SERVICES

How Our Services Could Work For You?

Ctrl Designer offers a suite of services to improve the design, development, implementation ,and optimization of an industrial plant process control. These services are specifically designed for two categories:

users who want to evaluate their facility and optimize its performance
users who want to utilize the ISA106 State-Based Control (SBC)

For the first category, we offer Plant Assessment and a State-Based Control family of products that will enable the user to identify and improve the plant performance and for the second category, we offer a week-long course on Industrial Process Control ,and Control Designer package to develop State-Based Control utilizing the state of the art process control design tool to generate User Requirement Specification (URS), Functional Requirement Specification (FRS). and Detail Design Specification (DDS). Then the Automatic Code Maker (AC) will convert the DDS to code for a selected DSC system (ABB, Honeywell, or Emerson Delta V).ll convert the FRS to Detailed Design Specification (DDS) to build Process Control Application.

Industrial Plant Assessment (IPA)

A comprehensive big data analysis of an operating plant using Excel and R. It provides evaluation of

Data Collection
Operability Performance
Controllability Performance
Control Loop Performance

The goal is to improve the current production by 3% to 5%.

ISA106 Work Process Implementation

Utilizing the newly developed ISA106 and CTRL Designer Lean Six Sigma methodology, the existing company work process will be reviewed with the CTRL Designer ISA106 work processes. The following six sigma phases are applied:

Define: Develop the charter and identify the project goals
Measure: Collect existing company work processes to develop process automation
Analyze: Compare CTRL Designer ISA106 and the company work process
Improve: Select and merge according to ISA106 work processes
Control: Implement the company work process and improve
Report the Compliance with ISA106 Requirements

State-Based Control (ISA106)

CTRL Designer CDL-Tools package provides a set of tools utilizing MS Excel to convert Standard Operating Procedure (SOP) to User Requirement Specification (URS), Functional Requirement Specification (FRS), and Detail Design Specification (DDS). Then the Automatic Code Maker (ACM) will convert the DDS to code for a selected DSC system (ABB, Honeywell, or Emerson Delta)

- Review ISA-106 Models
- Divide Plant into ISA106 Models
- Develop Operational Trend for each Plant
- Develop User Requirement Specification (URS)
- Develop Operational Trend for selected Units
- Develop the following for selected Units:
  - Mode of Operation
  - Steps
  - State transitions
  - Assign IO to Pre-Built CM and CCM Modules
- Generate Step Diagram
- Generate the CCM Step Dynamic Diagram

Industrial Process Control Course

A 5 days process control course to enable participants to understand and capable to design (is being taught at McMaster for last 10 years SEP-751).

Process Dynamic
Feedback Control
Enhanced Feed Back Control
State Based Control
Operating Trend
State Based Control of Mixing Tank
Distillation Column Control
- Simple Simulation of Binary Distillation
- Evaluation of Degree of Freedom and RGA
- Most Responsive Temperature (MRT)
- Controller Selection (SRDB)
State Based Control of Distillation Column
- Define URS
- Define FRS
  - Input / Output Assignment
  - Define Steps and Transitions
  - Assign AO to Control Modules
  - Assign DO to Control Modules
  - Assign Enablement for All CMs
  - Generate FRS Report

Quality Control

It provide a complete course in implementation of Quality Control in an industrial enviroment. It is being tought at Boston University for number of years.

CTRL Designer Six Sigma DMAIC
- Define
- Measure
- Analyze
- Improve
- Control
Statistical Quality Control (SQC)
- X & MR charts, X Bar&R Charts,and X Bar&S Charts
- P Chart, nP Chart, c Chart, u Chart
Statistical Process Control (SPC)
- Exponentially Weighted Moving Average (EWMA)
- Cumulative Sum Control Chart (CUSUM)
- Partial Component Analysis (PCA)
Design of Experiment
- Define the Objective
- Define the Process and Select Factors to be Studied
- Select a Response and Measurement System
- Select the Experimental Design
- Execute Experiments Accurately
- Check the Results Obtained for any Issues
Project Development
Industrial Examples

Control Builder

It provides users with a set of tools and work processes to develop the Detailed Design Specifications (DDS) based on CTRL Designer for each Unit Module (UM).

Map the Functional CM Module to the Selected Process Control Computer
Finalize Alarm Set points
Finalize the Controller Definitions
Review the Interaction Matrix
Build Process Control UM/EM/CM code