CDL CCM Library contains the following generic CM Modules.

Index Name Description
N Cm-Name Type
1 CmStep Step
2 CmTransition Step
3 CmAnalogIn Cm
4 CmAnalogCalc Cm
5 CmDigitalIn Cm
6 CmAnalogOut Cm
7 CmAnalogOutA Cm
8 CmAnalogOutB Cm
9 CmDigitalOut Cm
10 CCmAiSelector CCM-Digital
11 CCmBlockDo CCM-Digital
12 CCmBlock2Do CCM-Digital
13 CCmPump CCM-Digital
14 CCmDualPump CCM-Digital
15 CCmMotor CCM-Digital
16 CCmAgitator CCM-Digital
17 CCmFan CCM-Digital
18 CCmDODivertor CCM-Digital
19 CCmAiABCSel CCM-Analog
20 CCmAiABCDCalc CCM-Analog
21 CCmL1Cntl CCM-Analog
22 CCmLC1Cntl CCM-Analog
23 CCmL1AOSplitCntl CCM-Analog
24 CCmL1L2Cntl CCM-Analog
25 CCmLC1L2Cntl CCM-Analog
26 CCmL1L2SelCntl CCM-Analog
27 CCmLC1L2SelCntl CCM-Analog
28 CCmL1L2AL2BSplCntl CCM-Analog
29 CCmLC1L2AL2BSplCntl CCM-Analog
30 CCmLC1L2AL2BSplLC3Cntl CCM-Analog
31 CCmL1L2L3Cntl CCM-Analog
32 CCmLC1L2L3Cntl CCM-Analog
33 CCmLC1LC2L3Cntl CCM-Analog
34 CCmL1>L2L3SelCntl CCM-Analog
35 CCmLC1>L2L3SelCntl CCM-Analog
36 CCmDistT1T2>Ovr>StmCntl CCM-Analog
37 CCmDistT1T2>2Ovr>StmCntl CCM-Analog
38 CCmDistT1T2>3Ovr>StmCntl CCM-Analog

3.4 How to Construct CCM Modules

The CCM modules are built in {CM-CM-Definition} worksheet of CCm-library worksheet.

The following are example of how to construct CCM

3.4.1 The worksheet fields (Columns)

These are the fields (Columns) of the worksheet:

  • N: Index of worksheet
  • Cm-Name: Cm or CCM name of the object (CmStep, CCMPump)
  • Class: Name for User
  • Element: Element name within CCM
  • GenericName | CmName: the object internal name

Color Code

  • Blue: Single CM

  • Green: Root-Tag

  • Yellow: Optional or non-Root-Tag

  • Gray: Connections

3.4.2 CCmBlockDo - Simple CCM

The CCmBlockDo is constructed from three CM

Index Element CM Type
1 DiFBClosed CmDigitalIn Optional
2 DiFBOpen CmDigitalIn Optional
3 DO CmDigitalOut Root-Tag

The connections are

  • DiFBClosed >> DO

  • DiFBOpen >> DO

The “-v” establishes the connection

3.4.3 CCmDualPump - Medium CCM

The CCmBlockDo is constructed from fifteen CM

Index Element CM Type
1 DiAFBRun CmDigitalIn Optional
2 DiAFBStop CmDigitalIn Optional
3 DiAReady CmDigitalIn Optional
4 AiAPower CmAnalogIn Optional
5 DoAStop CmDigitalOut Optional
6 DoASel CmDOStatus Optional
7 DiBFBRun CmDigitalIn Optional
8 DiBFBStop CmDigitalIn Optional
9 DiBReady CmDigitalIn Optional
10 AiBPower CmAnalogIn Optional
11 DoBStop CmDigitalOut Optional
12 DoBSel CmDOStatus Optional
13 DoSel CmSelectorDO Optional
14 DOA CmDigitalOut Root-Tag
15 DOB CmDigitalOut Root-Tag(M)

The design in the {Cm-Cm-Definition} is shown below

The design in the {Drawing} is shown below

3.4.4 CCmDistT1T2>2Ovr>StmCntl - Complex CCM

This control control strategy is an example of complex CCM

The design in the {Cm-Cm-Definition} is shown below

The design in the {Drawing} is shown below

4 CCM-CM Builder Engine

The D-Engines folder contains the CCM-CM Builder Engine

  • CDL-P5-CCmLibrary-Builder-for-Excel.xlsm Engine

4.1 Step by Step

There are five steps to consider:

  1. Select CM CCM Library folder
  2. Select CM CCM Libraries
  3. Build Parent-Child DB
  4. Draw CCM
  5. Build CCM Database

4.1.1 Step 1 - Select CM CCM Library folder

Purpose: The purpose of this step is to select the CM and CCM libraries folder in the CDL Product.

To Do Please do the following :

  1. Click the [01] Select Library Folder Button
  2. Use the explorer to select

The CDL Tools folder contains:

  • A-Documentation
  • B-Templates
  • C-CM-CCM-Libraries
  • D-Engines
  • E-Issues

The C-CM-CCM-Libraries folder contains

  • CCm-Library.xlsx
  • Cm-Library.xlsx

4.1.2 Step 2 - Select CM CCM Libraries

Purpose: The purpose of this step is to select the CM and CCM libraries in the CDL Product.

To Do Please do the following :

  1. Type the Cm-Library.xlsx and CCM-Library.xlsx in cells C5 and C6
  2. Click the [02] Select CM and CCM Lib Button

4.1.3 Step 3 - Build Parent-Child DB

Purpose: The purpose of this step is to build Parent-Child Database.

To Do Please do the following :

  1. Open the CCm-Library.xlsx
  2. Review {CM-CM-Definition} worksheet, add new CCM
  3. Save it
  4. Click the [03] Build Parent-Child DB Button

There are 258 lines in the {CM-CM-Definition} with 296 objects (shape) and 205 connections

4.1.4 Step 4 - Draw CCM

Purpose: The purpose of this step is to draw all CCM with their associate CMs

To Do Please do the following :

  1. Click the [04] Draw CCm Button
  2. Use the explorer to select

Each CCM is drawn in a box called wrapper

The drawing is saved as a PDF file in the following folder

CDL-Products\\C-CM-CCM-Libraries\\Reports\\CCm-Library.pdf

4.1.5 Step 5 - Build CCM Database

Purpose: The purpose of this step is to build CCM data based to be used by the FRS Engine.

To Do Please do the following :

  1. Click the [05] Build CCM Lib DB Button

Reference