Consulting & Training

Expert Services for
Process Control
Teams.

CTRL Designer offers a focused suite of consulting services and training programs — designed to evaluate your facility, implement ISA‑106 State-Based Control, and build in-house capability across your engineering team.

Category A — Optimise
Evaluate & Improve Your Facility
For plants looking to baseline current performance and identify automation improvement opportunities.
Plant Assessment ISA‑106 Implementation Control Builder
Category B — Implement
Deploy State-Based Control
For teams ready to implement ISA‑106 SBC and build the skills to sustain it internally.
State-Based Control IPC Course (SEP‑751) Quality Control (ME518)
Plant Assessment ISA‑106 Work Process State-Based Control IPC Course Quality Control Control Builder
01
Assessment Service

Industrial Plant Assessment (IPA)

A comprehensive big data analysis of an operating plant using Excel and R. The goal is to improve current production by 3% to 5% through evidence-based identification of controllability and operability issues.

Data Reconciliation Report Operability Index Loop Performance Rating Oscillation Cluster Map
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  • Data Collection & Reconciliation — Historical process data (1‑minute snapshots) is collected, reconciled, and validated as the analytical foundation.
  • Operability Performance — Principal Component Analysis (PCA) is applied to all Analog Inputs (AI) and Analog Outputs (AO) to quantify how well the plant is operating relative to its design envelope.
  • Controllability Performance — Assesses how well the control system is maintaining setpoints and handling disturbances across all loops.
  • Control Loop Performance — Fast Fourier Transform (FFT) analysis identifies oscillation clusters; each P, PI, or PID controller is rated using CDL's proprietary indexing technology as: Requires Improvement, Normal, or Excellent.
Target Outcome

Most facilities achieve a measurable improvement of 3% to 5% in production throughput or energy efficiency as a direct result of IPA findings — before any capital investment in new control hardware.

02
Standards Service

ISA‑106 Work Process Implementation

Using CDL's Lean Six Sigma methodology, your existing company work process is reviewed and aligned to the ISA‑106 standard — following the full DMAIC improvement cycle.

ISA‑106 Gap Report Merged Work Process Compliance Report
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D
Define
M
Measure
A
Analyze
I
Improve
C
Control
  • Define — Develop the engagement charter and identify the specific project goals for ISA‑106 alignment.
  • Measure — Collect and document existing company work processes related to process automation development.
  • Analyze — Compare the CTRL Designer ISA‑106 work process framework against the company's current process, identifying gaps and overlaps.
  • Improve — Select the best elements from both frameworks and merge them into an improved, ISA‑106 aligned work process.
  • Control — Implement the merged work process and establish monitoring to sustain compliance over time.
  • Report — Deliver a formal Compliance Report documenting alignment with ISA‑106 requirements.
03
Core Service

State-Based Control (ISA‑106)

End-to-end SBC implementation using the full CDL‑Tools package — converting your Standard Operating Procedures through to deployable DCS code across Emerson, Honeywell, and ABB systems.

URS Document FRS Files DDS Specification DCS Code
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1
Review ISA‑106 Models — Align team on procedural automation models applicable to your plant.
2
Divide Plant into ISA‑106 Modules — Partition Plant Areas (PA) and Unit Modules (UM) per the ISA‑106 hierarchy.
3
Develop Operational Trends — Build OTB visualizations for each Plant Area using historian data.
4
Develop URS — Generate structured User Requirement Specifications for PA and selected Unit Modules.
5
Develop FRS per Unit — Define Modes of Operation, Steps, State Transitions; assign I/O to pre-built CM and CCM modules.
6
Generate Step Diagrams — Produce Step Diagrams and CCM Step Dynamic Diagrams for validation and review.
7
ACM Code Generation — Convert the completed FRS/DDS to production-ready DCS code using the Automatic Code Maker (P7).
04
Training — SEP‑751

Industrial Process Control Course

A 5‑day intensive process control course enabling participants to understand and design State-Based Control. Taught at McMaster University as SEP‑751 for over 10 years.

5-Day Program McMaster SEP‑751 Certificate
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Fundamentals
Process Dynamics Feedback Control Enhanced Feedback Control Operating Trends
State-Based Control
SBC Theory & ISA‑106 Framework SBC of Mixing Tank (Lab) SBC of Distillation Column
Distillation Column Module
Binary Distillation Simulation Degree of Freedom & RGA Analysis Most Responsive Temperature (MRT) Controller Selection (SRDB)
SBC Design Workshop
Define URS Define FRS I/O Assignment Steps & Transitions AO to Control Modules DO to Control Modules CM Enablement Logic Generate FRS Report
05
Training — ME518

Quality Control

A complete course in industrial Quality Control implementation, taught at Boston University as ME518. Covers Six Sigma DMAIC, Statistical Quality Control, SPC, and Design of Experiment.

Boston University ME518 Six Sigma DMAIC SPC Methods
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Six Sigma DMAIC
Define — Measure — Analyze — Improve — Control. Full CTRL Designer DMAIC methodology with industrial project examples.
Statistical Quality Control (SQC)
X & MR Charts • X̄ & R Charts • X̄ & S Charts • P Chart • nP Chart • c Chart • u Chart
Statistical Process Control (SPC)
EWMA (Exponentially Weighted Moving Average) • CUSUM Control Charts • Partial Component Analysis (PCA)
Design of Experiment (DoE)
Define Objective • Select Factors • Choose Response & Measurement System • Select Design • Execute • Analyse Results
Project Development
Structured team project applying the full QC methodology to a real industrial process scenario.
Industrial Examples
Case studies drawn from manufacturing, petrochemical, and process industries — bridging theory and plant-floor practice.
06
Implementation Service

Control Builder

The final stage of the CDL work process — taking the completed FRS and building the Detailed Design Specifications (DDS) and control code for each Unit Module, ready for deployment to the selected DCS.

DDS per Unit Module DCS Code Interaction Matrix
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  • Map Functional CM Modules — Assign each functional Control Module design to the specific Process Control Computer (PCC) hardware and software platform.
  • Finalize Alarm Setpoints — Review and confirm all alarm setpoints, deadbands, and priorities against the URS and operational limits.
  • Finalize Controller Definitions — Lock controller tuning parameters, modes, and fallback logic for all PID and advanced control blocks.
  • Review Interaction Matrix — Validate the complete interaction matrix to ensure no cross-module conflicts exist before code generation.
  • Build UM / EM / CM Code — Generate the complete Unit Module, Equipment Module, and Control Module code using CDL‑Tools and the ACM engine, ready for DCS upload and commissioning.
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Ready to Discuss Your
Project or Training Needs?

Whether you need a plant assessment, SBC implementation, or want to schedule a course for your team — reach out and we'll scope the right engagement.

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