An Excel program that builds structured visual models of your plant hierarchy — from Plant Area down to Control Modules — and produces operating trend visualisations for Startup, Normal Run, and Shutdown modes using historian data.
OTB bridges the gap between your IPA and LOA findings and the detailed design work in P5/P6. It makes the SBC design intent visible and understandable to operations teams — and generates the initial step list that flows directly into FRS development.
Before you can write a URS or design an FRS, your engineering team needs a shared understanding of how the plant currently operates — across its hierarchy, and through each of its operating modes. That is exactly what OTB provides.
Using data from your process historian, OTB builds structured Excel visualisations that map Process Areas, Unit Modules, and Control Modules — then overlays operating trend data for each mode (Startup, Run, Shutdown) to reveal the natural step boundaries that will become the SBC design.
OTB is used twice in the CDL pipeline — once at Plant Area level during FEL2, and again at Unit Module level during FEL3 requirements development.
OTB produces a separate trend visualisation for each of the three core operating modes. Each view maps the key process variables against time, revealing the natural transition points that define SBC states and step boundaries.
The Startup trend maps the transition from the initial equipment state through all pre-conditioning steps to stable normal operation. This is typically the most complex mode — with the most steps, interlocks, and transition conditions.
The Normal Run trend captures the steady-state operating window — the range of acceptable process variable values during continuous production. This defines the state boundary conditions for SBC hold and transfer logic.
The Shutdown trend maps the controlled transition from normal production to a defined safe state. Both planned shutdowns and emergency shutdown sequences are captured — revealing the step sequence and interlocks required.
Each OTB engagement produces a set of structured Excel deliverables that serve as the visual foundation for all subsequent P5 URS and P6 FRS design work.
The outputs are designed to be reviewed with operations and management — making the SBC design tangible before detailed engineering begins. This stakeholder alignment step is one of the most valuable aspects of the OTB process.
A structured visual map of the full Plant Area hierarchy — all Unit Modules and their associated Control Modules, laid out in ISA‑106 physical model format.
Startup, Normal Run, and Shutdown trend visualisations for each selected Unit Module — showing all key process tags over time and the natural transition points between modes.
The primary output — a structured list of steps for each operating mode, derived from the trend analysis. This step list is the direct input to P5 URS Builder and P6 FRS Engine.
A management and operations-facing overview of the SBC design — using the OTB visualisations to communicate automation intent before commitment to detailed design.
The OTB step list is not a standalone deliverable — it is the structured input that makes P5 URS development and P6 FRS design significantly faster and more accurate.
Historian data analysed. PA/UM hierarchy built. Startup, Run, Shutdown trends visualised. Initial step list generated for each UM.
OTB step list imported as the A5‑Startup-Run-Shutdown section. Steps reviewed and confirmed by engineering and operations team.
OTB step list added to C2‑Steps in the FRS. Step Transitions defined (C4). CCM Steps developed (C5). Step Diagrams generated (C3, C6).
All steps and transitions from FRS fed into ACM to generate DCS code automatically for Emerson, Honeywell, or ABB 800xA.
Two overview documents are available before purchase — a guided tour and a step-by-step walkthrough. Use your browser’s back arrow to return after reading.
A comprehensive presentation of the full OTB package is available by Zoom. Send your company email to info@CtrlDesigner.com to request a session — we normally respond within one business day.
The OTB package is available through our online store or directly via invoice. We recommend a service engagement first — we work with your historian data to produce results, then you decide on licensing.